Installation Instructions and Use & Care Guide RESIDENTIAL GAS WATER HEATERS FVIR GAS WATER HEATER (FLAMMABLE VAPOR IGNITION RESISTANT) FOR SPACE HEATING AND POTABLE WATER HEATING ONLY. NOT FOR USE IN MOBILE HOMES. This water heater complies with ANSI Z21.10.1-current edition regarding the accidental or unintended ignition of flammable vapors, such as those emitted by gasoline. For Your Safety AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER.
TABLE OF CONTENTS Water Heater Safety .......................................................................................................................................................................... 1 -2 Safe Installation, Use and Service ...................................................................................................................................................... 3 Safety Precautions ...........................................................................................
SAFE INSTALLATION, USE AND SERVICE Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater. Many safety-related messages and instructions have been provided in this manual and on your water heater to warn you and others of a potential hazard. Read and obey all safety messages and instructions throughout this manual.
Fire or Explosion Harzard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Avoid all ignition sources if you smell Natural or LP gas. Do not expose water heater control to excessive gas pressure. Use only gas shown on rating plate. Maintain required clearances to combustibles. Keep ignition sources away from faucets after extended period of non-use. Read instruction manual before installing, using or servicing water heater.
TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER - GAS MODELS A B C D E F G H I * Vent Pipe Draft hood Anode (Not Shown) Hot Water Outlet Insulation Gas Supply Piping Manual Gas Shut-off Valve Ground Joint Union Drip Leg (Sediment Trap) J K L M N O P Q R Inner Door Outer door Union Inlet Water Shut-off Valve Cold Water Inlet Inlet Dip Tube Temperature & Pressure Relief Valve Rating Plate Flue Baffle S T U V W X Y Gas Control Valve/Thermostat Drain Valve Pilot and Main Burner Flue Drain Pan Piezo Igni
INSTALLING YOUR GAS WATER HEATER Unpacking the 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.
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. Location Requirements WARNING Carbon Monoxide Poisoning Hazard WARNING Do not install in a mobile home. Doing so can result in carbon monoxide poisoning and death.
EXHAUST FAN REVERSE FLOW OF GASES IMPORTANT: The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure. Due to the normal corrosive action of water, the tank will eventually leak after an extended period of time. Also any external plumbing leak, including those from improper installation, may cause early failure of the tank due to corrosion if not repaired.
GAS SUPPLY WARNING MANUAL GAS SHUT-OFF VALVE GROUND JOINT UNION DISCHARGE PIPE (DO NOT PLUG OR CAP) CHECK WITH LOCAL UTILITY FOR MINIMUM HEIGHT Explosion Hazard • Use a new CSA approved gas supply line. 3” MINIMUM • Install a shut-off valve. 6” MAXIMUM AIR GAP DRIP LEG • Do not connect a natural gas water heater to an L.P. gas supply. SUITABLE DRAIN FIGURE 3. • Do not connect an L.P. gas water heater to a natural gas supply.
LP Gas Only 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, closets and areas below ground level will serve as pockets for the accumulation of gas. Before lighting an L.P. 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. WARNING When your L.P.
COMBUSTION AIR & VENTILATION TABLE 3 WARNING Carbon Monoxide Warning BTUH Input Minimum Square Feet with 8’ Ceiling 30,000 188 9 x 21 45,000 281 14 x 20 60,000 375 15 x 25 75,000 469 15 x 31 90,000 563 20 x 28 105,000 657 20 x 33 120,000 750 25 x 30 135,000 844 28 x 30 Water heater must be vented to outdoors. Vent must be installed by a qualified technician using the installation instructions.
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. 12” MAXIMUM 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 three inches.
GABLE VENT TO OUTDOORS ALTERNATIVE OPENING LOCATION INSTALL ABOVE INSULATION CONFINED SPACE 1 SQ. INCH CONFINED OUTLET AIR TO ATTIC 1 SQ. INCH PER 4000 BTUH PER 3000 BTUH SPACE INLET AIR FROM THE CRAWL SPACE ALTERNATE AIR INLET ALL AIR FROM OUTDOORS - USING A SINGLE PERMANENT OPENING 1 SQ. INCH PER 4000 BTUH OPEN FOUNDATION VENT FIGURE 8B.
Align the legs of the draft hood with the slots provided. Insert the legs and secure the draft hood to the water heater’s top with the four screws provided as shown in Figure 9. Do not alter the draft hood in any way. If you are replacing an existing water heater, be sure to use the draft hood supplied with this water heater. • • • Vent Pipe Size • It is important that you follow the guidelines in these instructions for sizing a vent pipe system.
LISTED VENT CAP 3 FT. MINIMUM WATER SYSTEM PIPING Piping Installation 2 FT. MINIMUM ABOVE ANY OBJECT WITHIN 10 FT. HORIZONTALLY 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. SUPPORT STRAP *MAINTAIN CLEARANCE TYPE B DOUBLE WALL VENT PIPE The water supply pressure should not exceed 80 psi.
