Instruction Manual ULTRA LOW NOX RESIDENTIAL GAS WATER HEATERS NOT FOR USE IN MANUFACTURED (MOBILE) HOMES LOW LEAD CONTENT • For Your Safety • AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER. ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
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 own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual.
GENERAL SAFETY 3
TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE............................2 GENERAL SAFETY..................................................................3 TABLE OF CONTENTS............................................................4 INTRODUCTION ......................................................................4 Preparing for the New Installation .....................................4 TYPICAL INSTALLATION......................................................5,6 LOCATING THE NEW WATER HEATER ..
TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER - GAS MODELS A B C D E F G H Vent Pipe Drafthood Anode Hot Water Outlet Outlet Insulation Gas Supply Manual Gas Shut-off Valve I J K L M N O P Ground Joint Union Sediment Trap Inner Door Outer door Union Inlet Water Shut-off Valve Cold Water Inlet Inlet Dip Tube Q R S T U V W X Temperature-Pressure Relief Valve Rating Plate Flue Baffle(s) Gas Control Valve/Thermostat Drain Valve Pilot and Main Burner Flue Metal Drain Pan (T) GAS CONTROL VALVE/THERMOST
TYPICAL INSTALLATION MIXING VALVE USAGE FIGURE 2. This water heater has been design certified as complying with ANSI Z21.10.3 current edition for water heaters and is considered suitable for: Water (Potable) Heating and Space Heating: All models are considered suitable for combination water (potable) heating and space heating. Not suitable for space heating applications only. Water Temperature °F (°C) Time for 1st Degree Burn (Less Severe Burns) 110 (43.3) (normal shower temp.) 116 ( 46.
LOCATING THE NEW WATER HEATER you must take special precautions. In addition to using the lowest possible temperature setting that satisfies your hot water needs, a means such as a *Mixing Valve should be used at the hot water taps used by these people or at the water heater. Mixing valves are available at plumbing supply or hardware stores. Consult a qualified installer or service agency. Follow mixing valve manufacturer’s instructions for installation of the valves.
This water heater must not be installed directly on carpeting. Carpeting must be protected by metal or wood panel beneath the appliance extending beyond the full width and depth of the appliance by at least 3” (76.2 mm) in any direction, or if the appliance is installed in an alcove or closet, the entire floor must be covered by the panel. Failure to heed this warning may result in a fire hazard. FIGURE 4.
COMBUSTION AIR AND VENTILATION FOR APPLIANCES LOCATED IN UNCONFINED SPACES UNCONFINED SPACE is space whose volume is not less than 50 cubic feet per 1,000 Btu per hour (4.8 m3 per kW) of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconfined space.
INSTALLING THE NEW WATER HEATER 6. Louvers and Grilles: In calculating free area, consideration shall be given to the blocking effect of louvers, grilles or screens protecting openings. Screens used shall not be smaller than 1/4 inch (6.4 mm) mesh. If the free area through a design of louver or grille is known, it should be used in calculating the size opening required to provide the free area specified.
This heater is provided with a properly certified combination temperature - pressure relief valve by the manufacturer. The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA 4.4, and the code requirements of ASME.
FILLING THE WATER HEATER Never use this water heater unless it is completely full of water. To prevent damage to the tank, the tank must be filled with water. Water must flow from the hot water faucet before turning “ON” gas to the water heater. To fill the water heater with water: The temperature-pressure relief valve must be manually operated at least once a year.
CGA 6.14 (covering electrically and mechanically actuated vent dampers). Before installation of any vent damper, consult the local gas utility for further information. To ensure proper venting of this gas-fired water heater, the correct vent pipe diameter must be utilized. Any additions or deletions of other gas appliances on a common vent with this water heater may adversely affect the operation of the water heater. Consult your gas supplier if any such changes are planned.
GAS PIPING Water heaters covered in this manual have been tested and approved for installation at elevations up to 7,700 feet (2,347 m) above sea level. For installation above 7,700 feet (2,347 m), the water heater’s Btu input should be reduced at the rate of 4 percent for each 1,000 feet (305 m) above sea level which requires replacement of the burner orifice in accordance with the National Fuel Gas Code ANSI Z223.1/NFPA 54. Contact your local gas supplier for further information.
SEDIMENT TRAP FIGURE 13. GAS PIPING WITH FLEXIBLE CONNECTOR. Use pipe joint compound or teflon tape marked as being resistant to the action of petroleum gases. The water heater and its gas connection must be leak tested before placing the appliance in operation. The water heater and its individual shut-off valve shall be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 pound per square inch (3.5 kPa).
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. FLAMMABLE BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A. This appliance has a pilot which is lit by a piezo- If you cannot reach your gas supplier, call the fire department. electric spark gas ignition system. When lighting the pilot, follow these instructions exactly. B.
TEMPERATURE REGULATION Never allow small children to use a hot water tap, or to draw their own bath water. Never leave a child or handicapped person unattended in a bathtub or shower. Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the thermostat setting by up to 30°F (16.7°C). If you experience this type of use you should consider using lower temperature settings to reduce scald hazards.
