American Water Heaters BFG1F4034T3NOV User Manual HEATER Manuals And Guides L0603477

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HEATERS

WARNING: If the information in these

instructions is not followed exactly, afire

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.

Installation and service must be performed

by a qualified installer, service agency or

the gas supplier.

Gas Water Heater

with the Flame Lock TM

Safety System

Installation

Instructions and

Use & Care Guide

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. 7 Digit product number

3. Serial number

4. Date of installation

Table of Contents ...................................................... 2

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

I;TALL! YOU GAS EATE

Consumer 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:

American Gas Association

1515 Wilson Boulevard

Arlington, VA22209

National Fire Protection Agency

1 Batterymarch Park

Quincy, MA02269

Check your phone listings for the local authorities

having jurisdiction over your installation.

Consumer Responsibilities

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.

Unpacking the Water Heater

Excessive Weight Hazard

Use two or more people to move and

install water heater.

Failure to do so can result in back or

other injury.

Removing Packaging Materials

Important: Do not remove any permanent instructions,

labels, or the data label from outside of the water heater

or on the inside of panels.

,, Remove exterior packaging and place installation

components aside.

,, Inspect all parts for damage prior to installation and

start-up.

,, Completely read all instructions before attempting

to assemble and install this product.

,, After installation, dispose of packaging material in

the proper manner.

_lLVapors from flammable liquids will

explode and catch fire causing death or

severe burns.

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 and pilot

flame. The pilot flame:

1. is on all the time and

2. will ignite flammable vapors.

Vapors:

1. cannot be seen,

2. are heavier than air,

3. go a long way on the floor and

4. can be carried from other rooms to

the pilot flame by air currents.

Do not install this water where flammable

products will be stored.

Location Requirements

Carbon Dioxide Poisoning Hazard

Do not install in a mobile home.

Doing so can result in death or carbon

monoxide poisoning.

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.

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.

Site Location

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.

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.

*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

areawhereleakageofthetankorconnectionswillnot

resultindamageto theareaadjacenttothewater

heaterortolowerfloorsof thestructure.Duetothe

normalcorrosiveactionofthewater,thetankwill

eventuallyleakafteranextendedperiodoftime.A

suitablemetaldrainpanshouldbeinstalledunderthe

waterheaterasshownbelow,tohelpprotectthe

propertyfromdamagewhichmayoccurfrom

condensateformationorleaksinthe piping

connectionsortank.Thepanmustlimitthewater

leveltoa maximumdepthof 13/4inchesandbetwo

incheswiderthantheheaterandpipedtoan

adequatedrain.Thepanmustnotrestrictcombustion

airflow.Locatethewaterheaternearasuitable

indoordrain.Outsidedrainsaresubjecttofreezing

temperatureswhichcanobstructthedrainline.The

pipingshouldbeat least3/4"IDandpitchedfor

properdrainage.Undernocircumstanceswillthe

manufacturerbeheldliableforanywaterdamagein

connectionwiththiswaterheater.

1 3/4" Max

tPipe 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.

Figure 1

Air Moving

Devices

Exhaust

Fan

L Reverse flow

of gases

Clearances and Accessibility

Notice: Minimum clearances from combustible

materials are stated on the data plate adjacent to the

thermostat of the water heater.

,, 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 Sides

service

T® l

View

II* Vent

CTI_i°Pn___

si es- lFI!

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

Explosion Hazard

Use anew AGA or CSA approved gas

supply line.

Install a shut-off valve.

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 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.

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.

2. 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.

3. 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.

Figure 3

Gas Piping

[

Check with

local utility

for min. height

Manual Gas c:::3

Sh ut-off Valve

Ground

Joint _---_

Union

3 in. min.

