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 • Do not try to light any appliance.
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 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. Read and follow water heater warnings and instructions.
• Locate the water heater near the existing gas piping. If installing a new gas line, locate the water heater to minimize the pipe length and elbows. NOTE: 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)-current edition.
Gas Supply Figure 5 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.
BTU/HR. 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. Failure to follow these instructions can result in death or carbon monoxide poisoning. IMPORTANT: Air for combustion and ventilation must not come from a corrosive atmosphere.
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 12 Draft hood Installation Alternative Opening Location Confined Space Draft hood Flue Damper 1 sq. Inch Per 3000 BTU/HR Draft hood Leg Tips* * Twist or bend the leg tips to secure the draft hood to the flue damper Figure 11 All Air from Outdoors Using a Single Permanent Opening Vent Pipe System This water heater uses a non-direct, single-pipe vent system to remove exhaust gases created by the burning of fossil fuels.
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 16). 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 connections for use in space heating applications. Note: this water heater, “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 potable (drinking water), the instructions listed below must be followed.
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 WARNING Read and understand these directions thoroughly before Explosion Hazard attempting to start or re-start the water heater. Make sure the viewport is not missing or damaged. (See Figure 28) Make sure the tank is completely filled with water before turning the power switch on. 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 Flames 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.P. gas water heater, smell all around the appliance at floor level.
The thermostat is adjusted to the pilot position when it is shipped from the factory. Water temperature can be regulated by moving the temperature dial to the preferred setting. The preferred starting point is 120°F at the “HOT” setting. Align the knob with the desired water temperature as shown in Figure 22. There is a hot water scald potential if the thermostat is set too high. NOTE: Temperatures shown on the gas control valve/ thermostat are approximates.
Electrical Connections WARNING Before plugging in the water heater, always make sure: • The Voltage and frequency correspond to that specified on the water heater. • The electrical outlet has the proper overload fuse or breaker protection. • Water heater to be located within 6 feet of 120VAC outlet. • Unit is to connect to a 120VAC electrical supply outlet (extension cord is not allowed). • The water heater and the outlet are properly grounded.
Operating the Temperature Control System Water Temperature Adjustment Figure 24: Status Codes Status Light Operating Modes and Settings STATUS ON OFF C A B The water temperature setting can be adjusted from 70°F to 160°F. Turn the Gas Control/Temperature Knob to the desired setting/temperature. RY VE OT H • • HOT • • LOW VAC Standard Mode - The controller adjusts the water heater to maintain the temperature set by the user.
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: Temperature and Pressure Relief Valve WARNING 1. Turn off the gas to the water heater at the manual gas shut-off valve. 1.
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 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: Removing the Burner from the Manifold Assembly Natural Gas Burner (Low Nox) & L.P. Burner 1. 2.
NOTE: To prevent any bending of the pilot bracket, use pliers to hold the pilot assembly bracket while loosening the pilot nut. 4. Pull the pilot tube from the pilot assembly (Figure 31). IMPORTANT: Be careful not to bend or alter the position of the pilot assembly components. Figure 31 Pilot/Thermopile Assembly Pilot Tube Igniter Wire Pilot/Ignitor-Flame Sensor Assembly Filter Installation and Cleaning IMPORTANT: It is essential that the filter be installed properly.
External Inspection & Cleaning of the Flame-trap Figure 32B Installing Air Filter Assembly: Trim excess material, making sure there is enough to overlap by 4 inches (100 mm). If the water heater has a sensor, the air filter must be trimmed around sensor. Although not likely to occur, if debris collects on the flametrap, use a vacuum, compressed air, or a soft bristle brush to remove it.
Replacing the Manifold Assembly WARNING Explosion Hazard Tighten both manifold door screws securely. Remove any fiberglass between gasket and combustion chamber. Replace viewport if glass is missing or damaged. Replace two piece wire connector if missing or removed. 7. If replacing the pilot tube, install ferrule nut supplied with kit into the gas valve at the pilot tube location, hand tight only.
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, flue damper, igniter, and flammable vapor sensor Removing the Gas Control Valve/Thermostat: 1. Turn off the gas at the manual shut-off valve on the gas supply pipe (Figure 5). 2. Move the ON/OFF switch on the gas control valve/ thermostat to the “OFF” position to turn off the water heater and unplug from the wall outlet. (Figure 22). 3.
PROBLEM BURNER FLAME YELLOWLAZY POSSIBLE CAUSE(S) CORRECTIVE ACTION 1. 2. 3. 4. Insufficient secondary air Low gas pressure Flue clogged Flue damper partially open 1. 2. 3. 4. 5. 6. 7. Main burner line clogged Heater installed in a confined area Obstruction in main burner orifice 5. 6. 7. Provide ventilation to water heater Check with gas utility company Clean, locate source and correct Cycle gas control valve/thermostat OFF then ON.
STATUS LIGHT CODE TROUBLESHOOTING TABLE Status Light Code LED FLASH SEQUENCE CONTROL STATUS Short flash once every four second IDLE (No call for heat, no fault conditions) “Heartbeat”, alternates bright/dim Call for Heat (No fault conditions) One Flash, three second pause Low Flame Signal (control continues to operate) Two Flash, three second pause End Switch Failed Closed CORRECTIVE ACTION Turn the power switch on the gas control valve to the “OFF” position and unplug the power cord from the pow
STATUS LIGHT CODE TROUBLESHOOTING TABLE Status Light Code LED FLASH SEQUENCE Six-Two Flash, three second pause CONTROL STATUS Soft Lockout - Recycle Limit - Flame Lost END Switch Fails CORRECTIVE ACTION Turn the power switch on the gas control valve to the “OFF” position and unplug the power cord from the power outlet. 1.
SEQUENCE OF OPERATION CHART Apply Power to Appliance. Is there a Call for Heat. Y Is Damper Closed? Will not attempt to light 2 flash error code. See Corrective Action Table on page 30. N Damper Energizes. Is Damper Open? Gas Valve attempts to open damper for 30 seconds, then waits 2 mintues. 3 flash error code. See Corrective Action Table page 30. N Pilot Valve Energizes Does Pilot Valve Open? Will not light. 8-4 flash error code. See Corrective Action Table on page 31.
REPAIR PARTS ILLUSTRATION 1 When ordering repair parts always give the following information: 1. 2. 3. 4. 5 4 Model, serial, and product number Type of gas Item number Parts description 2 Repair Parts List Item No.
Listed Parts Kits and Illustrations Item 12A: Pilot/Igniter-Flame Sensor assembly kit, which contains the pilot, igniter-flame sensor, and retainer clip (Natural Gas) Item 12B: Pilot/Igniter-Flame Sensor assembly kit, which contains the pilot, igniter-flame sensor, and retainer clip (L.P. Gas) Item 13A: Burner (Natural Gas/L.P. Gas) Item 13B: Burner (L.P.
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Instructions for DNG 50 Gallon Electrical Connections Water Heater Location Before plugging in the water heater, always make sure: Water heater location is important and can affect system performance. Please check the following: • The Voltage and frequency correspond to that specified on the water heater. • The electrical outlet has the proper overload fuse or breaker protection. • Water heater to be located within 19 feet of 120VAC outlet.
Repair Parts Illustration When ordering repair parts always give the following information: 1. 2. 3. 4. 1 Model, serial, and product number Type of gas Item number Parts description 5 17 Repair Parts List Item No.