Because of the suddenness and amount of water, condensation water may be diagnosed as a “tank leak”. After the water in the tank warms up (about 1-2 hours), the condition should disappear. OPERATIONAL CONDITIONS SMELLY WATER In each water heater there is installed at least one anode rod (see parts section) for corrosion protection of the tank. Certain water conditions will cause a reaction between this rod and the water.
PERIODIC MAINTENANCE You should check for sooting. Soot is not normal and will impair proper combustion. VENTING SYSTEM INSPECTION Soot build-up indicates a problem that requires correction before further use. Turn “OFF” gas to water heater and leave off until repairs are made, because failure to correct the cause of the sooting can result in a fire causing death, serious injury, or property damage.
The anode rod should be removed from the water heater tank every 3 years for inspection. NOTE: artificially softened water requires the anode rod to be inspected annually. HOUSEKEEPING The following are typical (but not all) signs of a depleted anode rod: • The majority of the rods diameter is less than 3/8”. • Signifi cant sections of the support wire (approx. 1/3 or more of the anode rod’s length) are visible. Vacuum around base of water heater for dust, dirt, and lint on a regular basis.
4. Connect a hose to the drain valve and terminate it to an adequate drain or external to the building. TEMPERATURE-PRESSURE RELIEF VALVE OPERATION 5. Open the water heater drain valve and allow all of 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 in this manual. If the water heater is going to be shut down for an extended period, the drain valve should be left open.
REPLACING PARTS REPLACEMENT PARTS Natural Gas Burner (Ultra Low Nox) IMPORTANT: The following maintenance procedures should be performed by a qualified person. Check the burner screen to see if it is dirty or clogged. The burner screen may be cleaned with a soft paint brush. Do not use a wire brush or any tool that might damage the burner screen. Replacement parts may be ordered through your plumber or the local distributor. Parts will be shipped at prevailing prices and billed accordingly.
Replacing the Burner Door Assembly Piezoelectric Igniter System The piezoelectric igniter system consists of the igniter button, electrode and wire. The pilot is ignited by an electric spark generated when the igniter button is pressed. The electrode should be centered between the pilot and thermocouple (Figure 23). Use only factory authorized piozoelectric igniter parts for replacement. WARNING Testing the Igniter System Turn off the gas to the water heater at the manual gas shut-off valve.
Removing and Replacing the Gas Control Valve/ Thermostat: 6. IMPORTANT: The gas control valve/thermostat is a standard valve with a right hand thread thermocouple. Use only factory authorized replacement parts. To remove the gas control valve/thermostat, thread a corerctly sized pipe into the the inlet and use it to turn the gas valve (counterclockwise). Do not use a pipe wrench or equivalent to grip body. Damage may result causing leaks.
LEAKAGE CHECKPOINTS Read this manual first. Then before checking the water heater make sure the gas supply has been turned “OFF”, and never turn the gas “ON” before the tank is completely full of water. Never use this water heater unless it is completely filled with water to prevent damage to the tank. Water must flow from the hot water faucet before turning “ON” gas to the water heater. A. Water at the draft hood is water vapor which has condensed out of the combustion products.
REPAIR PARTS Key No. Part Description 1 Pipe Nipple 2 Burner Tube 3 Burner Head 4 Thermocouple 5 Pilot 6 Draft Hood 7 Inlet Tube 8 Flue Baffle Assembly 9 Anode Rod 10 Outer Door 11 Gas Control Valve/Thermostat 12 T & P Relief Valve 13 Drain Valve 14 Pilot Tube 15 Orifices 16 Metal Drain Pan *17 8 9 7 12 11 Instruction Manual * Not Shown.
TROUBLESHOOTING GUIDELINES Problem WATER LEAKS LEAKING T&P VALVE SMELLY WATER PILOT WILL NOT LIGHT BURNER WILL NOT STAY LIT PILOT OUTAGE NO HOT WATER NOT ENOUGH HOT WATER WATER TOO HOT WATER HEATER SOUNDS Cause Solution Improperly sealed, hot or cold supply connection, relief valve, or thermostat threads. Tighten thread connections. Leakage from water lines. Inspect water lines and connections. Condensation of flue products. Refer to “Condensation” section.
TROUBLESHOOTING GUIDELINES Problem SIZZLING OR RUMBLING SOUND SOOTING Cause Solution Sediment or calcium in bottom of tank. Clean sediment from tank. Refer to “Draining” instructions in the maintenance setion of manual. Improper combustion. No adjustment available. Contact a service agency to determine cause. Lack of sufficient supply air VENT GAS ODORS Improperly installed vent piping. Contact a qualified service agency to determine cause. Downdraft. Poor combustion.
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ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, CONTACT RESIDENTIAL TECHNICAL ASSISTANCE AT 1-800-527-1953 COPYRIGHT © 2012, INC. ALL RIGHTS RESERVED.