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

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

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 Length of Pipe, Feet

Size, in. 10 20 30 40 50 60 70 80 90 100 125 150 175 200

1/2 132 92 73 63 56 50 46 43 40 38 34 31 28 26

3/4 278 190 152 130 115 105 96 90 84 79 72 64 59 55

1 520 350 285 245 215 195 180 170 160 150 130 120 110 100

1-1/4 1050 730 590 500 440 400 370 350 320 305 275 250 225 210

I-I/2 1600 1100 890 760 670 610 560 530 490 460 410 380 350 320

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:

Gas Input of Water Heater (BTU/HR)

Cu. Ft. Per Hr. Required= Heating Value of Gas (BTU/FT 3)

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 Length of Pipe, Feet

Size, in. 10 20 30 40 50 60 70 80 90 100 125 150

1/2 275 189 152 129 114 103 96 89 83 78 69 63

3/4 576 393 315 267 237 217 196 185 173 162 146 132

1 1071 732 590 504 448 409 378 346 322 307 275 252

I-1/4 2205 1496 1212 1039 913 834 771 724 677 630 567 511

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 Air Supply and

Ventilation

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

,, Water heaters installed in laundry, hobby or

craft rooms.

Water heaters installed near chemical storage

areas.

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 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 Typical Room

Input with 8' Ceiling

30,000 9x21

14x20

15x25

15x31

20 x 28

20 x 33

25x 30

28 x 30

45,000

60,000

75,000

90,000

105,000

120,000

135,000

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 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.

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.

2. All Air from Outdoors.

Figure 4

Opening Locations-

Confined Spaces

Permanent

openings to

the outside or

additional

rooms within

the building

12" inches maximum

...1.._

Closet

-- 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

+_.....1 square

inch/1000

BTUH

(min, 100

sq. in)

Figure 5

All Air From Inside Building

Confined Space Installation

All Air from 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.

Louvers and grilles must be locked open or

interconnected with the equipment so that they are

opened automatically during equipment operation.

Keep louvers and grilles clean and free of debris or

other obstructions.

Table 4

Minimum Free Area of Permanent Openings for Ventilation and

Combustion Air Supply - All Air from Ou_oor Only.

Based on the total BTUH input rating for all gas utilizing equipment

within the confined space.

Minimum Free Area

Opening Per Opening Reference

Source (sq. in.) Drawing

Direct to 1 Square inch per 4000 Figure 6

outdoors BTUH

Vertical ducts 1 Square inch per 4000 Figure 7

BTUH

Horizontal ducts 1 Square inch per 2000 Figure 8

BTUH

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.

Gable vent

to outdoors

Install above

insulation

Confined " Outlet

Space -- air to attic

1 Sq. inch per

4000 BTUH

Inlet air

Alternate _ from the

Air Inlet.. /crawl

/€ _ space

1 sq. inch per Open

4000 BTUH Foundation '_

Vent

Figure 6

All Air from Outdoors; Inlet Air from Ventilated

Crawl Space/Outlet Air to Ventilated Attic

Confined

Space

Figure 7

All Air from Outdoors

Through Ventilated Attic

Gable vent

to outdoors

[_S nstall above

insulation -,-.,,,

i _! Outletair

b to attic

1 Sq. inch per

4000 BTUH

Inlet air duct

1 sq. inch per

4000 BTUH

\\\ 12" inches max.

Confined

Space

1 Sqe,rnCh_..

2000 BTU H "___

Outlet t

Outdoor

Air Ducts

Inlet _'

Figure 8 1 sq. Inch

All Air from Outdoors per

Using Horizontal Ducts 2000 BTUH

Vent Pipe System

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").

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 carbon monoxide (CO)

detectors are recommended in all applications and

should be installed using the manufacturer's

instructions and local codes, 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)

_-_ Drafthood

_- Jacket top

Install the drafthood with

the four screws provided.

Vent Pipe Size

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.

Vent Connectors

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

2. 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.

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

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.

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.

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.

Figure 10

Chimney Termination

Vent System I

Maintain 3 Ft. Min.._1

clearance

6 inches

minimum

Certified Lined

F _himney

2 ft. min. above any object

within 10 ft,

Horizontally

Do not extend

beyond edge

of chimney

Connector

Figure 11

Vertical Gas

Vent System

With Type B

Double Wall

Vent Pipe

Maintain

clearance

6 inches

minimum

Cap

2 ft. min. above any object

within 10 ft,

horizontally

Type B Double

Wall Vent Pipe

Maintain

specified

clearance

Figure 12 _,

Venting Through

a Chimney 5 inches min,

with Type B Double

Wall Vent Pipe.

_l'_Listed Vent Cap

Maintain

specified

clearance

Maintain

clearance

6 inches

minimum

Vent

Connector

Unused chimney

flue or masonry

enclosure

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.

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.

Important: Always use a good grade of joint compound

and be certain that all fittings are drawn up tight.

