® o] Home Appliances Ultra Low Nox Gas Water Heater with the Flame Lock® Safety System WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. Installation Instructions and Use & Care Guide Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other 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 installed in accordance with Massachusetts Plumbing and Fuel Gas Code 248 CMR Section 2.
heater. Note: Not following these instructions and/or an inadequate air supply can cause the Flame Lock ® Safety System to disable the water heater. Please make required installation and venting/air supply changes prior to resetting the system (see "Combustion Air Supply and Ventilation" section). Flammable FIRE AND EXPLOSION Can result in serious _Do Do not use or store flammable products such as gasoline, solvents, or adhesives in the same room or area near the water heater.
IMPORTANT: Thewaterheatershouldbelocated in anareawhereleakageofthetankor connections willnotresultindamagetotheareaadjacenttothe waterheateror tolowerfloorsofthestructure.Due tothenormalcorrosiveactionofthewater,thetank willeventually leakafteranextendedperiodoftime. Alsoanyexternalplumbingleak,includingthosefrom improperinstallation, maycauseearlyfailureofthetank duetocorrosionif notrepaired.If thehomeowner is uncomfortable withmakingtherepaira qualifiedperson shouldbecontacted.
Gas Supply Figure 3 Gas Piping Manual Shut-off Gas Valve'---._ Joint Ground Union Check with local utility for minimum height3"M _ i Explosion Use a new CSA approved Install a shut-off Hazard Drip Leg gas supply line. 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.
Table1 NaturalGasPipeCapacityTable(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 Awater 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 Gable 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 Alternative Opening Location _ Metal Screws _ II Confined Space (four provided) _Draft hood t ] sq. Inch "_ Per 3000 BTU/HR Sl°tJ \ _ Jacket top P" LSl°t Install the draft hood with the four screws provided. Vent Pipe Size Figure 8B All Air from Outdoors Using a Single Permanent Opening 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)-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.
Pleasenotethefollowing: Closed System/Thermal Expansion • Thesystemshouldbeinstalledonlywithpipingthatis suitableforpotable(drinkable) watersuchas copper, CPVC,or polybutylene. Thiswaterheatermustnotbe installedusingironpipingor PVCwaterpiping. • Useonlypumps,valves,orfittingsthatarecompatible withpotablewater. • Useonlyfullflowballor gatevalves.Theuseof valves thatmaycauseexcessiverestriction towaterflowis notrecommended. Explosion Hazard • Useonly95/5tin-antimony orotherequivalentsolder.
Temperature Relief Valve and Pressure 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 IMPORTANT: Only a new temperature and pressure relief valve should be used with your water heater.
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.
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 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 Burner the Draft 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 drafthood. A steady Opening Mat flame drawn into the opening indicates proper draft.
Water Temperature Regulation 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 °F 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. Feel water before bathing or showering. Temperature limiting valves are available.
Operating the Temperature Control System Status Figure 19B: Status Codes Light Codes Normal Flashes: List of status codes are shown at top of gas control valve/thermostat • 0 Flashes Indicates Control Off/Pilot Out. • 1 Flash Indicates Normal Operation. • Continuous Light indicates the gas control valve/thermostat is shutting down. Diagnostic Flashes: If the water heater is not working, look for the following diagnostic flashes after lighting the pilot.
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: 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. Close the cold water inlet valve. 4.
Replacement Natural Gas Burner (Ultra Low Nox) 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 or the local distributor. Parts will be shipped prices and billed accordingly. When ordering parts, always have the following information 1. 2. 3.
Replacing the Pilot/Thermopile 1. 2. Assembly Remove the burner assembly as directed previously. Lift the retainer clip straight up from the back of the manifold component block (using a fiat-blade screwdriver), then remove the manifold component block from the burner door assembly (Figure 25).
Replacing the Burner Door Assembly Explosion Figure 28A Combustion Chamber Hazard Tighten both burner door screws securely. Door Gasket Remove any fiberglass between gasket and combustion chamber. Figure 28B Close-up inside _ view of the combustion chamber Replace viewport if glass is missing or damaged. Replace manifold component or removed. block if missing Replace door gasket if damaged. Failure to follow these instructions result in death, explosion, 1. can or fire.
Removing and Replacing the Gas Control Valve/Thermostat may result. Do not insert any sharp objects into the inlet or outlet connections. Damage to the gas control valve/thermostat may result. Gas Control Valve/Thermostat: To replace the gas control valve/thermostat, reassemble in reverse order. When replacing the gas control valve/ thermostat, thread a 4" section of gas pipe into the inlet and use it to turn the gas control valve/thermostat (clockwise.) DO NOT OVER TIGHTEN, damage may result.
PROBLEM PILOT WILL NOT LIGHT OR REMAIN LIT (continued) POSSIBLE CAUSE(S) 13. Flammable vapors incident, Flame Lock _ function utilized Replace gas control valve/thermostat Clean, locate source and correct Replace thermopite See maintenance section for inspection and cleaning of flame trap 13. Replace water heater, eliminate flammable vapors source. Call 1-877-817-6750. HIGH OPERATION COSTS 1. 2. 3. 4. 5. 6. 7. 8. 9.
STATUS LIGHT CODE TROUBLESHOOTING LED STATUS PROBLEM CHART CORRECTIVE ACTION 0 FLASHES (LED NOT LIT) Pilot light is not tit. 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 (mittivolts) to the gas control valve/thermostat, 1. Check all wiring connections.
PILOT LIGHT TROUBLESHOOTING Section A: Pilot light will not light (new installation). Section C: Pilot light will not remain lit.
REPAIR PARTS ILLUSTRATION When ordering repair parts always give the following information: 1. 2. 3. Model, serial, and product number Type of gas Item number 4. Parts description / Repair Parts List Item No.
Listed Parts Kits and Illustrations Item 12: Pilot assembly kit, which contains the pilot, electrode, and thermopile (Natural Gas) Item 13: Burner Door assembly, which contains the burner, gasket, door, pilot tube, manifold component block with retainer clip, temperature sensor, and pilot assembly.
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