® o] Home Appliances Residential Gas Water Heater with the Flame Lock® 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 NATURAL & L.P.
WATER HEATER SAFETY 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.
INSTALLING YOUR GAS WATER HEATER Important Information About This Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation environments. Please review the Installation Checklist found at the end of installed in accordance with Massachusetts Plumbing and Fuel Gas Code 248 CMR Section 2.
heater. Note: Not following these instructions and/or an inadequate air supply can cause the Flame Lock ® Safety System to disable the water heater. Please make required installation and venting/air supply changes prior to resetting the system (see "Combustion Air Supply and Ventilation" section). IMPORTANT: This water heater has a resettable thermal switch installed as part of the Flame Lock ®Safety System. Do not attempt to disable or modify this feature in any way.
IMPORTANT: Thewaterheatershouldbelocated in anareawhereleakageofthetankor connections willnotresultindamagetotheareaadjacenttothe waterheateror tolowerfloorsofthestructure.Due tothenormalcorrosiveactionofthewater,thetank willeventually leakafteranextendedperiodoftime. Alsoanyexternalplumbingleak,includingthosefrom improperinstallation, maycauseearlyfailureofthetank duetocorrosionif notrepaired.If thehomeowner is uncomfortable withmakingtherepaira qualifiedperson shouldbecontacted.
Gas Supply Figure 3 Gas Piping Manual Shut-off Gas Valve'---._ Joint Ground Union Check with local utility for minimum height3"M _ i Explosion Use a new CSA approved Install a shut-off Hazard Drip Leg gas supply line. valve. Do not connect a natural gas water heater to an L.P. gas supply. Do not connect an L.P. gas water heater to a natural gas supply. Failure to follow these instructions can result in death, explosion, or carbon monoxide poisoning.
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). Nominallron Pipe Size, in.
Unconfined Space Awater heater in an unconfined space uses indoor air for combustion and requires at least 50 cubic feet for each 1,000 BTU/HR of the total input for all gas appliances. The table below shows a few examples of the minimum square footage (area) required for various BTU/HR inputs.
All Air from Outdoors Gable 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.
Figure 9 Draft hood Installation Alternative Opening Location _ Metal Screws _ II Confined Space (four provided) _Draft hood t ] sq. Inch "_ Per 3000 BTU/HR Sl°tJ \ _ Jacket top P" LSl°t Install the draft hood with the four screws provided. Vent Pipe Size Figure 8B All Air from Outdoors Using a Single Permanent Opening It is important that you follow the guidelines in these instructions for sizing a vent pipe system.
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. Also consult local and state codes for proper chimney sizing and application or, in the absence of local and state codes, the "National Fuel Gas Code", ANSI Z223.1 (NFPA 54)-current edition.
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. The water supply pressure should not exceed 80 psi. If this occurs, a pressure reducing valve with a bypass should be installed in the cold water inlet line.
Pleasenotethefollowing: Closed System/Thermal Expansion • Thesystemshouldbeinstalledonlywithpipingthatis suitableforpotable(drinkable) watersuchas copper, CPVC,or polybutylene. Thiswaterheatermustnotbe installedusingironpipingor PVCwaterpiping. • Useonlypumps,valves,orfittingsthatarecompatible withpotablewater. • Useonlyfullflowballor gatevalves.Theuseofvalves thatmaycauseexcessiverestriction towaterflowis notrecommended. Explosion Hazard • Useonly95/5tin-antimony orotherequivalentsolder.
Temperature Relief Valve and Pressure Explosion Hazard If the temperature and pressure relief valve is dripping or leaking, have a qualified person replace it. Examples of a qualified person include: licensed plumbers, authorized gas company personnel, and authorized service personnel. Do not plug valve. Do not remove IMPORTANT: Only a new temperature and pressure relief valve should be used with your water heater.
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.
Important Information About This Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. The new technology used in meeting these standards makes this product more sensitive to installation errors. Please review the following checklist and make any required installation upgrades or changes. Questions? Call 1-877-817-6750.
OPERATING YOUR WATER HEATER Lighting Instructions Read and understand these directions thoroughly before attempting to light or re-light the pilot. Make sure the viewport is not missing or damaged. (See Figure 23) Make sure the tank is completely filled with water before lighting the pilot. Check the data plate near the gas control valve/thermostat for the correct gas. Do not use this water heater with any gas other than the one listed on the data plate.
L.P.G. (Bottled Propane) Models Burner 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 L.R gas water heater, smell all around the appliance at floor level.