1. 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".

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 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.

3. 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.

4. 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).

5. 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.

.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).

7. 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

Hot Water

In a closed system

use either:

1. Thermal Expansion Tank

_" 2. Pressure Relief Valve

Pressure reducing

valve with bypass

_, Cold Water

Inlet

Cold Water

Inlet Valve

perature and

Pressure Relief Valve

Drain Pan _"

1 3/4 inch depth max.

Discharge line

above drain

Drain line

3/4 inch ID

minimum Massachusetts: ]

j Drain Install vacuum relief

in cold water line per

sect on 19 MGL142.

Figure 14

Typical Tempering

Valve Installation

Follow the tempering

valve manufacturer's

instructions.

l Cold

Water

Inlet

Tempered water

to fixtures

Tempering valve

(Set to 120 ° f)

Pleasenotethefollowing:

DONOTinstallthiswaterheaterwithironpiping.

Thesystemshouldbeinstalledonlywithnewpiping

thatissuitableforpotable(drinkable)watersuchas

copper,CPVC,orpolybutylene.DONOTusePVC

waterpiping.

DONOTuseanypumps,valves,orfittingsthatare

notcompatiblewithpotablewater.

DONOTusevalvesthatmaycauseexcessive

restrictiontowaterflow.Usefullflowballorgate

valvesonly.

DONOTuse50/50tin-leadsolder(oranylead

basedsolder)inpotablewaterlines.Use95/5tin-

antimonyorotherequivalentmaterial.

DONOTtamperwiththegasvalve/thermostat,

igniter,thermocouple,ortemperatureandpressure

reliefvalve.Tamperingvoidsallwarranties.Only

qualifiedtechniciansshouldservicethese

components.

DONOTusewithpipingthathasbeentreatedwith

chromates,boilerseal,orotherchemicals.

DONOTaddanychemicalsto thesystempiping

whichwillcontaminatethepotablewatersupply.

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 and Pressure

Relief Valve

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.

location

some models only

F Temperature and

Pressure Relief Valve

Discharge line 3/4

min.

Do not cap or plug.

6 inch

- maximum

l Figure 15

Drain

Temperature and Pressure

Drain Pan 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.

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 & 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.

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.

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

"_'/--remove air bubbles

Out /

Temperingn 7 ^ Cold

Valve-,,,_J.[_ 1_1 Water

c::_,_::=:::::::__ Inlet

HotII I tJl it-----

Water_t;l_]_ _ "_ I1

out h

Unions _ ___._t ATer

Handler

I III Shut-off

Figure 16

Typical Tempering Valve Installation

Combination Space Heating/Potable

Water Heating System

Flow Control

Pump Valve

Massachusettscodedoesnot

a 0w th s typeof nsta aton

installation Checklist

Water Heater Location

• Centrally located with the water piping system.

Located as close to the gas piping and vent pipe

system as possible.

,, Located indoors and in a vertical position.

Protected from freezing temperatures.

,, Proper clearances from combustible surfaces

maintained and not installed directly on a carpeted

floor.

• Provisions made to protect the area from water

damage. Drain pan installed and piped to an

adequate drain.

• 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

,, Sufficient fresh air supply for proper water heater

operation.

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.

• 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.

Vent Pipe System

• Drafthood properly installed.

• Vent connectors securely fastened with screws and

supported properly to maintain 6 inch clearance.

,, Vent connector made of approved material and

sized correctly.

,, 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.

Water System Piping

,, 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.

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 GYOUR EATE

Lighting instructions

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.

LP.G. (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 dial counterclockwise _ to its

lowest setting.

120 °F

BAR

_o_N 1_

Depress the reset button all the way

in and IMMEDIATELY depress the igniter

button until you hear a loud click.

Observe the pilot through the view port.

Do not release the reset button. Repeat

immediately if pilot does not light on

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.

3. Turn gas control knob clockwise _'

to the "OFF" position.

4. To clear any gas that may have

accumulated wait ten (10) minutes.

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

on the cover. If you do not smell gas go to the next step.

5. Turn the gas control knob

counterclockwise V(_

to "PILOT".

IMPORTANT: If the pilot will not stay lit after several tries,

turn gas control knob to "OFF" and call your service

technician or gas supplier.

