Ultra Low Nox Gas Water Heater with the FVIR 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 • Do not try to light any appliance.
WATER HEATER SAFETY This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or injury. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.
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 the installation instructions section and make any required installation upgrades or changes.
WARNING 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. heater. Note: Not following these instructions and/or an inadequate air supply can cause the FVIR Safety System to disable the water heater.
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 Correct any leak found. Figure 3 Gas Piping Manual Gas Shut-off Valve WARNING Ground Joint Union Check with local utility for minimum height 3” Minimum Explosion Hazard Use a new CSA approved gas supply line. Install a shut-off 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.
Combustion Air Supply and Ventilation WARNING Carbon Monoxide Hazard Water heater must be vented to outdoors. Vent must be installed by a qualified person using the installation instructions. Examples of a qualified person include: gas technicians, authorized gas company personnel, and authorized service persons. Combustion air must be free of acid-forming chemicals such as sulfur, fluorine, and chlorine.
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 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 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 Sheet Metal Screws (four provided) Alternative Opening Location Draft hood Legs Legs Confined Space 1 sq. Inch Per 3000 BTU/HR Slot Slot Jacket top 3”- 4” Draft Hood Combination Install the draft hood with the four screws provided.
Chimney Connection Listed Lined Chimney 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.
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. • Use only full flow ball or gate valves. The use of valves that may cause excessive restriction to water flow is not recommended.
Temperature and Pressure Relief Valve WARNING 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 valve. Failure to follow these instructions can result in death, or explosion.
Special Applications Combination Space Heating/Potable Water System Some water heater models are equipped with inlet/outlet tappings suitable for combination water (potable) heating and space heating and not suitable for space heating applications only. 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.
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 the telephone number on the warranty sheet that was included with this manual.
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 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.
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. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.
Checking the Draft Burner Flames WARNING 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 all doors are closed when performing the draft test. Pass a match Figure 17 Drafthood flame around the relief opening of the Relief Opening drafthood.
Water Temperature Regulation WARNING NOTE: A water temperature range of 120°F - 140°F (49°C - 60°C) is recommended by most dishwasher manufacturers. 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 over 125°F can cause severe burns instantly or death from scalds. Children, disabled and elderly are at highest risk of being scalded.
Operating the Temperature Control System Figure 19B: Status Codes List of status codes are shown at top of gas control valve/thermostat. Water Temperature Adjustment The water temperature setting can be adjusted from 55°F to 155°F. Turn the Gas Control/Temperature Knob to the desired setting/temperature. NOTE: The temperatures indicated are approximates. The actual temperature of the heated water may vary. Also, some models are certified for 180°F outlet temperatures.
the gas supply to the burner if poor combustion is sensed (caused by a blocked vent or insufficient combustion air). If the gas control valve/thermostat shuts off the gas supply, check the diagnostic flash code and refer to the “Status Light Code Troubleshooting Chart.” If necessary, also refer to the “Troubleshooting Chart.” IMPORTANT: Correct any issues prior to resetting the gas control valve/thermostat.
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 WARNING 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.
Replacement Parts IMPORTANT: The following maintenance procedures are for the FVIR Safety System components and should be performed by a qualified person. 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: 6. Grasp the manifold tube and push down slightly to free the manifold, pilot tube, and thermopile. 7.
Replacing the Pilot/Thermopile Assembly 1. Remove the burner assembly. See Removing the Burner Door Assembly Section. 2. Lift the retainer clip straight up from the back of the manifold component block (using a flat-blade screwdriver), then remove the manifold component block from the burner door (Figure 25). IMPORTANT: Be careful not to bend or alter the position of the pilot tube. Note the placement/order of the wires in the manifold component block.
Figure 28 Pilot/Thermopile Assembly (50K Models) Igniter Connector Thermopile Connectors External Inspection & Cleaning of the Flame-trap Pilot Tube (Ferrule Nut Not Shown) Pilot/Thermopile Assembly Thermopile Pilot Although not likely to occur, if debris collects on the flametrap, use a vacuum, compressed air, or a soft bristle brush to remove it. NOTE: If unable to inspect or clean the flame trap from underneath, follow the “Cleaning the Combustion Chamber and Flame-trap” section instructions.
Replacing the Burner Door Assembly WARNING Figure 30A Combustion Chamber Flame-trap Bracket Explosion Hazard Tighten both burner door screws securely. Remove any fiberglass between gasket and combustion chamber. Door Gasket Figure 30B Close-up inside view of the combustion chamber Bracket Replace viewport if glass is missing or damaged. Replace manifold component block if missing or removed. Replace door gasket if damaged.
Removing and Replacing the Gas Control Valve/Thermostat Removing the Gas Control Valve/Thermostat: 1. Turn the gas control/temperature knob to the “OFF” position (Figure 19A). 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 on “Draining and Flushing” and follow the procedure. 4. Disconnect the igniter wire from the igniter lead wire.
PROBLEM PILOT WILL NOT LIGHT OR REMAIN LIT (continued) POSSIBLE CAUSE(S) 9. 10. 11. 12. ECO switch open Pilot line or orifice clogged Non-functioning thermopile Air for combustion obstructed 13. Flammable vapors incident, FVIR function utilized HIGH OPERATION COSTS 1. 2. 3. 4. 5. 6. 7. 8. 9. CORRECTIVE ACTION 9. 10. 11. 12. Replace gas control valve/thermostat Clean, locate source and correct Replace thermopile See maintenance section for inspection and cleaning of flame trap 13.
STATUS LIGHT CODE TROUBLESHOOTING CHART LED STATUS PROBLEM CORRECTIVE ACTION 0 FLASHES (LED NOT LIT) Pilot light is not lit. Not enough power (millivolts) 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 (millivolts) to the 1. gas control valve/thermostat. 2.
PILOT LIGHT TROUBLESHOOTING CHART Section A: Pilot light will not light (new installation). Is the manual gas shut-off valve, located in the supply line to the water heater, in the on position? YES Have you bled all the air from the pilot tube and gas supply line? YES NO While repeatedly depressing the igniter button, push in and hold the gas control/ temperature knob until the pilot is lit and maintains a stable flame, (status light will blink) then release the gas control/ temperature knob.
REPAIR PARTS ILLUSTRATION 1B When ordering repair parts always give the following information: 1. 2. 3. 4. 1A 5B 5A 4 2 Model, serial, and product number Type of gas Item number Parts description Repair Parts List 8 3 6A Item No.
Listed Parts Kits and Illustrations Item 12A: Pilot assembly kit, which contains the pilot, electrode, and thermopile (Natural Gas) Item 12B: Pilot assembly kit (50K Models), which contains the pilot, electrode, and thermopile (Natural Gas) Item 13A: Burner Door assembly, which contains the burner, gasket, door, pilot tube, manifold component block with retainer clip, temperature sensor, and pilot assembly.
NOTES 34
NOTES 35
