Energy Smart 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 Location Requirements WARNING Carbon Monoxide Poisoning Hazard Do not install in a mobile home. FLAMMABLES Doing so can result in death or carbon monoxide poisoning. 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.
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 WARNING 3. Install a ground joint union between the gas control valve/thermostat and the manual shut-off valve. This is to allow easy removal of the gas control valve/ thermostat. 4. Turn the gas supply on and check for leaks. Test all connections by brushing on an approved noncorrosive leak-detection solution. Bubbles will show 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.
Table 1 Natural Gas Pipe Capacity Table (Cu. Ft./Hr.) Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity of 0.60 (natural gas). Nominal Iron Pipe Size, in.
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. • Listed Lined Chimney 3 ft.
Water System Piping Figure 13 Water Piping Installation 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.
Closed System/Thermal Expansion Figure 15A Temperature and Pressure Relief Valve Installation Periodic discharge of the temperature and pressure relief valve may be due to thermal expansion in a closed water supply system. The water utility supply meter may contain a check valve, backflow preventer or water pressure reducing valve. This will create a closed water system. During the heating cycle of the water heater, the water expands causing pressure inside the water heater to increase.
• Figure 15B T&P Relief Valve Insulation T&P Relief Valve Insulation Manual Relief Lever T&P Relief Valve T&P Relief Valve Drain Line T&P Relief Valve and Pipe Insulation (Some Models) 1. Locate the T&P Relief Valve on the water heater. 2. Locate the slit running the length of the insulation. 3 Spread this slit open and slip it over the T&P Relief Valve. See Figure 15B. Apply gentle pressure to the insulation to ensure it is fully seated on the T&P Relief Valve.
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 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.
Checking the Draft Water Temperature Regulation WARNING 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 Figure 17 Drafthood the area are operating and Relief Opening all doors are closed when Match performing the draft test. Pass a match flame around the relief opening of the drafthood.
Operating the Temperature Control System NOTE: If the pilot lights, but will only stay lit with the knob depressed in the pilot position, look for the following status light codes. Figure 19B Temperature Control System STATUS LIGHT CODE 6 Second Solid Light followed by: 4 Flashes The unit will not relight because it detects an overheat failure. 7 Flashes The unit will not relight because it detects an electronic control failure. 8 Flashes The unit will not relight because it detects a valve failure.
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. 2. Close the cold water inlet valve. 3. Open a nearby hot water faucet. 4.
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: 1. model, serial, and product number Removing the Burner from the Manifold Assembly Natural Gas Burner (Low Nox) 1.
Replacing the Pilot Assembly 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. Locate and remove the screws on the underside of the burner. Remove the screw securing the pilot assembly to the manifold. 4. Using a wrench loosen the nut securing the pilot tube to the pilot assembly.
Replacing the Manifold Assembly WARNING 9. Check for leaks by brushing on an approved noncorrosive leak detection solution. Bubbles forming indicate a leak. Correct any leak found. IMPORTANT: All leaks must be fixed immediately. 10. Replace the outer door. Figure 28A Combustion Chamber Flame-trap Bracket Door Gasket Explosion Hazard Tighten both manifold door screws securely. Remove any fiberglass between gasket and combustion chamber. Replace viewport if glass is missing or damaged.
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. Turn the gas control/temperature knob 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. Refer to the section of “Draining and Flushing” on page 20 and follow the procedure. 4.
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 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 Is the igniter producing a spark? NO Turn the manual gas shut-off valve to the on position and follow the lighting instructions on the front of the water heater.
REPAIR PARTS ILLUSTRATION 1 5 4 2 8 3 6 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 10 9 Repair Parts List Item No.
Listed Parts Kits and Illustrations Item 12: Pilot assembly kit, which contains the pilot assembly, thermopile, and retainer clip (Natural Gas) Item 13: Burner (Natural Gas/Low Nox) Item 14: Manifold door assembly which contains the manifold tube, gasket, door, pilot tube, thermopile, two piece wire connector with retainer clip, thermal switch, and pilot assembly.