IMPORTANT: If the reset button does not pop up when

released, stop and immediately shut off the gas at the line

valve or tank. Call your service technician or gas supplier.

7. Turn the gas control knob __

counterclockwise _ to"ON".

8. Set the temperature dial to

the desired setting.

9. Replace the outer door.

TOTURNOFFGASTO APPLIANCE

1. Turn the temperature dial counterclockwise _'_ to its 2. Turn the gas control knob clockwise (_ to the "OFF"

lowest setting, position.

Checking the Draft

Burn Hazard

Do not touch vent.

Doing so can result in

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

the drafthood. A steady

flame drawn into the

opening indicates proper

draft. If the flame flutters or

is blown out, combustion

products are escaping from

the relief opening. If this

occurs, do not operate the

water heater until proper

Figure 17

Relief

Ma_ Opening

adjustments or repairs are made to the vent pipe

system.

Burner Flames

Inspect the burner

flames through the

viewport and compare

them to the drawings in

Figure 18. A properly

operating burner

should produce a soft

blue flame. Blue tips

with yellow inner cones

Figure 18

Flame Characteristics

Tips may have

a yellow tint

egow inner

cones are

atisfactory

Correct flame incorrect flame

soft blue lazy yellow

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.

Stacking

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 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.

Water Temperature Regulation

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 (49°C) more than 5 minutes

130°F (54°C) at 20 seconds

140°F (60°C) at 3 seconds

150°F (66°C) at 1-1/2 seconds

160°F (71 °C) at less than 1 second

Figure 19

Robertshaw Gas Valv_ Thermostat

Settings Reset

Gas

Control

Knob

Dial

Stop

Index

Bars

130OF

Bar

130OF 120°F

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.

2. 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 water heater may give off a small amount of smoke

and odor during the initial start-up of the unit. This is

due to the burning off of oil from metal parts of a new

unit and will disappear after a few minutes of operation.

Safety Shut-off

This water heater is designed to automatically shut-off

in the event of the following:

1. The pilot flame is extinguished for any reason.

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

3. Excessive combustion chamber temperatures.

4. The ignition of flammable vapors.

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

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.

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

water faucet to depressurize the water tank.

3. Drain approximately 5 gallons of water from tank

(Refer to "Draining and Flushing" for proper

procedures). Close drain valve.

4. Remove old anode rod.

5. Use Teflon® tape or approved pipe sealant on

threads and install new anode rod.

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 OF YOU WATER EATER

Draining 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.

2. Close the cold water inlet valve.

3. Open a nearby hot water faucet.

4. 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.

6. 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:

• 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.

,, 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.

Important: Verify proper operation after servicing this

water heater.

Temperature and Pressure

Relief Valve

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

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

on the temperature and

pressure relief valve to

Figure 20

Discharge line to drain

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.

Self-Cleaning (Some Models)

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.

Replacement Parts

The following maintenance procedures are for the

Flame Lock TM safety system components and

should be performed by a qualified service

technician.

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. Model, serial and product number.

2. Type of gas.

3. Item number.

4. Parts description.

See page 27 for a list of available repair parts.

Removing the Manifold Assembly

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

shut-off valve (Figure 3).

2. Turn the gas control knob on the combination gas

control valve/thermostat

clockwise to the "OFF"

position (Figure 19).

Remove the outer door.

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 (left-

hand) threads on the

manifold tube.

Figure 21

Igniter

Thermocouple Pilot

Tube

Manifold

Tube

6. Grasp the manifold tube and push down slightly to

free the manifold, pilot tube, and thermocouple.

7. Carefully remove the manifold assembly from the

burner compartment. Be sure not to damage

internal parts.

Figure 22

Burner Assembly

Removal

Gas Valve /

Thermostat

Thermocouple

Manifold

Tube

Manifold

Door

Piezo

igniter

Pilot Tube

Two Piece Wire

/Connector

Manifold

Screw (2)

Removing the Burner from the

Manifold Assembly

Natural Gas Burner

1. Turn the burner counterclockwise to remove it from

the manifold assembly.

2. 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 Two Piece Wire Manifold Door

Natural Gas Connector Assembly

Burner Assembly Burner Igniter Wire

To remove 1

burner Thermocouple

Manifold

Tube

Thermocouple

Retainer Clip

Gasket

Pilot Assembly

Thermocouple

Viewport

Natural Gas Burner (Low Nox)

1. 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 23B Manifold Door

Natural Gas (Low Nox) Assembly

Burner Assembly S

Two Piece Wire

Burner Connector ,_. Igniter Wire

Pilot

Tube

Gasket Thermocouple

Pilot Bracket Viewport

Thermocouple \

Retainer Clip Pilot Assembly

LP. Gas Burner

1. Separate the pilot bracket from the LR burner by

removing screw.

2. 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.

3. 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 Manifold Door

LP. Gas Burner Manifold Door Assembly

Assembly Gasket _ig

Two Piece Wire

niter Wire

\Pilot

Tube

Manifold

Pilot Assembly

Thermocoupte Pilot Bracket

Retainer Clip

Thermocouple

,'iewport

Replacing the Thermocouple

Important: Use only a factory authorized Flame

Lock TM safety system thermocouple for replacement.

1. Remove the manifold assembly as directed

previously.

2. 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).

3. Pull the thermocouple from the pilot assembly.

(Figures 23, and 27).

4. 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.

5. 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.

.See "Replacing Manifold Assembly" at the top of

next column.

Figure 24 Other fittings

Two Piece Wire not shown

Connector for clarity

Assembly igniter

Wire

Retainer Clip

Thermocouple

Manifold

S Door

Two Piece"

Wire Connector

Figure 25

Thermocouple

Assembly

Notice:

Thermocouple

must not be bent

in this location.

Cleaning the Combustion Chamber

and Flame-trap

1. Follow procedure outlined in "Removing the

Manifold Assembly".

2. Use a vacuum cleaner/shop vac to remove all loose

debris in the combustion chamber and flame-trap.

See Figure 26.

3. Reassemble following the procedure under

"Replacing the Manifold Assembly".

Replacing the Manifold Assembly

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.

2. Inspect the viewport for damage and replace as

required.

3. 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.

FI Bracket

Figure 26 _, , IIHII _" T_

Combustion Chamber u_J

4. 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 cross-

thread or apply any thread sealant to these fittings.

Note: L R gas systems use reverse (left-

hand) 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.

7. Reconnect the igniter wire.

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

Instructions" on page 17.

9. 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

Igniter /._ Thermocouple

_4/-I°°"°" //P,,O,_ /

ec', ode Eiectro0e

iSnap-on Connector

Figure 27B

LP. IgniterAssembty Pilot

ThermocouplePilot _

-- Snap-on Connector

Testing the Igniter System

Turn off the gas to the water heater at the manual gas

shut-off valve. Watch the electrode tip while activating

the igniter.A visible spark should jump from the

electrode. To avoid shock, do not touch the burner or

any metal part on the pilot or pilot assembly. If no spark

is visible, check the wire connections and make sure

the electrode is not broken. Replace the igniter if

defective. Dirt and rust on the pilot or electrode tip can

prevent the igniter spark. Wipe clean with a damp cloth

and dry completely. Rust can be removed from the

electrode tip and metal surfaces by lightly sanding with

an emery cloth or fine grit sandpaper.

Removing and Replacing the Gas

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).

2. Turn off the gas at the manual shut-off valve on the

gas supply pipe (Figure 3).

3. Drain the water heater. Refer to the section of

"Draining and Flushing" on page 20 and follow the

procedure.

4. 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.

5. 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.

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.

6. 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 Lock TM Safety System Operational Checklist

1. Manifold gasket properly sealed.

2. Viewport not damaged or cracked.

3. Flame-trap free of debris and undamaged.

4. Two piece wire connector properly installed.

5. No leaks at pilot and manifold connection.

6. Manifold door screws securely tightened.

TROUBLESHOOTING CHART

PROBLEM CORRECTIVE ACTION

BURNERWILL NOT IGNITE

POSSIBLE CAUSE(S}

1. Pilotnottit

2. Thermostatset toolow

3. Nogas

4. Dirtin thegaslines

5. Pilotlineclogged

6. Mainburnerlineclogged

7. Defectivethermocoupte

8. Defectivethermostat

9. Heaterinstalledin a confinedarea

1. Sulfidesin thewater

SMELLYWATER

BURNERFLAMEYELLOW-LAZY Insufficientsecondaryair 1. Provideventilationto water heater

Lowgas pressure 2. Checkwithgas utilitycompany

Flueclogged 3. Clean,locatesourceandcorrect

Mainburnerline clogged 4. Clean,locatesourceandcorrect

Heaterinstalledin a confinedarea 5. Properfreshairventilation

Obstructionin mainburnerorifice 6. Cleanor replaceorifice

PILOTWILL NOTLIGHTOR

REMAINLIT.

HIGHOPERATIONCOSTS

2,,

10.

11.

INSUFFICIENTHOT WATER

Air in gasline

Nogas

Dirtin gas lines

PilotIineororificeclogged

Thermocoupteconnectionloose

Defectivethermocoupte

Colddrafts

ThermostatECOswitchopen

Temperaturelimitswitchincombustionchamber

Activated

Defectiveigniter

Flammablevaporsincident,FlameLockTM function

utilized

12. Lowgas pressure

1. Thermostatset too high

2. Sedimentor lime intank

3. Waterheatertoosmallforjob

4. Wrongpipingconnections

5. Leakingfaucets

6. Gasleaks

7. Wastedhotwater

8. Longrunsof exposedpiping

9. Hotwater pipinginexposedwail

1. Thermostatset toolow

2. Sedimentor limein tank

3. WaterheatertoosmaIt

4. Wrongpipingconnections

5. Leakingfaucets

6. Wastedhotwater

7. Longrunsof exposedpiping

8. Hotwater pipingin outsidewall

9. Lowgas pressure

1. Lightpilot

2. Turn temp.dialto desiredtemperature

3. Checkwith gasutilitycompany

4. Notifyutility-installtrap ingas line

5. Clean,locatesourceandcorrect

6. Clean,locatesourceandcorrect

7. Replacethermocoupte

8. Replacethermostat

9. Providefresh airventilation

1. Replacetheanodewith a specialanode

1. Bleedthe airfromthegasline

2. Checkwithgasutilitycompany

3. Notifyutility-installdirttrap in gasline

4. Clean,locatesourceandcorrect

5. Fingertighten;then 1/4turnwithwrench

6. Replacethermocoupte

7. Locatesourceand correct

8. Replacethermostat

9. Call1-877-817-6750

10. Replaceigniterpilot assembly

11. Replacewaterheater,eliminateflammablevapors

source.Call1-877-817-6750

12. Checkwithgasutilitycompany

1. Settemperaturedial to lowersetting

2. Drain/Flush-Providewatertreatmentifneeded

3. Installadequateheater

4. Correctpiping-diptube mustbe in cold inlet

5. Repairfaucets

6. Checkwithutility-repairat once

7. Advisecustomer

8. Insulatepiping

9. Insulatepiping

1. Turntemperaturedialto desiredsetting

2. Drain/flush-providewatertreatmentif needed

3. Installadequateheater

4. Correctpiping-diptube mustbe incold inlet

5 Repairfaucets

6. Advisecustomer

7. Insulatepiping

8. Insulatepiping

9. Checkwithgasutilitycompany

continued on next page

TROUBLESHOOTING CHART (continued)

PROBLEM POSSIBLE CAUSE(S} CORRECTIVE ACTION

SLOWHOTWATER RECOVERY 1. Insufficientsecondaryair 1.

DRIPFROMRELIEFVALVE

THERMOSTATFAILSTOSHUT

OFF

COMBUSTIONODORS

SMOKINGAND CARBON 1.

FORMATION(SOOTING)

CONDENSATION

BURNERFLAMEFLOATSAND

LIFTS OFFPORTS

Provideventilationto waterheater.Checkflue way

Fluebaffleand burner

2. Cleanflue,locatesourceandcorrect

3. Checkwith gasutilitycompany

4. Replacethermostat

5, Turntemperaturedialto desiredsetting

6. Installadequateheater

7, Correctpiping-diptube mustbe incold inlet

8. Advisecustomer

1. Usea pressurereducingvalveand reliefvalve

2. Lowerthethermostatsetting

3. See"ClosedSystem/ThermalExpansion"

1. Replacethermostat

2. Replacethermostat

1. Provideventilationto waterheater.Checkflue

way,fluebaffle,burner

Clean,locatesourceandcorrect

Providefreshairventilation

2. Flueclogged

3. Lowgas pressure

4. Impropercalibration

5, Thermostatset toolow

6. Waterheatertoosmall

7, Wrongpipingconnections

8. Wastedhotwater

1. Excessivewaterpressure

2. Heaterstacking

3. Closedwater system

1. Defectivethermostat

2. Impropercalibration

1. Insufficientsecondaryair

2. Flueciogged

3. HeaterinstaItedin a confinedarea

1. Insufficientsecondaryair

2. Lowgas pressure

3. Flueclogged

4. Defectivethermostat

5, Heaterinstalledin a confinedarea

6. Burnerflame yellow-lazy

1. Temperaturesettingtoo low

1. Orificetoolarge

2. Highgas pressure

3. Flueclogged

4. Colddrafts

1. Orificetoo large

1. Defectivethermostat

2. Lowgas pressure

1. Pilottine ororifice clogged

2. Lowgas pressure

Provideventilationto waterheater.Checkflue way,

flue baffle,burner

2. Checkwith gasutilitycompany

3. Clean,locatesourceandcorrect

4. Replacethermostat

5, Providefreshairventilation

6. See"BurnerFlameYellow-Lazy"

1. Increasethetemperaturesetting

1. Replacewithcorrectorifice

2. Checkwith gasutilitycompany

3. Cleanflueand burner-locatesource& correct

4. Locatesourceand correct

BURNERFLAMETOOHIGH 1. Replacewithcorrectorifice

FLAMEBURNSATORIFICE 1. Replacethermostat

2. Checkwith gasutilitycompany

PILOTFLAME 1. Clean,locatesourceandcorrect

TOOSMALL 2. Checkwith gasutilitycompany

PARTS ILLUSTRAT!

Alternate anode ___

location for top

T&P

Anode location

for side T & P

When ordering repair parts always give the following

information:

1. Model, serial, and product number

2. Type of gas

3. Item number

4. Parts description

Repair Parts List

item Parts Description

No.

1 DRAFTHOOD

2 REDUCERRING- SOMEMODELS

3 FLUEBAFFLE

4 HEATTRAP(COLD)- SOMEMODELS

5 HEATTRAP(HOT)- SOMEMODELS

6 COLDWATERDIPTUBE

7 ANODEROD A,

8 TEMPERATURE& PRESSURERELIEFVALVE

(LOCATEDTOPORSIDE) •

9 DRAINVALVE

10 GASVALVE/THERMOSTAT _r

11,_ PILOTASSEMBLY/THERMOCOUPLEKIT

(NaturalGas)

12_ PILOTASSEMBLY/THERMOCOUPLEKIT

(L.P.Gas)

13 OUTERDOOR

14'_ MANIFOLDBURNERASSEMBLY(NaturalGas)

15_ MANIFOLDBURNERASSEMBLY(NaturalGas LowNox)

16'_ MANIFOLDBURNERASSEMBLY(L.P.Gas)

17_ TWO PIECEWIRECONNECTOR

WITH RETAINERCLIP

18'_ MANIFOLDDOORGASKET "k

19_ VlEWPORTASSEMBLY

Pictured on next page.

LEGEND

A Special anode rod (see page 19)

• Temperature and Pressure Relief Valve is required,

but may not be factory installed.

Unique: Flame Lock TM safety system parts

Listed Part Kits and Illustrations

item 11:

item 12:

item 14:

item 15:

item 16:

item 17:

item 18:

item 19:

Pilot assembly/thermocouple kit, which contains the pilot assembly with piezoelectric igniter,

thermocouple, and retainer clip. (Natural Gas)

Pilot assembly/thermocouple kit, which contains the pilot assembly with piezoelectric igniter,

thermocouple, and retainer clip. (LR Gas)

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)

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)

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)

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

Contains manifold door gasket.

Contains viewport.

Item #14 Item #15

Item #11 Ite

Item #16

Item #17

Item #18

Item #1_9 1

7MRegistered trademark/TM Trademark of Whirlpool, U.S.A. Printed in the U.S.

American Water Heaters BFG1F4034T3NOV User Manual HEATER Manuals And Guides L0603477

AMERICAN WATERHEATERS Water heater, Gas Manual L0603477 AMERICAN WATERHEATERS Water heater, Gas Owner's Manual, AMERICAN WATERHEATERS Water heater, Gas installation guides

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