Water Temperature Regulation 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: Table 4: Water Temperature °F 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. Feel water before bathing or showering. Temperature limiting valves are available.
Operating the Temperature Control System Status Light Code Figure 19B: Status Codes Normal Flashes: List of status codes are shown at top of gas control valve/thermostat, C • 0 Flashes Indicates Control Off/Pilot Out. • 1 Flash Indicates Normal Operation. • Continuous Light indicates the gas control valve/thermostat is shutting down. Diagnostic Flashes: If the water heater is not working look for the following diagnostic flashes after lighting the pilot.
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. NOTE: This condensation is normal and should not be confused with a leaking tank. Condensation may increase or decrease at different times of the year.
MAINTENANCE OF YOUR WATER HEATER Draining and Flushing It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up 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. Open a nearby hot water faucet until the water is no longer hot. 3. Close the cold water inlet valve. 4.
Replacement Parts IMPORTANT: The following maintenance procedures are for the Flame Lock ® Safety System components and should be performed by a qualified person. Replacement parts may be ordered through or the local distributor. Parts will be shipped prices and billed accordingly. When ordering parts, always have the following information 1. 2. 3.
Replacing the Pilot/Thermopile 1. 2. Assembly Remove the manifold assembly as directed previously. Lift the retainer clip straight up from the back of the manifold component block (using a fiat-blade screwdriver), then remove the manifold component block from the manifold door (Figure 25). Figure 25 Manifold Component Block Assembly Thermopile Connector _ , Burner and other fittings not show for clarity. NOTE: See figure 24A for correct burner orientation. 10.
Cleaning the Combustion Flame-trap 1. 2. 3. Chamber and Follow procedure outlined in "Removing the Manifold Assembly". Use a vacuum cleaner/shop vac to remove all loose debris in the combustion chamber (Figure 28A). Use compressed air to clear any dust or debris that may have accumulated in the flame-trap. Reassemble following the procedure under "Replacing the Manifold Assembly". Replacing 9. Check for leaks by brushing on an approved noncorrosive leak detection solution.
Removing and Replacing the Gas Control Valve/Thermostat gas control valve/thermostat (counterclockwise.) Do not use pipe wrench or equivalent to grip body. Damage may result, causing leaks. Do not insert any sharp objects into the inlet or outlet connections. Damage to the gas control valve/thermostat may result. IMPORTANT: The gas control valve/thermostat is a standard valve with wire leads that connect to a thermal switch. Gas Control Valve/Thermostat: Removing the Gas Control Valve/Thermostat: 1.
PROBLEM PILOT WILL NOT LIGHT OR REMAIN LIT (continued) POSSIBLE CAUSE(S) CORRECTIVE ACTION 14. Flammable vapors incident, Flame Lock _ function utilized 11. Clean, locate source and correct 12. Replace thermopite 13. See maintenance section for inspection and cleaning of flame trap 14. Replace water heater, eliminate flammable vapors source. Call 1-877-817-6750 HIGH OPERATION COSTS 1. 2. 3. 4. 5. 6. 7. 8. 9.
STATUS LIGHT CODE TROUBLESHOOTING LED STATUS PROBLEM CHART CORRECTIVE ACTION 0 FLASHES (LED NOT LIT) Pilot light is not lit. Not enough power (mitlivolts) to keep it lit. Follow the lighting instructions on the front of the water heater and record any diagnostic codes. See Diagnostic Status Light Code section. 1 FLASH (EVERY 3 SECONDS) Normal operation. No corrective action necessary. 2 FLASHES Insufficient power (mitlivolts) to the gas control valve/thermostat, 1. Check all wiring connections.
PILOT LIGHT TROUBLESHOOTING Section A: Pilot light will not light (new installation). Section C: Pilot light will not remain lit.
REPAIR PARTS ILLUSTRATION When ordering repair parts always give the following information: 1. 2. 3. Model, serial, and product number Type of gas Item number 4. Parts description Repair Parts List Item No.
Listed Parts Kits and Illustrations Item 12: Pilot assembly kit, which contains the pilot assembly, thermopile, and retainer clip (Natural Gas) Item 12: Pilot assembly kit, which contains the pilot assembly, thermopile, and retainer clip (L.P. Gas) Item 13: Burner (Natural Gas/L.R Gas) Item 13: Burner (L.R Gas) Item 14: Manifold door assembly which contains the manifold tube, gasket, door, pilot tube, thermopile, manifold component block with retainer clip, thermal switch, and pilot assembly.
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