Gas Water Heater with the Flame Guard® Safety System Installation Instructions and Use & Care Guide R Made under license from Flame Guard Water Heaters, Inc. WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance.
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.
INSTALLING YOUR GAS WATER HEATER Consumer Information Unpacking the Water Heater 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, the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-latest edition.
Location Requirements FLAMMABLES Flammable Vapors FIRE AND EXPLOSION HAZARD Can result in serious injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Storage of or use of gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or death. Read and follow water heater warnings and instructions.
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 the 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 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. 4. Turn the gas supply on and check for leaks. Test the water heater by brushing on an approved noncorrosive leak detection solution. Bubbles forming indicate a leak. Correct any leak found. Figure 3 Gas Piping Explosion Hazard Use a new CSA approved gas supply line. Install a shut-off valve.
Combustion Air Supply and Ventilation 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.
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.
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.
Vent Pipe System Vent Pipe Size This water heater uses a non-direct, single-pipe vent system to remove exhaust gases created by the burning of fossil fuels. Air for combustion is taken from the immediate water heater location or is ducted in from the outside (see “Combustion Air Supply and Ventilation”). 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)-latest edition. • 3 ft.
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.
Please note the following: DO NOT install this water heater with iron piping. The system should be installed only with piping that is suitable for potable (drinkable) water such as copper, CPVC, or polybutylene. DO NOT use PVC water piping. Closed System/Thermal Expansion DO NOT tamper with the gas valve/thermostat, igniter, thermocouple, or temperature and pressure relief valve. Tampering voids all warranties. Only qualified service technicians should service these components.
Temperature and Pressure Relief Valve 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: • • Explosion Hazard If the temperature and pressure relief valve is dripping or leaking, have a qualified service technician replace it. Do not plug valve. Do not remove valve.
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.
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.
OPERATING YOUR WATER HEATER 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.
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. Make sure all other appliances in the area are operating and Figure 17 Drafthood all doors are closed when performing the draft test. Pass Relief Opening a match flame around the relief Match opening of the drafthood. A steady flame drawn into the opening indicates proper draft.
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.
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: Temperature and Pressure Relief Valve 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.
Replacement Parts The following maintenance procedures are for the Flame Guard® 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.
Replacing the Thermocouple 1. Remove the manifold assembly as directed previously. 2. Remove the retainer clip from the back of the two piece wire connector and remove the two piece wire connector from the manifold door (Figure 25). 3. Pull the thermocouple from the pilot assembly (Figure 29). Be careful not to bend or alter the position of the pilot assembly components. 4. Push the new thermocouple through the holes in the pilot bracket.
Replacing the Manifold Assembly Explosion Hazard Tighten both manifold door screws securely. Remove any fiberglass between the door 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. Figure 28A Combustion Chamber Door Gasket Flame-trap Tab Figure 28B Manifold Assembly Close-up Close-up inside view of the combustion chamber.
Removing and Replacing the Gas Control Valve/Thermostat Important: The gas control valve/thermostat is a standard valve with wire leads that connect to a thermal switch. Removing the Gas Valve: 1. On the gas control valve/thermostat turn the temperature dial counterclockwise to its lowest setting. Depress the dial stop and 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.
PROBLEM POSSIBLE CAUSE(S) 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 CHART Does pilot light go out NO when button is released? YES Has the thermal switch tripped? NO YES Check Draft. (See Checking the Draft section of this manual.) Are the wires from the gas control valve/thermostat firmly connected to the switch? Secure connections and attempt a relight. NO YES Are the wires damaged and/or frayed? Is the thermocouple NO connection loose? YES NO YES Tighten the connection Replace the gas control valve/thermostat.
REPAIR PARTS ILLUSTRATION 5 Alternate anode location for top T&P 4 1 6 Anode location for side T&P 2 8 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 assembly kit, which contains the pilot assembly, igniter electrode and retainer clip (Natural Gas) Item 13: Pilot assembly kit, which contains the pilot assembly, igniter electrode and retainer clip (L.P. Gas) Item 14: Burner (Natural Gas/Low Nox) Item 15: Burner (L.P. Gas) Item 16: Manifold door assembly which contains the manifold tube, gasket, door, pilot tube, thermocouple, two piece wire connector with retainer clip, thermal switch, and pilot assembly.