Please note the following: • The system should be installed only with piping that is suitable for potable (drinkable) water such as copper, CPVC, or polybutylene. This water heater must not be installed using iron piping or PVC water piping. • Use only pumps, valves, or fittings that are compatible with potable water. • It is recommend that only full flow ball or gate valves are used in water piping installations. The use of valves that may cause excessive restriction to water flow is not recommended.
valve or have any reducing coupling installed in the discharge line. Temperature and Pressure Relief Valve Explosion Harzard • Temperature-pressure relief valve must comply with ANSI Z21.22-CSA 4.4 and ASME code. • Properly sized temperaturepressure relief valve must be installed in opening provided. • Must terminate a maximum of six inches above a floor drain or external to the building. • Must be capable of withstanding 250°F (121°C) without distortion.
• 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. • • • 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.
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.
OPERATING YOUR WATER HEATER Lighting Instructions WARNING Read and understand these directions thoroughly before attempting to light or re-light the pilot. Make sure the view port is not missing or damaged. (See Figure 23) Make sure the tank is completely filled with water before lighting the pilot. Check the rating 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 rating plate.
Robertshaw Gas Control Valve/Thermostat - Lighting Instructions FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance has a pilot which is lighted by a piezoelectric igniter. When lighting the pilot, follow these instructions exactly. B. BEFORE LIGHTING smell all around the appliance area for gas.
heater. Mixing valves are available at plumbing supply or hardware stores, see Figure 14. Follow manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat see Figure 19. Using the lowest hot water temperature that meets your needs will also provide the most energy efficient operation of the water heater. Never allow small children to use a hot water tap, or to draw their own bath water.
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.
Anode Rod/Water Odor Draining and Flushing 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. Once the anode is depleted, the tank will start to corrode, eventually developing a leak. Certain water conditions will cause a reaction between this rod and the water.
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 allow the valve to operate freely and return to its closed position. See Figure 21.
2. Check the burner to see if it is dirty or clogged. The burner may be cleaned with soap and hot water (Figure 24). Replacing the Pilot/ Pilot Tube Assembly 1. PILOT ASSEMBLY (BOTTOM VIEW) Remove the manifold/burner assembly. See Removing the Manifold/Burner Assembly. 2. Lift the retainer clip straight up from the back of the two piece wire connector (using a flat-blade screwdriver), then remove the two piece wire connector from the manifold door (Figure 25.
10. Reposition the two piece wire connector in the manifold door opening and secure it with the retainer clip. Replacing the Manifold/Burner Assembly 11. Carefully bend the new pilot tube and thermocouple to match the bend of the manifold tube. NOTE: When bending DO NOT crimp or crease the pilot tube or thermocouple. (Figure 25) WARNING 12. Before you proceed to the next step, install the new brass ferrule nut in the gas control valve/thermostat’s pilot tube opening. HAND TIGHT ONLY. 13.
tight in the gas control valve/thermostat. Finally, start the thermocouple nut and turn it all the way in by hand. An additional quarter turn with a 3/8” open-end wrench will then be sufficient to seat the lockwasher. When you are finished, connect the two wire leads that go to the thermal switch. 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.
Replacing the Gas Valve: 1. To replace the gas control valve/thermostat, reassemble in reverse order. When replacing the gas control valve/ thermostat, thread a correctly sized pipe into the inlet and use it to turn the gas valve (clockwise.) DO NOT OVER TIGHTEN or damage may result. NOTE: Use an approved TEFLON® tape or pipe compound only on the threaded section of the gas control valve/thermostat that screws into the tank. 2. Reconnect the gas piping to the gas control valve/ thermostat.
PROBLEM HIGH OPERATION COSTS POSSIBLE CAUSE(S) 1. 2. 3. 4. 5. 6. 7. 8. 9. INSUFFICIENT HOT WATER 1. 2. 3. 4. 5. 6. 7. 8. 9. SLOW HOT WATER RECOVERY 1. CORRECTIVE ACTION Thermostat set too high Sediment or lime in tank Water heater too small for job Wrong piping connections Leaking faucets Gas leaks Wasted hot water Long runs of exposed piping Hot water piping in exposed wall 1. 2. 3. 4. 5. 6. 7. 8. 9.
PILOT LIGHT TROUBLESHOOTING FLOWCHART Does pilot light go out when button is released? NO Check Draft. (See “Checking the Draft” section of this manual.) NO Are the wires from the gas control valve/thermostat firmly connected to the switch? YES Has the thermal switch tripped? YES Secure connections and attempt a relight. NO YES Are the wires damaged and/or frayed? Is the thermocouple connection loose? NO NO YES YES Check for insufficient combustion air.
REPAIR PARTS ILLUSTRATION When ordering repair parts always give the following information: 1. 2. 3. 4. Model, serial, and product number Type of gas Item number Parts description Repair Parts List Item No.
Listed Parts Kits and Illustrations Item 12: Pilot/Pilot Tube Assembly kit, which contains the pilot assembly, thermocouple, igniter electrode and retainer clip (Natural Gas) Item 13: Pilot/Pilot Tube Assembly kit, which contains the pilot assembly, thermocouple, igniter electrode and retainer clip (L.P. Gas) Item 14: Burner (Natural Gas/Low Nox) Item 15: Burner (L.P.
NOTES 34
LIMITED RESIDENTIAL GAS WARRANTY THIS WARRANTY IS APPLICABLE TO THE ORIGINAL OWNER ONLY, in accordance with the warranty terms and conditions specified below.
REPLACEMENT OF THE HEATER OR PARTS. THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPERTY, OR OTHER CONSEQUENTIAL DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR IN TORT.