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Home My WebLink AboutG6-S4040PVR.pdf 100XXXXXX (A)_200XXXXXX (Ver. 00) October 2016 Residential Gas Water Heater InstallaƟ on InstrucƟ ons and Use & Care Guide Keep this manual in the pocket on heater for future reference whenever maintenance, adjustment or service is required. Retain your original receipt as proof of purchase. ResidenƟ al Atmospheric Gas Water Heater with the Flammable Vapor IgniƟ on Resistant Safety System Read this manual and the labels on the water heater before you install, operate, or service it. If you have diffi culty following the direcƟ ons, or aren’t sure you can safely and properly do any of this work yourself: • Call our Technical Assistance Hotline at 1-877-817-6750 or visit hƩ p:// www.AOSmithAtLowes.com. We can help you with installaƟ on, operaƟ ons, troubleshooƟ ng, or maintenance. Before you call, write down the model and serial number from the water heater’s data plate. Incorrect installaƟ on, operaƟ on, or service can damage the water heater, your house and other property, and present risks including ﬁ re, scalding, electric shock, and explosion, causing serious injury or death. Do not store or use gasoline or other ﬂ ammable 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. • Do not touch any electrical switch; do not use any phone in your build-ing. • Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instrucƟ ons. • If you cannot reach your gas sup- plier, call the ﬁ re department. InstallaƟ on and service must be per- formed by a qualiﬁ ed installer, service agency or the gas supplier. WARNING: If the informaƟ on in these instrucƟ ons is not followed exactly, a ﬁ re or explosion may result causing property damage, personal injury or death. LOW LEAD CONTENT Table of Contents Page IMPORTANT SAFETY INFORMATION .............................................3 GETTING STARTED ........................................................................7 INSTALLATION .............................................................................14 OPERATION .................................................................................23 TROUBLESHOOTING ...................................................................25 MAINTENANCE ...........................................................................28 NOTES .........................................................................................31 REPAIR PARTS .............................................................................35 2000536058 (Ver. 00) 100277333 (A) DO NOT RETURN THIS UNIT TO THE STORE COMPLETED INSTALLATION ΈTYPICALΉ Expansion tank (Connect to cold water supply) Hot water line T&P relief valve Cold water shut off DraŌ hood T&P discharge pipe Drain pan discharge pipe Metal drain pan Gas control valve/thermostat Cold water line Gas supply shut off Vent pipe Drain valve Gas supply Sediment Trap ResidenƟ al Standard Gas Water Heater Use and Care Guide • 3 SAFETYIMPORTANT SAFETY INFORMATION Important informaƟ on to keep Fill out this secƟ on and keep this manual in the pocket of the water heater for reference. Date Installed: Model number: Serial number: Maintenance performed:* Date: This is the safety alert symbol. It is used to alert you to potenƟ al physical injury hazards. Obey all safety mes- sages that follow this symbol to avoid possible property damage, serious injury or death. Do not remove any permanent instrucƟ ons, labels, or the data plate from either the outside of the water heater or on the inside of the access panels. Keep this manual near the water heater. DANGER Read and follow all safety messages and instrucƟ ons in this manual. DANGER indicates hazardous situa- Ɵ on that, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situaƟ on that, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a hazardous situaƟ on that, if not avoided, could result in minor or moderate injury. NOTICE NOTICE indicates pracƟ ces not related to physical injury. WARNING! If the informaƟ on in these instrucƟ ons is not followed exactly, a ﬁ re or explosion may result causing property damage, personal injury or death. Do not store or use gasoline or other ﬂ ammable vapors and liquids in the vicinity of this or any other appliance. An odorant is added by the gas supplier to the gas used by this water heater. This odorant may fade over an extended period of Ɵ me. Do not depend upon this odorant as an indicaƟ on of leaking gas. We recommend installing a fuel gas and carbon monoxide detector.*Drain and ﬂ ush tank and remove and inspect anode rod aŌ er ﬁ rst six months of operaƟ on and at least annually thereaŌ er. Operate the Temperature and Pressure Relief Valve (T&P) annu- ally and inspect T&P valve every 2-4 years (see the label on the T&P valve for maintenance schedule). See the Main- tenance secƟ on for more informaƟ on about maintaining this water heater. 4 • ResidenƟ al Standard Gas Water Heater Use and Care GuideSAFETY 4 • ResidenƟ al Standard Gas Water Heater Use and Care Guide IMPORTANT SAFETY INFORMATION T o reduce the risk of property damage, serious injury or death, read and follow the precauƟ ons below, all labels on the water heater, and the safety messages and instrucƟ ons throughout this manual. RISKS DURING INSTALLATION AND MAINTENANCE LiŌ ing Risk WARNING! The water heater is heavy. Follow these precau- Ɵ ons to reduce the risk of property damage, injuries from liŌ ing or impact injuries from dropping the water heater. • Use at least two people to liŌ the water heater. • Be sure you both have a good grip before liŌ ing. • Use an appliance dolly or hand truck to move the water heater. Explosion Risk WARNING! Read the water heater’s data plate to determine the type of gas required. Failure to follow these instrucƟ ons can result in serious injury or death from explosion, ﬁ re or carbon monoxide poisoning. • 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. • Use a new CSA approved gas supply line. • Install a shut-off valve on the gas supply line. Gas Pressure WARNING! The gas supply pressure must not exceed the maximum supply pressure as stated on the water heater’s data plate. The minimum supply pressure is for the purpose of input adjustment. L.P. gas supply pressure must not exceed 13” water column. Have a qualiﬁ ed person (licensed plumber, gas company personnel, or authorized service technician) check for proper L.P. gas pressure. L.P. gas pressures exceeding 13” water column can result in serious injury or death from explosion or ﬁ re. RISKS DURING OPERATION Scalding Risk This water heater can make water hot enough to cause severe burns instantly, resulƟ ng in severe injury or death. • Feel water before bathing or showering. • To reduce the risk of scalding, install ThermostaƟ c Mixing Valves (temperature limiƟ ng valves) at each point-of-use. These valves automaƟ cally mix hot and cold water to limit the temperature at the tap. Mixing valves are available from Lowe’s®. Follow manufac- turer’s instrucƟ ons for installaƟ on and adjustment of the valves. • The gas control valve on this water heater has been factory set to its lowest seƫ ng to reduce the risk of scalding. Higher temperatures increase the risk of scalding, but even at 120°F, hot water can scald. If you choose a higher tempera- ture seƫ ng, ThermostaƟ c Mixing Valves located at each point-of-use are parƟ cularly important to help avoid scalding. Table 1 Temperature Time to Produce a Serious Burn 120°F (49°C) More than 5 minutes 125°F (52°C) 1½ to 2 minutes 130°F (54°C) About 30 seconds 135°F (57°C) About 10 seconds 140°F (60°C) Less than 5 seconds 145°F (63°C) Less than 3 seconds 150°F (66°C) About 1½ seconds 155°F (68°C) About 1 second For informaƟ on about changing the factory temperature seƫ ng, refer to the “AdjusƟ ng the Temperature” sec- Ɵ on in this manual . Even if you set the water heater’s gas control valve to a low seƫ ng, higher water temperatures may occur in cer- tain circumstances: • In some cases, repeated small draws of water can cause the hot and cold water in the tank to “stack” in layers. If this happens, the water can be as much as thirty degrees hoƩ er than the gas control valve seƫ ng. This temperature variaƟ on is the result of your usage paƩ ern and is not a malfuncƟ on. • Water temperature will be hoƩ er if someone adjusted the gas control valve to a higher seƫ ng. • Problems with the gas control valve or other malfuncƟ ons may result in higher than expected water tem- peratures. • If the water heater is in a hot envi- ronment, the water in the tank can become as hot as the surrounding air, regardless of the temperature seƫ ng. ResidenƟ al Standard Gas Water Heater Use and Care Guide • 5 SAFETYResidenƟ al Standard Gas Water Heater Use and Care Guide • 5 IMPORTANT SAFETY INFORMATION • If the water supplied to the water heater is pre-heated (for example, by a solar system) the temperature in the tank may be higher than the water heater’s temperature seƫ ng. • Should overheaƟ ng occur or the burner fail to shut off , turn off the manual gas supply valve to the water heater and call a qualiﬁ ed person. To reduce the risk of unusually hot wa- ter reaching the ﬁ xtures in the house, install ThermostaƟ c Mixing Valves at each point-of-use. If anyone in your home is at parƟ cular risk of scalding (for example, the elder- ly, children, or people with disabiliƟ es) or if there is a local code or state law requiring a certain water temperature at the hot water tap, these precauƟ ons are parƟ cularly important. According to a naƟ onal standard (ASSE 1070) and many local plumbing codes, the water heater’s gas control valve should not be used as the sole means to regulate water temperature and avoid scalds. Properly adjusted ThermostaƟ c Mixing Valves installed at each point-of-use al- low you to set the tank temperature to a higher seƫ ng without increasing risk of scalds. A higher temperature seƫ ng allows the tank to provide much more hot water and can help provide proper water temperatures for appliances such as dishwashers and washing machines. Higher tank temperatures (140°F) also kill bacteria that cause a condi- Ɵ on known as “smelly water” and can reduce the levels of bacteria that cause water-borne diseases. Water ContaminaƟ on Risk Do not use chemicals that could con- taminate the potable water supply. Do not use piping that has been treated with chromates, boiler seal, or other chemicals. Fire Risk This water heater is equipped with a Flam- mable Vapor IgniƟ on Resistance (FVIR) system. FVIR is designed to reduce the risk of ﬂ ammable vapor-related ﬁ res. FVIR makes this product more sensiƟ ve to installaƟ on errors or improper installa- Ɵ on environments. The FVIR system will not prevent a possible ﬁ re/explosion if the igniter is depressed and ﬂ ammable vapors have accumulated in the combus- Ɵ on chamber with the pilot light off . Do not aƩ empt to light this appliance, or depress the igniter buƩ on, if you suspect ﬂ ammable vapor have accumu- lated inside or outside the appliance. Immediately call a qualiﬁ ed person to inspect the appliance. Water heaters subjected to a ﬂ ammable vapors inci- dent will show a discoloraƟ on on the ﬂ ame arrestor and require replacement of the enƟ re water heater. Improper installaƟ on or an inadequate air supply can also cause the FVIR system to dis- able the water heater. WARNING! This water heater has a reseƩ able thermal switch installed as part of the FVIR system. Do not aƩ empt to disable or modify this feature in any way. Doing so can lead to ﬁ re, explosion or excessive and abnormal producƟ on of carbon monoxide. To reduce the risk of a ﬁ re that could result in property damage, or serious injury or death: • Do not store things that can burn easily such as paper or clothes next to the water heater. • Do not store or use gasoline or other ﬂ ammable substances in the vicinity of this or any other appliance. • Keep the water heater from becom- ing wet. Immediately shut the water heater off and have it inspected by a qualiﬁ ed person if you ﬁ nd that the wiring, thermostat(s) or surround- ing insulaƟ on have been exposed to water in any way (e.g., leaks from plumbing, leaks from the water heater itself can damage property and could cause a ﬁ re risk). If the water heater is subjected to ﬂ ood condiƟ ons or the thermostat(s) have been submerged in water, the enƟ re water heater must be replaced. • Replace the water heater’s viewport if glass is missing or damaged. Repair the combusƟ on chamber door seals if damaged. Explosion Risk High temperatures and pressures in the water heater tank can cause an explosion re- sulƟ ng in property damage, serious in- jury or death. A new Temperature and Pressure (T&P) Relief Valve is included with your water heater to reduce risk of explosion by discharging hot water. AddiƟ onal temperature and pressure protecƟ ve equipment may be required by local codes. A naƟ onally recognized tesƟ ng labo- ratory maintains periodic inspecƟ on of the valve producƟ on process and cerƟ ﬁ es that it meets the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22. The T&P Relief Valve’s relief pressure must not exceed the working pressure raƟ ng of the wa- ter heater as stated on the raƟ ng plate. Maintain the T&P Relief Valve properly. Follow the maintenance instrucƟ ons provided by the manufacturer of the T&P Relief Valve (label aƩ ached to T&P Relief Valve). An explosion could occur 6 • ResidenƟ al Standard Gas Water Heater Use and Care GuideSAFETY 6 • ResidenƟ al Standard Gas Water Heater Use and Care Guide IMPORTANT SAFETY INFORMATION if the T&P Relief Valve or discharge pipe is blocked. Do not cap or plug the T&P Relief Valve or discharge pipe. Fire and Explosion Risk if Hot Water is Not Used for Two Weeks or More. CAUTION! Hydrogen gas builds up in a hot water system when it is not used for a long period (two weeks or more). Hydrogen gas is extremely ﬂ ammable. If the hot water system has not been used for two weeks or more, open a hot water faucet for several minutes at the kitchen sink before using any electrical appliances connected to the hot water system. If hydrogen is present there will probably be an unusual sound such as “air” escaping through the pipe as hot water begins to ﬂ ow. Do not smoke or have an open ﬂ ame or other igniƟ on source near the faucet while it is open. Carbon Monoxide Risk WARNING! This water heater operates by burning gas. Carbon monoxide is a colorless, odorless, gas that is a by-product of burning of fuels such as coal, wood, charcoal, oil, kerosene, propane, and natural gas. Breathing excessive and abnormal amounts of carbon monoxide can cause carbon monoxide poisoning, resulƟ ng in serious injury or death. This water heater must be supplied with adequate combusƟ on air and must be properly vented to the outdoors. Have a qualiﬁ ed person (licensed plumber, authorized gas company personnel, or authorized service technician) install the venƟ ng system using these installaƟ on instrucƟ ons. When the installaƟ on is complete, check the vent’s draŌ using the instrucƟ ons on pages 23-24. • Install a fuel gas and carbon mon- oxide detector in the living areas of your home. • Do not install this water heater in a mobile home or manufactured housing. • Failure to follow these instruc- Ɵ ons can result in serious injury or death from carbon monoxide poisoning. Burn Risk This water heater’s vent- ing system can become hot enough to burn. Do not touch the venƟ ng system while water heater is on, or unƟ l the water heater is turned off and the venƟ ng allowed to cool. InstallaƟ on Accessories Figure 1 - Gas Water Heater Hook-Up Kit Figure 2 - Install a Pressure Reducing Valve set to 50 to 60 PSI. ResidenƟ al Standard Gas Water Heater Use and Care Guide • 7 GETTING STARTEDResidenƟ al Standard Gas Water Heater Use and Care Guide • 7 GETTING STARTED 1 Review all of the instrucƟ ons before you begin work. If you aren’t sure that you can safely and properly do this work yourself, call your Lowe’s® store to arrange for Professional InstallaƟ on (you may also call a qualiﬁ ed person of your choice, such as a licensed plumber, to have the work done). Improper installaƟ on can damage the water heater, your home and other property, and can present risks of serious injury or death. 2 This water heater is design- cerƟ ﬁ ed by CSA InternaƟ onal as a Category I, non-direct vented water heater which takes its combusƟ on air either from the installa- Ɵ on area or from air ducted to the unit from the outside. This water heater must be installed according to all local and state codes or, in the absence of local and state codes, the “NaƟ onal Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current ediƟ on. This is available from the following: CSA America, Inc. 8501 East Pleasant Valley Road Cleveland, OH 44131 NaƟ onal Fire ProtecƟ on AssociaƟ on 1 BaƩ erymarch Park Quincy, MA 02269 Check with local code offi cials about codes governing this installaƟ on. Have your installaƟ on inspected by a code offi cial to ensure the installaƟ on meets all local codes. NOTICE: If you lack the necessary skills required to properly install this water heater, or you have diffi culty follow- ing the instrucƟ ons, you should not proceed but have a qualiﬁ ed person perform the installaƟ on of this water heater. MassachuseƩ s code requires this water heater to be installed in accordance with MassachuseƩ s 248-CMR 2.00 and 248-CMR 5.00: State Plumbing Code. Other local and state authoriƟ es may have similar requirements or other codes applicable to the installaƟ on of this water heater. 3 Before you start, be sure you have the following tools and supplies: • Common plumbing tools (depend- ing on what type of water pipes you have). • Te ﬂ on® tape or pipe joint com- pound approved for potable water. • For homes with copper pipes, you may purchase a Gas Water Heater Hook-Up Kit ( available from Lowes®) with compression ﬁ ƫ ngs that don’t require soldering. This kit includes two 12” ﬂ ex water lines, two compression ﬁ ƫ ngs, an 18” ﬂ exible gas line, two nipples, and Teﬂ on® tape. • For homes with plasƟ c pipe, use threaded connectors suitable for the speciﬁ c type of plasƟ c pipe used: CPVC or PEX (cross-linked polyethylene). Do not use PVC pipe. • Non-corrosive gas leak detecƟ on soluƟ on made from hand dish- washing soap mixed with water (1 part soap to 15 parts water) or chil- dren’s soap bubbles and a small, soŌ -bristled brush. • An appliance dolly or hand truck to move the water heater. Recommended Accessories: • A metal drain pan. • AutomaƟ c water leak detecƟ on and shut-off device. • Pressure Reducing Valve. • Thermal Expansion Tank. • ThermostaƟ c Mixing Valves at each point-of-use. • Fuel gas and carbon monoxide detector. CombusƟ on and Ven Ɵ laƟ on Air Supply Before installing the water heater, you must determine the amount of air needed to supply this water heater and any other gas appliances in the same area and provide adequate air for combusƟ on and venƟ laƟ on. Consult a qualiﬁ ed person if you’re unsure of the proper way to supply air to your water heater. WARNING! This gas water heater requires an adequate source of clean air for combusƟ on and venƟ laƟ on. Without suffi cient air, your water heater will have frequent pilot outages and may emit excessive and abnormal amounts of carbon monoxide. Before beginning: Calculate total BTU/HR raƟ ng of all ap- pliances. To calculate the combusƟ on air and venƟ laƟ on required, add up the total BTU/HR raƟ ngs of all gas burning ap- pliances (e.g., water heaters, furnaces, clothes dryers) in the same area. Your water heater’s BTU/HR raƟ ng is on the data plate, located next to the gas control valve/thermostat. The BTU/HR raƟ ngs should be on the other appli- ances’ data plates. If you have trouble determining the BTU/HR raƟ ngs, contact the manufacturer or have a qualiﬁ ed person determine the venƟ la- Ɵ on requirements. NOTICE: If you are replacing your old water heater with one that has a higher BTU/HR raƟ ng, the amount of venƟ laƟ on required may be greater. 8 • ResidenƟ al Standard Gas Water Heater Use and Care GuideGETTING STARTED 8 • ResidenƟ al Standard Gas Water Heater Use and Care Guide GETTING STARTED Example: Gas Burning Appliance BTU/HR RaƟ ng Gas Water Heater 40,000 Furnace 75,000 Dryer 20,000 Total 135,000 Your Appliances: Gas Burning Appliance BTU/HR RaƟ ng Gas Water Heater Total Table 2 provides examples of minimum square footage (area) required for various BTU/HR totals. Areas used for storage or which contain large objects containing less air than is assumed for the room sizes in Table 2 – see OpƟ on A for more speciﬁ c calculaƟ ons. OpƟ on A: InstallaƟ on without outside venƟ laƟ on (not recom- mended) Ven Ɵ laƟ on with outside air is recom- mended for all installaƟ ons. Even if the water heater is installed in a large, open room inside the house, outdoor air is usually needed because modern homes are very Ɵ ghtly sealed and oŌ en do not supply enough air to the water heater. However, when installed in a large indoor space, it may be pos- sible to provide enough air without outside venƟ laƟ on. If you are unsure if your installaƟ on locaƟ on has enough venƟ laƟ on, contact your local gas uƟ lity company or code offi cials for a safety inspecƟ on. The following instrucƟ ons will help de- termine if it may be possible to install without outside venƟ laƟ on. Even if this may be possible, you will need to conduct the vent draŌ test on pages 23-24 when installaƟ on is ﬁ nished. If there is not enough venƟ laƟ on, you will need to venƟ late with outside air. Check for Chemicals: InstallaƟ ons where corrosive chemi- cals may be present require outside air. Air for combusƟ on and venƟ laƟ on must be clean and free of corrosive or acid-forming chemicals such as sulfur, ﬂ uorine, and chlorine. VenƟ laƟ on with outside air will reduce these chemicals, but it may not completely eliminate them. Failure due to corrosive chemi- cals is not covered by the warranty. Examples of locaƟ ons that require outside air due to chemicals include: • Beauty salons • Photo processing labs • Indoor pools • Laundry, hobby, or craŌ rooms • Chemical storage areas Products such as aerosol sprays, de- tergents, bleaches, cleaning solvents, gasoline, air fresheners, paint and varnish removers, and refrigerants should not be stored or used near the water heater. A1: Calculate the air volume of the room Air requirements depend on the size of the room. Floor Area (Square feet) X Ceiling Height (feet) = Room Volume (cubic feet) If there are large objects in the room (e.g., refrigerator, furnace, car), sub- tract their volume from the volume of the room to get a beƩ er esƟ mate of the air available. Room Volume – Object Volume = Air Volume Table 2 BTU/HR Minimum Square Typical Room Input Feet with 8’ Ceiling with 8’ Ceiling 30,000 188 9 x 21 45,000 281 14 x 20 60,000 375 15 x 25 75,000 469 15 x 31 90,000 563 20 x 28 105,000 657 20 x 33 120,000 750 25 x 30 135,000 844 28 x 30 ResidenƟ al Standard Gas Water Heater Use and Care Guide • 9 GETTING STARTEDResidenƟ al Standard Gas Water Heater Use and Care Guide • 9 GETTING STARTED A2: Calculate required air volume A water heater installed in an unconﬁ ned aƫ c or garage requires that the space be at least 50 cubic feet per 1,000 BTU/ HR of the total input for all gas burning appliances in the same area. [Total BTU/HR/1000] x 50 = Cubic feet of air required. Example: (135,000 / 1000) x 50 = 6,750 If the air volume of the room is less than the required air volume, you must provide two permanent outside air openings that draw in suffi cient air. Use OpƟ on B. If the air volume of the room is greater than the required air volume, it may be possible to install the water heater without outside venƟ laƟ on. A3: Check that combusƟ on ven- Ɵ laƟ on is adequate Because modern homes are oŌ en well- sealed to prevent draŌ s, even a large room may not provide enough combus- Ɵ on air without venƟ laƟ on. To con- ﬁ rm that your installaƟ on has enough combusƟ on air, conduct the vent draŌ test on pages 23-24 when installaƟ on is ﬁ nished. OpƟ on B: Install with outside venƟ laƟ on Ven Ɵ laƟ on with outside air is recom- mended, and, for most installaƟ ons, is needed. There may be exisƟ ng venƟ la- Ɵ on that is adequate, or you may need to add more venƟ laƟ on. Supplying outside air to typically requires two openings. One opening must be within 12 inches from the ﬂ oor and the second opening must be within 12 inches from the ceiling. Although a single opening is not preferred, you may use a single opening to outside air if the mini- mum free area is sized according to Table 3. Two openings must be used when venƟ laƟ ng with air from another room. The outside air can be taken from a crawl space or aƫ c open to the out- doors and adequately venƟ lated. You may use verƟ cal or horizontal ducts. B2: Determine type of venƟ la- Ɵ on There are several types of venƟ laƟ on that can be used : 1. Direct to outdoors 2. VerƟ cal ducts 3. Horizontal ducts 4. Single opening (not recom- mended; must be at least 100 square inches. Not appropriate for conﬁ ned spaces smaller than 50 cubic feet per 1,000 BTU/HR as calculated in secƟ on A or when geƫ ng air from another room.) 5. From a larger room inside the house (not recommended – refer to secƟ on A above to determine if the combined volume of the rooms may be adequate). B3: Determine minimum free area required for each vent opening The size of the vent openings depends on the total BTU/HR raƟ ng of all appli- ances in the space (use your calculaƟ on from “Before beginning”) and the type of vent used. Table 3 provides the mini- mum free area for each vent opening depending on the type of venƟ laƟ on. B4: Calculate minimum size of vent openings and ducts The vent cross-secƟ onal area needed to provide the free area depends on the covering on the vent openings. Typical vents use louvers or grilles to protect the opening. The louver or grill itself blocks some of the free area, so the opening may need to be larger to meet the minimum free area requirements. Use the following formula to calculate the required cross-secƟ onal area: Cross-secƟ onal area = minimum free area required ÷ percent free area of Table 3 Minimum Free Area of Permanent Openings for VenƟ laƟ on and CombusƟ on Air Supply – All Air from Outdoors Only. Based on the total BTU/HR input raƟ ng for all gas burning appliances within a conﬁ ned space. Opening Source Minimum Free Area Per Opening (sq. in.) *Direct to outdoors 1 sq. in. per 4,000 BTU/HR (see ﬁ gure on page 10) Ver Ɵ cal ducts 1 sq. in. per 4,000 BTU/HR (see ﬁ gure on page 10) Horizontal ducts 1 sq. in. per 2,000 BTU/HR (see ﬁ gure on page 10) Single Opening 1 sq. in. per 3,000 BTU/HR (see ﬁ gure on page 10) *These openings connect directly with the outdoors through a venƟ lated aƫ c, a venƟ lated crawl space, or through an outside wall. 10 • ResidenƟ al Standard Gas Water Heater Use and Care GuideGETTING STARTED 10 • ResidenƟ al Standard Gas Water Heater Use and Care Guide GETTING STARTED covering (in decimals – e.g., 60% = .6) For example, an installaƟ on area that requires openings with 100 square inches of free area would need 134 square inch openings if using metal louvers rated at 75% free area (100 sq. in. ÷ .75 = 134 sq. in.). If you do not know the % free area for your louver or grill, use the following values: • For wood louvers or grilles: 20% • For metal louvers or grilles: 60% Follow these rules to ensure that vents and ducts provide adequate air ﬂ ow: • Each vent opening must be no smaller than 100 square inches . • Ducts must have the same cross- secƟ onal area as free area of the opening. • Rectangular ducts must have a minimum dimension of no less than three inches . • All screens must have mesh ¼” or larger. • Moveable louvers must be locked open or interconnected with the equipment so that they open au- tomaƟ cally during operaƟ on. • Keep louvers and grills clean and free of debris or other obstruc- Ɵ ons. B5: Check that air source is clean and free of chemicals Air for combusƟ on and venƟ laƟ on must be clean and free of corrosive or ﬂ ammable chemicals. A failure due to corrosive chemicals in the air is not covered by the warranty. Combus- Ɵ on air must be free of acid-forming chemicals such as sulfur, ﬂ uorine, and chlorine. Be sure that air at the vent inlets is free of such chemicals. B6: Check that combusƟ on venƟ laƟ on is adequate To conﬁ rm that your installaƟ on has enough combusƟ on air, conduct the vent draŌ test on pages 23-24 when installaƟ on is ﬁ nished. CombusƟ on Air Supply OpƟ ons Figure 3 - Direct to outdoors openings Figure 4 - Vertical duct openings Figure 5 - Horizontal duct openings Figure 6 - Single opening ResidenƟ al Standard Gas Water Heater Use and Care Guide • 11 GETTING STARTEDResidenƟ al Standard Gas Water Heater Use and Care Guide • 11 GETTING STARTED Ven Ɵ ng WARNING! Carbon Monoxide Hazard. This water heater must be supplied with adequate air and vented to outdoors. The vent system must be installed by a qualiﬁ ed person. Examples of a qualiﬁ ed person include gas technicians, authorized gas company personnel, and authorized service technicians. Failure to properly vent the water heater can result in severe injury or death from carbon monoxide poisoning. The vent system must be installed according to local and state codes, or in the absence of local or state codes, the current ediƟ on of the NaƟ onal Fuel Gas Code, ANSI Z223.1 (NFPA 54). Do not common vent this water heater with any power vented appliance. Do not use a vent damper anywhere in the vent system of this water heater. To reduce the risk of carbon monoxide poisoning, install a fuel gas and carbon monoxide detector. Install and maintain the detector in accordance with the manufacturer’s instrucƟ ons and local codes. Replacing a Water Heater Using the ExisƟ ng Vent System Read the “Installing a New Vent Sys- tem” secƟ on of this manual and make sure your vent system is properly in- stalled. Inspect the exisƟ ng vent system for obstrucƟ ons, corrosion, and proper installaƟ on. Repair or replace if neces- sary. The exisƟ ng vent system must be UL listed Type B double wall or single wall metal vent pipe of either 3 inch or 4 inch diameter and installed according to the vent manufacturer’s instrucƟ ons and the terms of its lisƟ ng. Do not use other materials such as dryer vent hose. Installing a New Vent System The vent pipe must meet the following speciﬁ caƟ ons: Type of Material UL listed Type B double wall or single wall metal vent pipe must be used. Local codes may be more restricƟ ve and may not allow single wall vent pipe. Single-wall vent pipe cannot be used for water heaters located in aƫ cs and may not pass through aƫ c spaces, crawl spaces, or any conﬁ ned or inaccessible locaƟ on. Single-wall vent pipe cannot pass through any interior wall. Clearance to CombusƟ ble Materials The vent pipe cannot pass through any ceiling, ﬂ oor, ﬁ rewall, or ﬁ re parƟ Ɵ on. