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HEATERS

Gas Water Heater
with the Flame Lock TM
Safety System

Installation
Instructions and
Use & Care Guide

WARNING:
If the information in these
instructions is not followed
exactly, a fire
or explosion
may result causing property
damage, personal
injury or death.
Do not store or use gasoline or other
flammable
vapors and liquids in the
vicinity of this or any other appliance.
WHAT
•
+

TO DO IF YOU SMELL

GAS

Do not try to light any appliance.
Do not touch any electrical switch;
do not use any phone in your
building.

Immediately
call your gas supplier
from a neighbor's
phone. Follow the
gas supplier's
instructions.

If you cannot reach your gas
supplier,
call the fire department.

To obtain technical, warranty, or service assistance during or
after the installation of this water heater, call toll free:

1-877-817-6750
When

calling

for assistance,

please

have the following

information ready:
I.
Model number
2.
3.

7 Digit product number
Serial number

Date of installation

Table of Contents

......................................................

Installation
and service must be performed
by a qualified
installer, service agency or
the gas supplier.

6510233
September 2001

Your safety

and the safety

of others are very important.

We have provided many important safety messages in this manual and on your appliance. Always read and obey all
safety messages.
This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word "DANGER" or
"WARNING" These words mean:
You can be killed or seriously injured if you don't
immediately follow instructions.
You can be killed or seriously injured if you don't
follow instructions.
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you
what can happen if the instructions are not followed.

Important

Instructions

•

Do not use this appliance if any part has been under water. Immediately call a qualified service technician. Water
heaters subjected to flood conditions or anytime the gas controls, main burner or pilot have been submerged in
water require replacement of the entire water heater.

•

Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame. To
prevent the possibility of injury under these conditions, we recommend the hot water faucet be opened for several
minutes at the kitchen sink before using any electrical appliance which is connected to the hot water system. If
hydrogen is present, there will probably be an unusual sound such as air escaping through the faucet as water
begins to flow. Do not smoke or have any open flame near the faucet at the time it is open.

The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of
substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires
businesses to warn of potential exposure to such substances.
Warning: This product contains a chemical known to the State of California to cause cancer, birth defects, or other
reproductive harm.
This appliance can cause low-level exposure to some of the substances listed, including formaldehyde, carbon
monoxide, and soot.

PAGE
Water Heater Safety
....................................................................
1-2
Installing Your Gas Water Heater
................................................
3-16
Unpacking the Water Heater
.......................................................
3
Location Requirements
..............................................................
4
Gas Supply
.................................................................................
6
Combustion Air Supply and Ventilation
.......................................
7
Water System Piping ................................................................
12
Installation Checklist
................................................................
16
Operating YourWater Heater ....................................................
17-19
Lighting Instructions
.......................................................................
17
Operational Conditions
............................................................
19
Maintenance of YourWater Heater .....................................
20-24
Trouble Shooting Chart
............................................................
25-26
Repair Parts Illustration
............................................................
27-28

;TALL!

Consumer

YOU

GAS

EATE

information

This water heater is design-certified by CSA
International as a Category I, non-direct vented water
heater which takes its combustion air either from the
installation 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 with the "National Fuel Gas Code", ANSI
Z223.1 (N FPA 54)- latest edition. This is available from
the following:

Unpacking the Water Heater
Excessive
Weight
Hazard
Use two or more people to move and
install
water heater.
Failure
to do so can
other injury.

Removing

result

Packaging

in back

Materials

American Gas Association
1515 Wilson Boulevard
Arlington, VA22209

Important: Do not remove any permanent instructions,
labels, or the data label from outside of the water heater
or on the inside of panels.

National Fire Protection Agency
1 Batterymarch Park
Quincy, MA02269

Remove exterior packaging and place installation
components aside.

Check your phone listings for the local authorities
having jurisdiction over your installation.

Inspect all parts for damage prior to installation and
start-up.

Completely read all instructions before attempting
to assemble and install this product.

Consumer Responsibilities

After installation, dispose of packaging material in
the proper manner.

This manual has been prepared to acquaint you with
the installation, operation and maintenance of your gas
water heater and provide important safety information in
these areas.
Read all of the instructions thoroughly before
attempting the installation or operation of this water
heater. Keep this manual for future reference.
Service to the Flame Lock TM safety system should
only be performed by a qualified service technician.
The manufacturer of this water heater will not be liable
for any damages caused by failure to comply with the
installation and operating instructions outlined in this
manual.
If you lack the necessary skills required to properly
install this water heater or you have difficulty following
the instructions, you should not proceed but have a
qualified person perform the installation of this water
heater. Massachusetts code requires this water heater
to be installed in accordance with Massachusetts
Plumbing and Fuel Gas Code 248 CMR section 2.00
and 5.00.
A data plate identifying your water heater can be found
next to the gas control valve/thermostat. When referring
to your water heater always have the information listed
on the data plate readily available.

Location Requirements
Carbon Dioxide Poisoning Hazard
Do not install in a mobile home.
Doing so can result in death or carbon
monoxide
poisoning.

_lLVapors

from

explode
and catch
severe burns.

flammable
fire

liquids

causing

will

death

Do not use or store flammable
products
such as gasoline, solvents
or adhesives
in the same room or area near the water
heater.
Keep flammable
products:
1. far away from heater
2. in approved
containers,
3. tightly closed and
4. out of children's
reach.
Water heater has a main burner
flame. The pilot flame:
1. is on all the time and
2. will

ignite

flammable

and pilot

Although this water heater is equipped with the Flame
Lock TM safety system, areas where flammable liquids
(gasoline, solvents, liquid propane, butane, etc.) or
other substances which emit flammable vapors are
stored are not suitable for water heater installation.
Never store or use flammable substances in the same
room or area containing a gas water heater. If such
flammables must be used, all gas burning appliances in
the vicinity must be shut off and their pilot lights
extinguished. Open the doors and windows for
ventilation while flammable substances are in use.
If flammable liquids or vapors have spilled or leaked in
the area of the water heater, leave the area immediately
and call the fire department from a neighbor's home. Do
not attempt to clean the spill until all ignition sources
have been extinguished.

vapors.

Vapors:
1. cannot be seen,
2. are heavier than air,

Site

3. go a long way on the floor
4. can be carried
the pilot flame

The Flame Lock TM safety system is designed to reduce
the risk of flammable vapor related fires. The patented
system protects your family by trapping the burning
vapors within the water heater combustion chamber
through the special flame-trap. The burning vapors
literally "burn themselves out" without escaping back
into the room. In the event of a flammable vapor
incident, the Flame Lock TM safety system shuts off the
gas supply to the water heater's burner and pilot
preventing re-ignition of any remaining flammable
vapors in the area. This will permanently disable the
water heater.

Select a location near the center of the water piping
system. The water heater must be installed indoors
and in a vertical position on a level surface.

from other rooms to
by air currents.

Do not install this water
products
will be stored.

where

Location

and

Locate the water heater as close to the chimney or
gas vent as practical. Consider the vent system
piping and combustion air supply requirements
when selecting the water heater location. The
venting system must be able to run from the water
heater to termination with minimal length and
elbows.

flammable

Locate the water heater near the existing gas
piping. If installing a new gas line, locate the water
heater to minimize the pipe length and elbows.

Note: The water heater must be installed according to
all local and state codes or in absence of the local and
state codes with the "National Fuel Gas Code", ANSI
Z223.1 (NFPA54)-Iatest edition.

Important:Thewaterheatershouldbelocatedinan
areawhereleakageofthetankor connections
will not
resultindamageto theareaadjacenttothewater
heateror tolowerfloorsof thestructure.Duetothe
normalcorrosiveactionofthewater,thetankwill
eventually
leakafteranextendedperiodoftime.A
suitablemetaldrainpanshouldbeinstalledunderthe
waterheaterasshownbelow,tohelpprotectthe
propertyfromdamagewhichmayoccurfrom
condensate
formationor leaksinthe piping
connections
ortank.Thepanmustlimitthewater
leveltoa maximumdepthof 1 3/4inchesandbetwo
incheswiderthantheheaterandpipedtoan
adequate
drain.Thepanmustnotrestrictcombustion
airflow.Locatethewaterheaterneara suitable
indoordrain.Outsidedrainsaresubjecttofreezing
temperatures
whichcanobstructthedrainline.The
pipingshouldbeat least3/4"IDandpitchedfor
properdrainage.Undernocircumstances
willthe
manufacturer
beheldliableforanywaterdamagein
connection
withthiswaterheater.

Figure 1
Air Moving
Devices

Exhaust
Fan

/
L

Clearances

Pipe to
adequate
drain
At least 2" inches greater
than the diameter of the
water heater.

•

"--_

The water heater should be located in an area not
subject to freezing temperatures. Water heaters
located in unconditioned spaces (i.e., attics,
basements, etc.) may require insulation of the water
piping and drain piping to protect against freezing.
The drain and controls must be easily accessible
for operation and service. Maintain proper
clearances as specified on the data plate.
Do not locate the water heater near an air-moving
device. The operation of air-moving devices such
as exhaust fans, ventilation systems, clothes
dryers, fire-places, etc., can affect the proper
operation of the water heater. Special attention
must be given to conditions these devices may
create. Flow reversal of flue gases may cause an
increase of carbon monoxide inside of the dwelling.

and Accessibility

Notice: Minimum clearances from combustible
materials are stated on the data plate adjacent to the
thermostat of the water heater.
,,

1 3/4" Max

Reverse flow
of gases

The water heater is certified for installation on a
combustible floor.

Important: If installing over carpeting, the carpeting
must be protected by a metal or wood panel beneath
the water heater. The protective panel must extend
beyond the full width and depth of the water heater by
at least 3 inches (76.2mm) in any direction or if in a
alcove or closet installation, the entire floor must be
covered by the panel.
Figure 2 may be used as a reference guide to locate
the specific clearance locations. A minimum of 24
inches of front clearance should be provided for
inspection and service.
Figure 2
Minimum Clearance
Locations

vi"-Back

II* Vent

Sides

CTI_i°Pn
___

service

T®
View

si FI!
es- l

State of California
Note: The water heater must be braced, anchored, or
strapped to avoid moving during an earthquake.
Contact local utilities for code requirements in your area
or call 1-877-817-6750 and request instructions.

Gas Supply

Figure 3
Gas Piping
Manual Gas

c:::3

Sh ut-off Valve

[

Ground
Joint _---_
Union

Check with
local utility
for min. height

Explosion

Use a new AGA or CSA approved
supply line.
Install a shut-off valve.

gas

Do not connect a natural gas water
heater to a L.P. Gas Supply.
Failure to follow these instructions can
result in death, explosion, or carbon
monoxide
poisoning.
OBSERVE ALL GOVERNING

Hazard

3 in. min.

t/
Drip leg"

Gas

Pressure

Important: 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.

Gas Pressure

Testing

CODES AND ORDINANCES.

Gas Requirements
Read the data plate to be sure the water heater is
made for the type of gas you will be using in your
home. This information will be found on the data plate
located near the gas control valve. If the information
does not agree with the type of gas available, do not
install or light. Call your dealer.
Note: An odorant is added by the gas supplier to the
gas used by this water heater. This odorant may fade
over an extended period of time. Do not depend upon
this odorant as an indication of leaking gas.

Gas Piping
The gas piping must be installed according to all local
and state codes or in absence of local and state codes
with the "National Fuel Gas Code", ANSI Z223.1
(NFPA54)-Iatest edition.
Tables 1 and 2 on page 7 are provided as a sizing
reference for commonly used gas pipe materials.
Consult the "National Fuel Gas Code" for the
recommended gas pipe size of other materials.

Important: This water heater and its gas connection
must be leak tested before placing the appliance in
operation.
•

If the code requires the gas lines to be tested at a
pressure exceeding 14" W.C., the water heater and
its manual shut-off valve must be disconnected
from the gas supply piping system and the line
capped.

If the gas lines are to be tested at a pressure less
than 14" W.C., the water heater must be isolated
from the gas supply piping system by closing its
manual shut-off valve.

U.L recognized fuel gas and carbon monoxide (CO)
detectors are recommended in all applications and
should be installed using the manufacturer's
instructions and local codes, rules, or regulations.
Note: Air may be present in the gas lines and could
prevent the pilot from lighting on initial start-up. The gas
lines should be purged of air by a qualified service
technician after installation of the gas piping system.

LP Gas

Refer To Figure 3
Note: When installing gas piping, apply approved pipe
joint compound.
1.

Install a readily accessible manual shut-off valve in
the gas supply line as recommended by the local
utility. Know the location of this valve and how to
turn off the gas to this unit.

Install a drip leg (if not already incorporated as part
of the water heater) as shown. The drip leg must be
no less than 3 inches long for the accumulation of
dirt, foreign material and water droplets.

Install a ground joint union between the gas
valve/thermostat and the manual shut-off valve.
This is to allow easy removal of the gas valve/
thermostat.
Turn the gas supply on and check for leaks. Use a
chloride-free soap and water solution (bubbles
forming indicate a leak) or other approved method.

Explosion

Hazard

Have a qualified
person make sure L.R
gas pressure does not exceed 13" water
column.

Examples
of a qualified
person include
licensed heating personnel,
authorized
gas company
personnel,
and authorized
service personnel.
Failure to do so can result in death,
explosion,
or fire.

Table 1
Natural Gas Pipe Capacity Table (Cu. Ft./hr)
Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity

of 0.60 (natural gas).
Nominal Iron Pipe
Size, in.
10
20
1/2
3/4
1
1-1/4
I-I/2

132
278
520
1050
1600

92
190
350
730
1100

73
152
285
590
890

63
130
245
500
760

56
115
215
440
670

Length of Pipe, Feet
60
70
80
90

100

125

150

175

200

50
105
195
400
610

38
79
150
305
460

34
72
130
275
410

31
64
120
250
380

28
59
110
225
350

26
55
100
210
320

46
96
180
370
560

43
90
170
350
530

40
84
160
320
490

After the length of pipe has been determined, select the pipe size which will provide the minimum cubic feet per hour
required for the gas input rating of the water heater. By formula:
Cu. Ft. Per Hr.

Gas Input of Water

Required=

Heating

Value

Heater

(BTU/HR)

of Gas (BTU/FT

The gas input of the water heater is marked on the water heater data plate. The heating value of the gas (BTU/FT _)
may be determined by consulting the local natural gas utility.

Table 2
LP Gas Capacity Table
Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches water
column pressure). Based on a Pressure Drop of 0.5 Inch Water Column.
Nominal
Iron Pipe
Size, in.
10

1/2
3/4
1
I-1/4

275
576
1071
2205

189
393
732
1496

152
315
590
1212

129
267
504
1039

Length
50

of Pipe,
60

114
237
448
913

103
217
409
834

Feet
70

96
196
378
771

89
185
346
724

83
173
322
677

100

125

150

78
162
307
630

69
146
275
567

63
132
252
511

Example: Input BTU requirement of the water heater I00,000 BTUH
Total pipe length, 80 feet = 3/4" IPS required.
Additional tables are available in the latest edition of the "National Fuel Gas Code", ANSI Z223.1

Combustion
Ventilation

Air Supply

and

Water heaters installed in laundry, hobby or
craft rooms.
Water heaters installed near chemical storage
areas.

Carbon Monoxide Warning
Follow all the local and state codes or in
absence of local and state codes the
"National
Fuel Gas Code", ANSI Z223.1
(NFPA 54)- latest edition to properly
install vent system.
Failure to do so can result in death,
explosion,
or carbon monoxide
poisoning.
Important: Air for combustion and ventilation must not
come from a corrosive atmosphere. Any failure due to
corrosive elements in the atmosphere is excluded from
warranty coverage.
The following types of installation (but not limited to the
following) will require outdoor air for combustion due to
chemical exposure and may reduce but not eliminate
the presence of corrosive chemicals in the air:
,,

Beauty shops

Photo processing labs

Buildings with indoor pools

Combustion air must be free of acid-forming chemicals
such as sulfur, fluorine, and chlorine. These elements
are found in aerosol sprays, detergents, bleaches,
cleaning solvents, air fresheners, paint and varnish
removers, refrigerants, and many other commercial and
household products. When burned, vapors from these
products form highly corrosive acid compounds. These
products should not be stored or used near the water
heater or air inlet.
Combustion and ventilation air requirements are
determined by the location of the water heater. The
water heater may be located in either an open
(unconfined) area or in a confined area or small
enclosure such as a closet or small room. Confined
spaces are areas with less than 50 cubic feet for each
1,000 BTUH of the total input for all gas-using
appliances.

Unconfined

Figure 4
Opening LocationsConfined Spaces

Space

A water heater in an unconfined space uses indoor air
for combustion and requires at least 50 cubic feet for
each 1,000 BTUH of the total input for all gas
appliances. The table below shows a few examples of
the minimum square footage (area) required for various
BTUH inputs.
Table 3
BTUH
Input

9x21

45,000

14x20

60,000

15x25

75,000

15x31

90,000

20 x 28

105,000

20 x 33

120,000

25x 30

135,000

28 x 30

Important:
,,

The area must be open and be able to provide the
proper air requirements to the water heater. Areas
that are being used for storage or contain large
objects may not be suitable for water heater
installation.

Water heaters installed in open spaces in buildings
with unusually tight construction may still require
outdoor air to function properly. In this situation,
outside air openings should be sized the same as
for a confined space.

•

Modern home construction usually requires
supplying outside air into the water heater area.

Confined

...1.._

Closet

Permanent
openings to
the outside or
additional
rooms within
the building

The size of each opening (free area) is determined by
the total BTUH input of all gas utilization equipment
(i.e., water heaters, furnaces, clothes dryers, etc.) and
the method by which the air is provided. The BTUH
input can be found on the water heater data plate.
Additional air can be provided by two methods:
1.

All Air from Inside the Building.

All Air from Outdoors.

or
Other
Confined
Space

12" inch
maximum

All Air from

Inside

the Building

When additional air is to be provided to the confined
area from additional room(s) within the building, the
total volume of the room(s) must be of sufficient size to
properly provide the necessary amount of fresh air to
the water heater and other gas utilization equipment in
the area. If you are unsure that the structure meets this
requirement, contact your local gas utility company or
other qualified agency for a safety inspection.
Each of the two openings shall have a minimum free
area of 1 square inch per 1,000 BTUH of the total input
rating of all gas utilization equipment in the confined
area, but not less than 100 square inches (Figure 5).

Confined
Space

Permanent
Openings
inch/1000
BTUH
(min, 100
+_.....1 sq.square
in)

Space

For the correct and proper operation of this water
heater, ample air must be supplied for the combustion,
ventilation and dilution of flue gases. Small enclosures
and confined areas must have two permanent openings
so that sufficient fresh air can be drawn from outside of
the enclosure. One opening shall be within 12 inches of
the top and one within 12 inches of the bottom of the
enclosure as shown in Figure 4.

Typical Room
with 8' Ceiling

30,000

12" inches maximum

Figure 5
All Air From Inside Building
Confined Space Installation

All Air from

Gable

Outdoors

vent

to outdoors

Outdoor fresh air can be provided to a confined area
either directly or by the use of vertical and horizontal
ducts. The fresh air can be taken from the outdoors or
from crawl or attic spaces that freely communicate with
the outdoors. Attic or crawl spaces cannot be closed
and must be properly ventilated to the outside.
Ductwork must be of the same cross-sectional area as
the free area of the opening to which they connect. The
minimum dimension of rectangular air ducts cannot be
less than 3 inches.
The size of each of the two openings is determined by
the method in which the air is to be provided. Refer to
Table 4 to calculate the minimum free area for each
opening. Figures 6, 7, and 8 are typical examples of
each method.

Louvers

and Grilles

In calculating free area for ventilation and combustion
air supply openings, consideration must be given to the
blocking effect of protection louvers, grilles, and
screens. These devices can reduce airflow, which in
turn may require larger openings to achieve the
required minimum free area. Screens must not be
smaller than 1/4-inch mesh. If the free area through a
particular design of louver or grille is known, it should
be used in calculating the specified free area of the
opening. If the design and free area are not known, it
can be assumed that most wood louvers will allow
20 - 25% of free area while metal louvers and grilles will
allow 60 - 75% of free area.

Install above
insulation

Confined
Space

F
1 sq. inch per
4000 BTUH

Figure 6
All Air from Outdoors; Inlet Air from Ventilated
Crawl Space/Outlet
Air to Ventilated Attic

Gable

[_S

1 Square inch per 4000
BTUH

Figure 6

Vertical ducts

1 Square inch per 4000
BTUH

Figure 7

Horizontal ducts

1 Square inch per 2000
BTUH

Figure 8

nstall above
insulation

Confined
Space

-,-.,,,

b to attic
1 Sq. inch per
4000 BTUH
Inlet air duct
1Outletair
sq. inch per
4000 BTUH

\
\

Figure 7
All Air from Outdoors
Through Ventilated Attic

12" inches max.

and

Based on the total BTUH input rating for all gas utilizing equipment
within the confined space.

Direct to
outdoors

vent

to outdoors

Table 4

Minimum
Free Area
Per Opening
(sq. in.)

Open
Foundation '_
Vent

Keep louvers and grilles clean and free of debris or
other obstructions.

Opening
Source

Inlet air
_ from the
/ crawl
/€ _
space

Alternate
Air Inlet..

Louvers and grilles must be locked open or
interconnected with the equipment so that they are
opened automatically during equipment operation.

Minimum Free Area of Permanent Openings for Ventilation
Combustion
Air Supply - All Air from Ou_oor Only.

" Outlet
air to attic
1 Sq. inch per
4000 BTUH

1 Sqe,rnCh_..

Reference

2000

Drawing
Confined
Space

BTU H

"___

Outlet

t
Outdoor
Air Ducts

Inlet

Example: A water heater with an input rate of 50,000 BTUH using
horizontal ducts would require each opening to have a minimum
free area of 25 square inches.
Minmum Free area = 50,000 BTUH x 1 sq. in. / 2000 BTUH = 25
Sq. Inches.

These openings connect directly with the outdoors
through a ventilated attic, a ventilated crawl space,
or through an outside wall.
Consult the local codes of your area for specific
ventilation and combustion air requirements.

Figure 8
All Air from Outdoors
Using Horizontal
Ducts

1 sq. Inch
per
2000 BTUH

Vent Pipe System

Vent Pipe Size

This water heater uses a non-direct, single-pipe vent
system to remove exhaust gases created by the
burning of fossil fuels. Air for combustion is taken from
the immediate water heater location or is ducted in from
the outside (see "Combustion Air Supply and
Ventilation").

The vent pipe must be installed according to all local
and state codes or in absence of local and state codes
with the "National Fuel Gas Code", ANSI Z223.1
(NFPA54)-Iatest edition. It is important that you follow
the guidelines in these instructions for sizing a vent pipe
system. If a transition to a larger vent size is required,
the vent transition connection must be made at the
drafthood outlet.

This water heater must be properly vented for the
removal of exhaust gases to the outside atmosphere.
Correct installation of the vent pipe system is
mandatory for the proper and efficient operation of this
water heater and is an important factor in the life of the
unit.
The vent pipe must be installed according to all local
and state codes or in absence of local and state codes
with the "National Fuel Gas Code", ANSI Z223.1
(NFPA54)qatest edition. The vent pipe installation must
not be obstructed so as to prevent the removal of
exhaust gases to the outside atmosphere.
U.L recognized fuel gas and
detectors are recommended
should be installed using the
instructions and local codes,

carbon monoxide (CO)
in all applications and
manufacturer's
rules, or regulations.

Important:
If you lack the necessary skills required to
properly install this venting system, you should not
proceed, but get help from a qualified installation
technician.

Drafthood

Installation

Align the legs of the draft hood with the slots provided.
Insert the legs and secure the drafthood to the water
heater's top with the four screws provided as shown in
Figure 9. Do not alter the drafthood in any way. If you
are replacing an existing water heater be sure to use
the new drafthood supplied with the water heater.
Figure 9
Drafthood Installation

heet_tal

Screws (four provided)
_-_

Jacket top

Connectors

Type B, Double Wall, U.L Listed Vent Pipe.

Single Wall Vent Pipe.

Maintain the manufacturer's specified minimum
clearance from combustible materials when using type
B doublewall vent pipe.
Vent connectors made of type B, double wall vent pipe
material may pass through walls or partitions
constructed of combustible material if the minimum
listed clearance is maintained.
Maintain a 6 inch minimum clearance from all
combustible materials when using single wall vent pipe.
Important: Single wall vent pipe cannot be used for
water heaters located in attics and may not pass
through attic spaces, crawl spaces or any confined or
inaccessible location. Asingle wall metal vent connector
cannot pass through any interior wall.
When installing a vent connector, please note the
following:
•

Install the vent connector avoiding unnecessary
bends, which create resistance to the flow of vent
gases.

Install without dips or sags with an upward slope of
at least 1/4-inch per foot.

Joints must be fastened by sheet metal screws or
other approved means. It must be supported to
maintain clearances and prevent separation of
joints and damage.

The length of the vent connector cannot exceed
75% of the vertical vent height.

•

The vent connector must be accessible for
cleaning, inspection and replacement.

•

Vent connectors cannot pass through any ceiling,
floor, fire wall, or fire partition.

Drafthood

Install the drafthood with
the four screws provided.

Vent

Important: Existing vent systems must be inspected for
obstructions, corrosion and proper installation.

Chimney

Connection

Important: Before connecting a vent to a chimney,
make sure the chimney passageway is clear and free of
obstructions. The chimney must be cleaned if
previously used for venting solid fuel appliances or
fireplaces.
•

The connector must be installed above the extreme
bottom of the chimney to prevent potential
stoppage of the flue gases.
The connector must be firmly attached and sealed
to prevent it from falling out.

To aid in removing the connector, a thimble or slip
joint may be used.

The connector must not extend beyond the inner
edge of the chimney as it may restrict the space
between it and the opposite wall of the chimney
(Figure 10).

Do not terminate the vent connector in a chimney that
has not been certified for this purpose. Some local
codes may prohibit the termination of vent connectors
in a masonry chimney.

Vertical

Exhaust

Gas Vent

I
Maintain
clearance

_himney
2 ft. min. above any object
within 10 ft,
Horizontally

3 Ft. Min.._1

Do not extend
beyond edge
of chimney

6 inches
minimum
Connector

Figure 11
Vertical Gas

Cap

Vent System
With Type B
Double Wall

2 ft. min. above any object
within 10 ft,
horizontally

Vent Pipe

Maintain
clearance

Vertical exhaust gas vents must be installed with UL
listed type B vent pipe according to the vent
manufacturer's instructions and the terms of its listing.
It must be connected to the water heater's drafthood by
a certified vent connector or by directly originating at
the drafthood opening.

Certified Lined

Figure 10
Chimney Termination
Vent System

Type B Double
Wall Vent Pipe

Maintain
specified
clearance

6 inches
minimum

Vertical gas vents must terminate with a listed cap or
other roof assembly and be installed according to their
manufacturer's instructions.
Gas vents must be supported to prevent damage, joint
separation, and maintain clearances to combustible
materials (Figures 11 and 12).
Important: This gas vent must be terminated in a
vertical position to facilitate the removal of the burnt
gases.
An unused chimney flue or masonry enclosure may be
used as a passageway for the installation of a gas
vent(Figure 12).
Common (combined) venting is allowable with vertical
type B vent systems and lined masonry chimneys. The
vent pipe must be installed according to all local and
state codes or in absence of local and state codes with
the "National Fuel Gas Code", ANSI Z223.1 (NFPA 54)latest edition.

Figure 12
Venting Through
a Chimney
with Type B Double
Wall Vent Pipe.

_,
5 inches min,

_l'_Listed

Vent Cap
Maintain
specified
clearance

Maintain
clearance

±
t
6 inches
minimum

Vent
Connector
Unused chimney
flue or masonry
enclosure

Figures 10-12 are examples of vent pipe system
installations and may or may not be typical for your
specific application. Consult the "National Fuel Gas
Code", NFPA54, ANSI Z223.1-1atest edition and the
guidelines set forth by prevailing local codes.

Water System Piping
Piping Installation
Piping, fittings, and valves should be installed according
to the installation drawing (Figure 13). If the indoor
installation area is subject to freezing temperatures, the
water piping must be protected by insulation.
Water supply pressure should not exceed 80% of the
working pressure of the water heater. The working
pressure is stated on the water heater's data plate. If
this occurs a pressure limiting valve with a bypass may
need to be installed in the cold water inlet line. This
should be placed on the supply to the entire house in
order to maintain equal hot and cold water pressures.

After piping has been properly connected to the
water heater, remove the aerator at the nearest hot
water faucet. Open the hot water faucet and allow
the tank to completely fill with water. To purge the
lines of any excess air, keep the hot water faucet
open for 3 minutes after a constant flow of water is
obtained. Close the faucet and check all
connections for leaks.
Figure 13
Water Piping Installation

_,
Cold Water
Inlet Valve

Important:
Some models may contain energy saving
heat traps to prevent the circulation of hot water within
the pipes. Do not remove the inserts within the heat
traps.
2.

The manufacturer of this water heater recommends
installing a tempering valve or an anti-scald device
in the domestic hot water line as shown in Figure
14. These valves reduce the point of use
temperature of the water by mixing cold and hot
water and are readily available for use. Contact a
licensed plumber or the local plumbing authority.

If installing the water heater in a closed water
system, install a relief valve or expansion tank in
the cold water line as specified under "Closed
System/Thermal Expansion" (Page 13).

Install a shut-off valve in the cold water inlet line. It
should be located close to the water heater and be
easily accessible. Know the location of this valve
and how to shut off the water to the heater.

The installation of unions in both the hot and cold
water supply lines is recommended for ease of
removing the water heater for service or
replacement.

Install a temperature and pressure relief valve in
the opening marked "Temperature and Pressure(T
& P) Relief Valve" on the water heater. Add a
discharge line to the opening of the T & P relief
valve. Follow the instructions under Temperature
and Pressure Relief Valve" (Page 14).

Cold Water
Inlet

perature and
Pressure Relief Valve
Discharge line

Important: Always use a good grade of joint compound
and be certain that all fittings are drawn up tight.
Install the water piping and fittings as shown in
Figure 13. Connect the cold water supply (3/4"
NPT) to the fitting marked "C". Connect the hot
water supply (3/4" NPT) to the fitting marked "H".

Pressure
valve
with reducing
bypass

Hot Water

Important: Heat cannot be applied to the water fittings
on the heater as they may contain nonmetallic parts. If
solder connections are used, solder the pipe to the
adapter before attaching the adapter to the hot and cold
water fittings.

In a closed system
use either:
1. Thermal Expansion Tank
_"
2. Pressure Relief Valve

above drain
Drain line
3/4 inch ID

Drain Pan _"
1 3/4 inch depth max.

j
Drain
minimum

Figure 14
Typical Tempering
Valve Installation
l

Install vacuum relief
in
cold water line per ]
Massachusetts:
sect on 19 MGL142.

Water
Cold
Inlet

Follow the tempering
valve manufacturer's
instructions.

Tempered water
to fixtures
Tempering valve
(Set to 120 ° f)

Pleasenotethefollowing:
DONOTinstallthiswaterheaterwithironpiping.
Thesystemshouldbeinstalledonlywithnewpiping
thatis suitableforpotable(drinkable)
watersuchas
copper,CPVC,or polybutylene.
DONOTusePVC
waterpiping.
DONOTuseanypumps,valves,or fittingsthatare
notcompatible
withpotablewater.
DONOTusevalvesthatmaycauseexcessive
restriction
towaterflow.Usefullflowballor gate
valvesonly.
DONOTuse50/50tin-leadsolder(oranylead
basedsolder)inpotablewaterlines.Use95/5tinantimonyorotherequivalent
material.
DONOTtamperwiththegasvalve/thermostat,
igniter,thermocouple,
or temperature
andpressure
reliefvalve.Tampering
voidsallwarranties.
Only
qualifiedtechnicians
shouldservicethese
components.
DONOTusewithpipingthathasbeentreatedwith
chromates,
boilerseal,orotherchemicals.
DONOTaddanychemicals
to thesystempiping
whichwillcontaminate
thepotablewatersupply.

Closed

System/Thermal

Expansion

Periodic discharge of the temperature and pressure
relief valve may be due to thermal expansion in a
closed water supply system. The water utility supply
meter may contain a check valve, backflow preventer or
water pressure reducing valve. This will create a closed
water system. During the heating cycle of the water
heater, the water expands causing pressure inside the
water heater to increase. This may cause the
temperature and pressure relief valve to discharge
small quantities of hot water. To prevent this from
happening, there are two recommendations:
1.

Install a diaphragm-type expansion tank that is
suitable for potable water on the cold water supply
line. The expansion tank must have a minimum
capacity of 1.5 U.S. gallons for every 50 gallons of
stored water.
Install a 125 PSI pressure relief valve in the cold
water supply line. Make sure the discharge of this
valve is directed to an open drain and protected
from freezing. Contact the local water supplier or
plumbing inspector for information on how to
control this situation. Do not plug the temperature
and pressure relief valve.

Temperature
Relief Valve

and Pressure

Important: Only a new temperature and pressure relief
valve should be used with your water heater. Do not
use an old or existing valve as it may be damaged or
not adequate for the working pressure of the new water
heater. Do not place any valve between the relief valve
and the tank.
The Temperature

Explosion

Hazard

Temperature and
Pressure Relief Valve

Discharge line 3/4
min.
Do not cap or plug.

6 inch
- maximum
Drain
l
Drain Pan

t Figure

15
Temperature and Pressure
Relief Valve Installation

For protection against excessive pressures and
temperatures, a temperature and pressure relief valve
must be installed in the opening marked "T & P RELIEF
VALVE" (see Figure 15). This valve must be design
certified by a nationally recognized testing laboratory
that maintains periodic inspection of the production of
listed equipment or materials as meeting the
requirements for Relief Valves andAutomatic Shut-off
Devices for Hot Water Supply Systems, ANSI Z21.22.
The function of the temperature and pressure relief
valve is to discharge water in large quantities in the
event of excessive temperature or pressure developing
in the water heater. The valve's relief pressure must not
exceed the working pressure of the water heater as
stated on the data plate.

& Pressure Relief Valve:

Must not be in contact with any electrical part.

Must be connected to an adequate discharge line.

Must not be rated higher than the working pressure
shown on the data plate of the water heater.

The Discharge

Line:

Must not be smaller than the pipe size of the relief
valve or have any reducing coupling installed in the
discharge line.

•

Must not be capped, blocked, plugged or contain
any valve between the relief valve and the end of
the discharge line.

•

Must terminate a maximum of 6 inches above a
floor drain or external to the building.

Must be capable of withstanding 250°F (121°C)
without distortion.

Must be installed to allow complete drainage of
both the valve and discharge line.

Special Applications
Combination
Space Heating/Potable
Water System
Some water heater models are equipped with
inlet/outlet tappings for use with space heating
applications. If this water heater is to be used to supply
both space heating and domestic potable (drinking)
water, the instructions listed below must be followed.
•

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 existing boiler installation.

•

Do not use with piping that has been treated with
chromates, boiler seal or other chemicals and do
not add any chemicals to the water heater piping.

If the space heating system requires water
temperatures in excess of 120°F, a tempering valve
or an anti-scald device should be installed per its
manufacturer's instructions in the domestic
(potable) hot water supply to limit the risk of scald
injury.

•

Pumps, valves, piping and fittings must be
compatible with potable water.

Some jurisdictions may require a backflow preventer in
the incoming cold water line. This may cause the
temperature and pressure relief valve on the water
heater to discharge or weep due to expansion of the
heated water. A diaphragm-type expansion tank
suitable for potable water will normally eliminate this
weeping condition. Please read and follow the
manufacturer's instructions for the installation of such
tanks.
Also see "Water System Piping" (Page 12) for
additional instructions on the safe and correct
installation and operation of this water heater.

Solar Installation
If this water heater is used as a solar storage heater or
as a backup for the solar system, the water supply
temperatures to the water heater tank may be in excess
of 120°F. Atempering valve or other temperature
limiting valve must be installed in the water supply line
to limit the supply temperature to 120°F.
Note: Solar water heating systems can often supply
water with temperatures exceeding 180°F and may
result in water heater malfunction.
Domestic

Hot Water
Must be vertical to
air bubbles
Out "_'/--remove
/

A properly installed flow control valve is required to
prevent thermosiphoning. Thermosiphoning is the
result of a continuous flow of water through the air
handler circuit during the off cycle. Weeping (blow
off) of the temperature and pressure relief valve (T
& P) or higher than normal water temperatures are
the first signs of thermosiphoning.
•

The domestic hot water line from the water heater
should be vertical past any tempering valve or
supply line to the air handler to remove air bubbles
from the system. Otherwise, these bubbles will be
trapped in the air handler heat exchanger coil,
reducing the efficiency.
Do not connect the water heater to any system or
components previously used with non-potable
water heating appliances when used to supply
potable water.

Temperingn

Cold

Valve-,,,_J.[_
1_1
c::_,_::=:::::::__

HotII
I tJl
Water
_t;l_]_ _
"_

out
Unions

Flow Control

Water
Inlet

Pump

Valve

it----I1

_ ___._t

ATe
r

Handler

III

Shut-off

Figure 16
Typical Tempering Valve Installation
Combination Space Heating/Potable
Water Heating System

Massachusettscode does not
a 0w th s type of nsta aton

installation Checklist
Water
•

Heater Location

Vent Pipe System

Centrally located with the water piping system.
Located as close to the gas piping and vent pipe
system as possible.

•

Drafthood properly installed.

•

Vent connectors securely fastened with screws and
supported properly to maintain 6 inch clearance.

Located indoors and in a vertical position.
Protected from freezing temperatures.

Vent connector made of approved material and
sized correctly.

Proper clearances from combustible surfaces
maintained and not installed directly on a carpeted
floor.

•

Provisions made to protect the area from water
damage. Drain pan installed and piped to an
adequate drain.

Vent pipe system in accordance to all local and
state codes or in absence of local and state codes
with the "National Fuel Gas Code", NFPA54, ANSI
Z223.1-1atest edition.

Flue baffle engaged in slots provided in the flue
tube.

Flue way, drafthood or vent pipe system not
obstructed in any way.

•

Installation area free of corrosive elements and
flammable materials.

•

Sufficient room to service the water heater.
Water heater not located near an air moving device.

Combustion
,,

Air Supply

and Ventilation

Water System
,,

Sufficient fresh air supply for proper water heater
operation.

•

Fresh air openings sized correctly with
consideration given to the blocking effect of louvers
and grilles.
Ductwork is the same cross-sectional area as the
openings.

Temperature and pressure relief valve properly
installed with a discharge line run to an open drain
and protected from freezing.
All piping properly installed and free of leaks.

Fresh air not taken from areas that contain negative
pressure producing devices such as exhaust fans,
fireplaces, etc.
Fresh air supply free of corrosive elements and
flammable vapors.

Piping

Heater completely filled with water.
Closed system pressure build-up precautions
installed.
•

Tempering valve installed per manufacturer's
instructions.

Gas Supply and Piping
•

Gas supply is the same type as listed on the water
heater data plate.

Gas line equipped with shut-off valve, union and
drip leg.
Approved pipe joint compound used.

Adequate pipe size and of approved material.

Chloride-free soap and water solution or other
approved means used to check all connections and
fittings for possible gas leaks.

OPE
Lighting

G YOUR

EATE

instructions

LP.G.

Read and understand these directions thoroughly
before attempting to light or re-light the pilot. Make sure
the tank is completely filled with water before lighting
the pilot. Check the data plate near the gas valve
control/thermostat for the correct gas. Do not use this
water heater with any gas other than the one listed on
the data plate. If you have any questions or doubts,
consult your gas supplier or gas utility company.

(Bottled

Propane)

Models

Liquefied Petroleum Gas is over 50% heavier than air
and in the occurrence of a leak in the system the gas will
settle at floor level. Basements, crawl spaces, skirted
areas under mobile homes (even when ventilated),
closets and areas below ground level will serve as
pockets for the accumulation of gas. Before lighting an
LP. gas water heater, smell all around the appliance at
floor level. If you smell gas, follow the instructions as
given in the warning on the front page.
When your LP. tank runs out of fuel, turn off the gas at
all gas appliances including pilot lights. After the tank is
refilled, all appliances must be re-lit according to their
manufacturer's instructions.

Explosion

Hazard

Replace viewport
if glass is missing or damaged.
Failure to do so can result in death, explosion or fire.

LIGHTINGINSTRUCTIONS
1. Remove the outer door.
2. Turn the temperature

Depress

dial counterclockwise

to its

button

lowest setting.

the reset button

all the way

in and IMMEDIATELY depress the igniter
until

you

hear a loud

click.

Observe the pilot through the view port.
Do not release the reset button. Repeat
120 ° F
BAR

_o_N

immediately

if pilot does not light

the first try. If the pilot does not light
by the fourth

attempt with the i_

_eat

steps 3 - 6. Continue to hold the

button

for about

(1) minute

after the

pilot is lit. Release the reset button and
it will pop back up. Pilot should remain
lit.

If the pilot

light

goes out, repeat

steps 2- 6.
IMPORTANT: If the pilot will not stay lit after several tries,
turn gas control knob to "OFF" and call your service

3. Turn gas control knob clockwise _'

technician

to the "OFF" position.

IMPORTANT: If the reset button does not pop up when

4. To clear any gas that may have
accumulated

or gas supplier.

released, stop and immediately

wait ten (10) minutes.

If you then smell gas, STOPt Refer to the safety warning

shut off the gas at the line

valve or tank. Call your service technician

or gas supplier.

on the cover. If you do not smell gas go to the next step.
7. Turn
the gas control_ knob
counterclockwise
to"ON".

5. Turn the gas control knob
counterclockwise
V(_

8. Set the temperature

to "PILOT".

dial to

the desired setting.
9. Replace the outer door.

TO TURN OFFGAS TO APPLIANCE
1. Turn the temperature
lowest setting,

dial counterclockwise

_'_

to its

2. Turn the gas control knob clockwise

to the "OFF"

position.

Checking

the Draft

Water Temperature

Regulation

Burn Hazard
Do not touch

vent.

Doing so can result
burns.

After successfully lighting the water heater, allow the
unit to operate for 15 minutes and check the drafthood
relief opening for proper draft. Pass a match flame
around the relief opening of
Figure
17
the drafthood. A steady
Relief
flame drawn into the
opening indicates proper
draft. If the flame flutters or
is blown out, combustion
Ma_
Opening
products are escaping from
the relief opening. If this
occurs, do not operate the
water heater until proper
adjustments or repairs are made to the vent pipe
system.

Burner

Flames
Figure
Flame

18
Characteristics

Inspect the burner
Tips may have
flames through the
a yellow tint
viewport and compare
them to the drawings in
cones
are
atisfactory
Figure 18. A properly
egow inner
operating burner
should produce a soft
Correct
flame
incorrect
flame
soft blue
lazy yellow
blue flame. Blue tips
with yellow inner cones
are satisfactory. The tips of the flame may have a slight
yellow tint. The flame should not be all yellow or have a
sharp blue-orange color. Contaminated air may cause
an orange colored flame. Contact a qualified service
technician if the flame is not satisfactory.

Water temperature
over 125°F can cause
severe burns instantly or death from
scalds.
Children,
disabled and elderly are at
highest risk of being scalded.
See instructions manual before setting
temperature
at water heater.
Feel water before bathing or showering.
Temperature
limiting valves are available.
The thermostat is adjusted to its lowest temperature
when it is shipped from the factory. Water temperature
can be regulated by moving the temperature dial to the
preferred setting. The preferred starting point is
120°F. Align the index bar on the thermostat with the
desired water temperature as shown in Figure 19.
There is a hot water scald potential if the
thermostat is set too high.
Important:
Adjusting the thermostat past the 120°F bar
on the temperature dial will increase the risk of scald
injury. Hot water can produce first degree burns within:
120°F
130°F
140°F
150°F
160°F
Figure
19
Robertshaw

Gas Valv_

(49°C)
(54°C)
(60°C)
(66°C)
(71 °C)

more than 5 minutes
at 20 seconds
at 3 seconds
at 1-1/2 seconds
at less than 1 second

Thermostat

Settings

Shut

Down

Important: Should overheating occur or the gas supply
fails to shut off, turn off the water heater's manual gas
control valve and call a qualified service technician.

120°F

Gas

Stacking occurs when a series of short draws of hot
water (3 gallons or less) are taken from the water
heater tank. This causes increased cycling of the
burner and can result in increased water temperatures
at the hot water outlet. An anti-scald device is
recommended in the hot water supply line to reduce the
risk of scald injury.

Emergency

130OF

Reset

Stacking

Control
Knob
Dial
Stop
Index
Bars

130OF
Bar

Note: During low demand periods when hot water is
not being used, a lower thermostat setting will reduce
energy losses and may satisfy your normal hot water
needs. If hot water use is expected to be more than
normal, a higher thermostat setting may be required to
meet the increased demand. When leaving your home
for extended periods (vacations, etc.) turn the
temperature dial to its lowest setting. This will maintain
the water at low temperatures with minimum energy
losses and prevent the tank from freezing during cold
weather.

Operational

Conditions

Condensation
Moisture from the products of combustion condenses
on the tank surface and the outside jacket of the water
heater and forms drops of water which may fall onto the
burner or other hot surfaces. This will produce a
"sizzling" or "frying" noise. This condensation
is
normal and should not be confused with a leaking
tank. Condensation may increase or decrease at
different times of the year.
High efficient energy saver water heaters will produce
larger amounts of condensation on initial start up or
when a large amount of hot water is being used. Do not
confuse this with a "tank leak". Once the water
reaches a temperature of 120°F and the tank warms up
(usually 1-2 hours), the condensation will stop.
Important: It is always recommended that a suitable
drain pan be installed under the water heater to protect
the area from water damage resulting from normal
condensation production, a leaking tank or piping
connections. Refer to "Location Requirements" on page
4. Under no circumstances is the manufacturer to be
held responsible for any water damage in connection
with this water heater.

Water Heater Sounds
During the normal operation of the water heater, sounds
or noises may be heard. These noises are common and
may result from the following
1.

Normal expansion and contraction of metal parts
during periods of heat-up and cool-down.

Condensation causes sizzling and popping within
the burner area and should be considered normal.

Sediment buildup in the tank bottom will create
varying amounts of noise and may cause
premature tank failure. Drain and flush the tank as
directed under "Draining and Flushing".

Smoke/Odor
The
and
due
unit

water heater may give off a small amount of smoke
odor during the initial start-up of the unit. This is
to the burning off of oil from metal parts of a new
and will disappear after a few minutes of operation.

which is designed to disable the gas valve in the event
of excessive combustion chamber temperatures or a
flammable vapor ignition. If the fuse opens, the water
heater cannot be used unless the thermocouple is
replaced by a qualified service technician. Contact the
Product Service and Support Department for service
information at 1-877-817-6750.
A high temperature limit switch or ECO (Energy Cut Off)
in the tank is used to shut off the unit if the water
temperature exceeds 180°F (83°C). The ECO is a
single use switch and requires complete replacement of
the entire thermostat. If the ECO should function, the
water heater cannot be used until the thermostat is
replaced by a qualified service agency. Contact your
local dealer for service information.

Anode

Rod/Water

Odor

Each water heater contains at least one anode rod,
which will slowly deplete while protecting the glass-lined
tank from corrosion and prolonging the life of the water
heater. Certain water conditions will cause a reaction
between this rod and the water. Once the anode is
depleted, the tank will start to corrode, eventually
developing a leak. The most common complaint
associated with the anode rod is a "rotten egg smell"
produced from the presence of hydrogen sulfide gas
dissolved in the water. Do not remove this rod
permanently as it will void any warranties, stated or
implied. The parts list includes a special anode that
can be ordered if water odor or discoloration occurs.
This rod may reduce but not eliminate water odor
problems. The water supply system may require special
filtration equipment from a water conditioning company
to successfully eliminate all water odor problems.
Artificially softened water is exceedingly corrosive
because the process substitutes sodium ions for
magnesium and calcium ions. The use of a water
softener may decrease the life of the water heater tank.
The anode rod should be removed from the water
heater tank every 3 years for inspection. If the rod is
more than 50% depleted, the anode rod should be
replaced.
In replacing the anode:
1.

Turn off gas supply to the water heater.

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

This water heater is designed to automatically shut-off
in the event of the following:

Drain approximately 5 gallons of water from tank
(Refer to "Draining and Flushing" for proper
procedures). Close drain valve.

Remove old anode rod.

The pilot flame is extinguished for any reason.

The water temperature exceeds 180°F (83°C).

Use Teflon® tape or approved pipe sealant on
threads and install new anode rod.

Excessive combustion chamber temperatures.

The ignition of flammable vapors.

Safety Shut-off

A thermocouple is used to determine if a pilot flame is
present and will shut off the gas supply to the main
burner and the pilot burner if the flame is absent. In
addition, as part of the Flame Lock TM safety system,
this thermocouple is equipped with a thermal fuse

Turn on water supply and open nearby hot water
faucet to purge air from water system.
Restart the water heater as directed under
"Operating Your Water Heater." See the "Repair
Parts Illustration" for anode rod location on
page 27.

NTENANCE
Draining

OF YOU

and Flushing

It is recommended that the tank be drained and flushed
every 6 months to remove sediment which may buildup
during operation. The water heater should be drained if
being shut down during freezing temperatures. To drain
the tank, perform the following steps:
1.

Turn off the gas to the water heater at the Manual
Gas Shut-off Valve.

Close the cold water inlet valve.

3.
4.

Open a nearby hot water faucet.
Connect a hose to the drain valve and terminate it
to an adequate drain.

Note: The drain hose should be rated for at least
200°F. If the drain hose does not have this rating, open
the cold water inlet valve and a nearby hot faucet until
the water is no longer hot.
5.

Open the water heater drain valve and allow all the
water to drain from the tank. Flush the tank with
water as needed to remove sediment.

Close the drain valve, refill the tank, and restart the
heater as directed under "Operating Your Water
Heater".

If the water heater is going to be shut down for an
extended period, the drain valve should be left open.
Important:
Condensation may occur when refilling the
tank and should not be confused with a tank leak.

3 Month Inspection
At least every 3 months, a visual inspection should be
made of the venting and air supply system, piping
systems, main burner and pilot burner. Check the water
heater for the following:

EATER

Temperature
Relief Valve

and Pressure

Explosion

Hazard

If the temperature
and pressure
relief
valve is dripping
or leaking, have a
licensed plumber repair it.
Do not plug valve.
Do not remove valve.
Failure to follow these instructions can
result in death, or explosion.
Manually operate the temperature and pressure relief
valve at least once a year to make sure it is working
properly. To prevent water
Figure 20
damage, the valve must
be properly connected to
a discharge line which
terminates at an
adequate drain. Standing
clear of the outlet
(discharged water may be
hot), slowly lift and
release the lever handle
Discharge
line to drain
on the temperature and
pressure relief valve to
allow the valve to operate freely and return to its closed
position. If the valve fails to completely reset and
continues to release water, immediately shut off the
manual gas valve and the cold water inlet valve and call
a qualified service technician.

•

Obstructions, damage, or deterioration in the
venting system. Make sure the ventilation and
combustion air supplies are not obstructed. See
section titled "Cleaning the Combustion Chamber
and Flame-trap."

Build-up of soot and carbon on the main burner and
pilot burner. Check for a soft blue flame.

Self-Cleaning

,,
,,

Leaking or damaged water and gas piping.
Presence of flammable or corrosive materials in the
installation area.

•

Presence of combustible materials near the water
heater.

Some water heaters may include a self-cleaning device
that inhibits the build-up of lime and other sediment on
the metal surfaces of the water heater. As cold water
passes through the dip tube, lime-causing particles and
minerals are suspended automatically. This controls
sediment and lime build-up within the tank and results
in higher efficiencies and lower operation costs.

Important: Verify proper operation after servicing this
water heater.

WATER

(Some Models)

Replacement

Parts

Figure
22
Burner Assembly
Removal

The following maintenance procedures are for the
Flame Lock TM safety system components and
should be performed by a qualified service
technician.

Gas Valve
Thermostat

Model, serial and product number.

Type of gas.

Item number.

Parts description.

Turn off the gas to the water heater at the manual
shut-off valve (Figure 3).

Turn the gas control knob on the combination gas
control valve/thermostat
Figure 21
clockwise to the "OFF"
Igniter
position (Figure 19).
Remove the outer door.

Piece Wire

Connector

Manifold
Door

(2)

from

the

Natural Gas Burner

the Manifold Assembly

Remove the (2) screws
securing the manifold door
assembly to the skirt
(Figure 22).
Disconnect the
thermocouple (left-hand
thread), pilot tube, the
igniter wire from the igniter
button, and manifold tube
at the thermostat. (Figure
21.) Note: LR gas
systems use reverse (lefthand) threads on the
manifold tube.

Two

Tube

Removing
the Burner
Manifold Assembly

Tube

Manifold

See page 27 for a list of available repair parts.

Pilot
Manifold

Screw

Removing

igniter

Thermocouple

Replacement parts may be ordered through your
plumber or the local distributor. Parts will be shipped at
prevailing prices and billed accordingly. When ordering
replacement parts, always have the following
information ready:
1.

Piezo

Turn the burner counterclockwise
the manifold assembly.

Check the burner to see if it is dirty or clogged. The
burner may be cleaned with soap and hot water
(Figure 23A).

Figure 23A
Natural
Gas

Burner

Assembly

burner
To remove

Two Piece Wire
Connector

Burner

to remove it from

Manifold Door
Assembly

Igniter

Thermocouple

Wire
1

Manifold
Tube

Gasket

Thermocouple
Viewport

Thermocouple

Pilot
Tube
Manifold

Thermocouple
Retainer
Clip

Pilot Assembly

Tube

Grasp the manifold tube and push down slightly to
free the manifold, pilot tube, and thermocouple.

Carefully remove the manifold assembly from the
burner compartment. Be sure not to damage
internal parts.

Natural
1.
.

Gas Burner (Low

Nox)

Replacing

Take off the burner by removing the two(2) screws
located underneath the burner.
Check the burner to see if it is dirty or clogged. The
burner may be cleaned with soap and hot water
(Figure 23B).

Figure
Natural

23B
Gas (Low

Burner

Manifold Door
Assembly

Nox)

Assembly

Important:
Use only a factory authorized Flame
Lock TM safety system thermocouple for replacement.
1.

Remove the manifold assembly as directed
previously.

Remove the retainer clip from the back of the two
piece wire connector. Remove the two piece wire
connector from the manifold door. Remove the
thermocouple (Figure 24).

Pull the thermocouple from the pilot assembly.
(Figures 23, and 27).

Push the new thermocouple through the holes in
the pilot bracket. Insert the thermocouple tube into
the holes provided in the pilot assembly until it
clicks into place.

Position the new thermocouple through the larger
opening of the two piece wire connector (Figure
24). Note: Thermocouple
contains a thermal
fuse. Do not bend in the location shown below
(Figure 25). Be sure igniter wire is positioned
through the small opening of the two piece wire
connector.

S
Two

Burner

Piece

Wire

Connector

,_.

Igniter

Wire

Pilot

Tube

Gasket

Pilot
Thermocouple
Retainer

Clip

Thermocouple

Bracket

Viewport

\
Pilot

Assembly

LP. Gas Burner
1.
2.

Separate the pilot bracket from the LR burner by
removing screw.
Loosen set screw located on top of the L P. burner
near the manifold door. Carefully, pull the burner
away from the manifold door assembly.
Check the burner to see if it is dirty or clogged. The
burner may be cleaned with soap and hot water
(Figure 23C).

Figure
23C
LP. Gas Burner

Manifold
Two

Assembly

Piece
Gasket

the Thermocouple

See "Replacing Manifold Assembly" at the top of
next column.

Figure 24
Two Piece Wire

Other fittings
not shown

Connector

for

Assembly

igniter
Wire
Retainer

Manifold
Door
Assembly

Door

Manifold

Wire
_ig

Thermocouple
niter

Wire

Pilot
Tube
Manifold

Two Piece"
Wire Connector
Thermocouple
,'iewport
Pilot

Assembly
Thermocoupte
Retainer
Clip

Pilot

Bracket

Figure 25
Thermocouple
Assembly
Notice:
Thermocouple
must not be bent
in this location.

Clip

/
Door

clarity

Cleaning the Combustion
and Flame-trap

Chamber

Follow procedure outlined in "Removing the
Manifold Assembly".

Use a vacuum cleaner/shop vac to remove all loose
debris in the combustion chamber and flame-trap.
See Figure 26.

Reassemble following the procedure under
"Replacing the Manifold Assembly".

Replacing

the Manifold Assembly

Figure 26
_,
,
Combustion Chamber

Explosion

Hazard

Tighten both manifold door screws
securely.
Remove any fiberglass
between gasket
and combustion chamber.
Replace viewport if glass is missing
or
damaged.
Replace two piece wire connector if
missing
or removed.
Replace door gasket if damaged.
Failure to do so can result in death,
explosion,
or fire.
1.

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

Inspect the viewport
required.

Insert the manifold assembly into the burner
compartment making sure that tab of the manifold
tube engages in the slot of the bracket inside the
combustion chamber (Figure 26). The tab is located
at the bottom of the burner for L.R models.

for damage and replace as

Bracket

IIHII
u_J

Inspect the door gasket and make sure there is no
fiberglass insulation between the gasket and the
combustion chamber.
Replace the two (2) screws which secure the
manifold assembly door to the combustion
chamber. Tighten securely. There should be no
space between the gasket part of the manifold door
and combustion chamber. Do not operate the
water heater if the door gasket is not sealed.
Reconnect the manifold tubing, pilot tubing, and
thermocouple to the thermostat. Do not crossthread or apply any thread sealant to these fittings.
Note: L R gas systems use reverse (lefthand) threads on the manifold tube.
,,

The thermocouple nut should be started and
turned all the way in by hand. Note: These are
left-hand threads. An additional quarter turn
with a 7/16" open-end wrench will then be
sufficient to seat the Iockwasher.

Reconnect the igniter wire.

Turn gas supply on and refer to the "Lighting
Instructions" on page 17.

Check for leaks. Use a chloride-free soap and
water solution (bubbles forming indicate a leak) or
other approved method. All leaks must be fixed
immediately.

10. Replace the outer door.

Piezoelectric

Igniter

System

The piezoelectric igniter system is part of the Flame
Lock TM safety system and consists of the igniter button,
electrode and wire. The pilot is ignited by an electric
spark generated when the igniter button is pressed. The
spark gap of 0.125 inch is set when the electrode is
installed at the factory. (See Figure 27Aand 27B). Use
only factory authorized Flame Lock TM safety system
piezoelectric igniter parts for replacement.
Figure 27A
Natural Gas igniter

Assembly

_4/-I°°"°"
Igniter

ec', ode
iSnap-on

//P,,O,_ /
/._

Thermocouple

Removing and Replacing
Control Valve/Thermostat

Important: The gas control valve/thermostat is a
standard valve with a left hand thread thermocouple
that is unique to the Flame Lock TM safety system. Use
only factory authorized replacement parts.
1.

On the gas control valve/thermostat turn the
temperature dial counterclockwise to its lowest
setting. Turn the gas control knob clockwise to the
"OFF" position (Figure 19).

Turn off the gas at the manual shut-off valve on the
gas supply pipe (Figure 3).

Drain the water heater. Refer to the section of
"Draining and Flushing" on page 20 and follow the
procedure.

Disconnect the igniter wire from the igniter button.
Remove the igniter button by depressing front and
rear holding tabs and lift. Remove igniter bracket.
Disconnect the thermocouple (left hand threads),
pilot tube, and manifold tube at the thermostat
(Figure 21). Note: L. P. gas systems use
reverse(left-hand) threads on the manifold tube.

Refer to "Gas Piping" (Figure 3) and disconnect the
ground joint union in the gas piping. Disconnect the
remaining pipe from the gas valve/thermostat.

Eiectro0e

Connector

Figure
27B
LP. IgniterAssembty
Pilot

Pilot

Important:
When removing the gas control
valve/thermostat do not use pipe wrench or vise to grip
body. Do not insert any type of blunt instrument into the
inlet or outlet connections. Using these type tools may
result in damage to the gas control valve/thermostat.

Thermocouple

Snap-on

Testing

Connector

the Igniter

the Gas

System

Turn off the gas to the water heater at the manual gas
shut-off valve. Watch the electrode tip while activating
the igniter.A visible spark should jump from the
electrode. To avoid shock, do not touch the burner or
any metal part on the pilot or pilot assembly. If no spark
is visible, check the wire connections and make sure
the electrode is not broken. Replace the igniter if
defective. Dirt and rust on the pilot or electrode tip can
prevent the igniter spark. Wipe clean with a damp cloth
and dry completely. Rust can be removed from the
electrode tip and metal surfaces by lightly sanding with
an emery cloth or fine grit sandpaper.

Turn the gas control valve/thermostat
counterclockwise. Remove the gas control
valve/thermostat.

To replace the gas control valve/thermostat reassemble
in reverse order. The gas control valve/thermostat is a
standard valve with a left hand thread thermocouple
that is unique to the Flame Lock TM safety system. Use
only factory authorized replacement parts.
•

Be sure to use approved Teflon tape or pipe joint
compound on the gas piping connections and fitting
on the back of gas valve that screws into tank.

Be sure to remove the pilot ferrule nut from the new
gas control valve/thermostat.
Turn gas supply on and check for leaks. Use a
chloride-free soap and water solution (bubbles
forming indicate a leak) or other approved method.

Be sure tank is completely filled with water before
lighting and activating the water heater. Follow the
"Lighting Instructions" on page 17.
If additional information is required, contact the
Service Department at: 1-877-817-6750.

Flame
1.
2.
3.
4.
5.
6.

Lock

Safety

System

Operational

Checklist

Manifold gasket properly sealed.
Viewport not damaged or cracked.
Flame-trap free of debris and undamaged.
Two piece wire connector properly installed.
No leaks at pilot and manifold connection.
Manifold door screws securely tightened.

TROUBLESHOOTING
PROBLEM

CHART
CORRECTIVE ACTION

POSSIBLE CAUSE(S}

BURNERWILL NOT IGNITE

1.
2.
3.
4.
5.
6.
7.
8.
9.

Pilotnot tit
Thermostatset too low
Nogas
Dirtin the gas lines
Pilotlineclogged
Mainburnerlineclogged
Defectivethermocoupte
Defectivethermostat
Heaterinstalledin a confinedarea

1.
2.
3.
4.
5.
6.
7.
8.
9.

Lightpilot
Turn temp.dialto desiredtemperature
Checkwith gas utilitycompany
Notifyutility-installtrap ingas line
Clean, locatesourceandcorrect
Clean, locatesourceandcorrect
Replacethermocoupte
Replacethermostat
Providefresh air ventilation

SMELLYWATER

Sulfidesin the water

Replacethe anodewith a specialanode

BURNERFLAMEYELLOW-LAZY

Insufficientsecondaryair
Lowgas pressure
Flueclogged
Mainburnerline clogged
Heaterinstalledin a confinedarea
Obstructionin mainburnerorifice

1.
2.
3.
4.
5.
6.

Provideventilationto water heater
Checkwithgas utilitycompany
Clean,locatesourceandcorrect
Clean,locatesourceandcorrect
Properfreshair ventilation
Cleanor replaceorifice

Air in gasline
Nogas
3. Dirtin gas lines
4.
PilotIine or orificeclogged
5. Thermocoupteconnectionloose
6. Defectivethermocoupte
7. Colddrafts
8. ThermostatECOswitchopen
9. Temperaturelimitswitchincombustionchamber
Activated
10. Defectiveigniter
11. Flammablevapors incident,FlameLockTM function
utilized
12. Lowgas pressure

1.
2.
3.
4.
5.
6.
7.
8.
9.

Bleedthe air from the gas line
Checkwithgas utilitycompany
Notifyutility-installdirt trap in gasline
Clean,locatesourceandcorrect
Fingertighten;then 1/4 turnwithwrench
Replacethermocoupte
Locatesourceand correct
Replacethermostat
Call 1-877-817-6750

1.
2.
3.
4.
5.
6.
7.
8.
9.
1.
2.
3.
4.
5.
6.
7.
8.
9.

1.
2.
3.
4.
5.
6.
7.
8.
9.

Set temperaturedial to lowersetting
Drain/Flush-Providewatertreatmentif needed
Installadequateheater
Correctpiping-diptube mustbe in cold inlet
Repairfaucets
Checkwith utility-repairat once
Advisecustomer
Insulatepiping
Insulatepiping

1.
2.
3.
4.
5
6.
7.
8.
9.

Turntemperaturedialto desiredsetting
Drain/flush-providewatertreatmentif needed
Installadequateheater
Correctpiping-diptube mustbe incold inlet
Repairfaucets
Advise customer
Insulatepiping
Insulatepiping
Checkwithgas utilitycompany

2.
3.
4.
5.
6.
PILOTWILL NOT LIGHTOR
REMAINLIT.

HIGHOPERATIONCOSTS

INSUFFICIENTHOT WATER

1.
2,,

Thermostatset too high
Sedimentor lime intank
Waterheatertoo smallforjob
Wrongpipingconnections
Leakingfaucets
Gasleaks
Wastedhot water
Long runsof exposedpiping
Hotwater pipinginexposedwail
Thermostatset too low
Sedimentor limein tank
Waterheatertoo smaIt
Wrongpipingconnections
Leakingfaucets
Wastedhot water
Long runsof exposedpiping
Hotwater pipingin outsidewall
Lowgas pressure

10. Replaceigniterpilot assembly
11. Replacewaterheater,eliminateflammablevapors
source.Call 1-877-817-6750
12. Checkwith gas utilitycompany

continued on next page

TROUBLESHOOTING
PROBLEM
SLOWHOTWATER RECOVERY

POSSIBLE CAUSE(S}

CORRECTIVE ACTION

Insufficientsecondaryair

2.
3.
4.
5,
6.
7,
8.

Flueclogged
Lowgas pressure
Impropercalibration
Thermostatset too low
Waterheatertoo small
Wrongpipingconnections
Wastedhot water

2.
3.
4.
5,
6.
7,
8.

Provideventilationto waterheater.Checkflue way
Fluebaffleand burner
Cleanflue, locatesourceandcorrect
Checkwith gas utilitycompany
Replacethermostat
Turntemperaturedialto desiredsetting
Installadequateheater
Correctpiping-diptube mustbe incold inlet
Advise customer

DRIPFROMRELIEFVALVE

1.
2.
3.

Excessivewaterpressure
Heaterstacking
Closedwater system

1.
2.
3.

Usea pressurereducingvalveand reliefvalve
Lowerthe thermostatsetting
See"ClosedSystem/ThermalExpansion"

THERMOSTATFAILSTO SHUT
OFF

1.
2.

Defectivethermostat
Impropercalibration

1.
2.

Replacethermostat
Replacethermostat

COMBUSTIONODORS

Insufficientsecondaryair

2.
3.

Flueciogged
HeaterinstaItedin a confinedarea

Provideventilationto waterheater.Checkflue
way,fluebaffle,burner
Clean,locatesourceandcorrect
Providefreshair ventilation

Insufficientsecondaryair

2.
3.
4.
5,
6.

Lowgas pressure
Flueclogged
Defectivethermostat
Heaterinstalledin a confinedarea
Burnerflame yellow-lazy

2.
3.
4.
5,
6.

Provideventilationto waterheater.Checkflue way,
flue baffle,burner
Checkwith gas utilitycompany
Clean,locatesourceandcorrect
Replacethermostat
Providefreshair ventilation
See"BurnerFlameYellow-Lazy"

CONDENSATION

Temperaturesettingtoo low

Increasethe temperaturesetting

BURNERFLAMEFLOATSAND
LIFTS OFF PORTS

1.
2.
3.
4.

Orificetoo large
Highgas pressure
Flueclogged
Colddrafts

1.
2.
3.
4.

Replacewithcorrectorifice
Checkwith gas utilitycompany
Cleanflue and burner-locatesource& correct
Locatesourceand correct

BURNERFLAMETOOHIGH

Orificetoo large

Replacewithcorrectorifice

FLAMEBURNSATORIFICE

1.
2.

Defectivethermostat
Lowgas pressure

1.
2.

Replacethermostat
Checkwith gas utilitycompany

PILOTFLAME
TOOSMALL

1.
2.

Pilottine ororifice clogged
Lowgas pressure

1.
2.

Clean,locatesourceandcorrect
Checkwith gas utilitycompany

SMOKINGAND CARBON
FORMATION(SOOTING)

CHART (continued)

PARTS ILLUSTRAT!
location for top
T&P
Alternate anode ___

Anode location
for side T & P

When ordering repair parts always give the following
information:
1.

Model, serial, and product number

Type of gas

Item number

Parts description

Repair Parts List
item
No.

Parts Description

DRAFTHOOD

REDUCERRING - SOMEMODELS

FLUEBAFFLE

HEATTRAP(COLD)- SOMEMODELS

5
6

HEATTRAP(HOT)- SOMEMODELS
COLDWATERDIPTUBE

7
8

ANODEROD
TEMPERATURE& PRESSURERELIEFVALVE
(LOCATEDTOPOR SIDE)

DRAINVALVE

GASVALVE/THERMOSTAT

11,_

PILOTASSEMBLY/THERMOCOUPLE
KIT
(NaturalGas)

12_
13

PILOTASSEMBLY/THERMOCOUPLE
KIT
(L.P.Gas)
OUTER DOOR

14'_

MANIFOLDBURNERASSEMBLY(NaturalGas)

15_

MANIFOLDBURNERASSEMBLY(NaturalGas LowNox)

A Special anode rod (see page 19)

16'_

MANIFOLDBURNERASSEMBLY(L.P.Gas)

17_

TWO PIECEWIRECONNECTOR
WITH RETAINERCLIP

• Temperature and Pressure Relief Valve is required,
but may not be factory installed.

18'_

MANIFOLDDOORGASKET

19_

VlEWPORTASSEMBLY

Pictured

on next

A,
•
_r

LEGEND

Unique: Flame Lock

safety system parts

page.

Listed Part Kits and Illustrations
item 11:

Pilot assembly/thermocouple
kit, which contains the pilot assembly with piezoelectric igniter,
thermocouple, and retainer clip. (Natural Gas)

item 12:

Pilot assembly/thermocouple
kit, which contains the pilot assembly with piezoelectric igniter,
thermocouple, and retainer clip. (LR Gas)

item 14:

Manifold burner assembly which contains the manifold tube, gasket, door, pilot tube, thermocouple, two
piece wire connector with retainer clip, and pilot assembly. (Natural Gas)

item 15:

Manifold burner assembly which contains the manifold tube, gasket, door, pilot tube, thermocouple, two
piece wire connector with retainer clip, and pilot assembly. (Natural Gas Low Nox)

item 16:

Manifold burner assembly which contains the manifold tube, gasket, door, pilot tube, thermocouple, two
piece wire connector with retainer clip, and pilot assembly. (LR Gas)

item 17:

Contains two piece wire connector with retainer clip, and pilot assembly.

item 18:

Contains manifold door gasket.

item 19:

Contains viewport.
Item #11

Item #14

Ite

Item

Item #15

#16

Item #17
Item #18

Item #1_9

7MRegistered trademark/TM

Trademark

of Whirlpool, U.S.A.

Printed in the U.S.

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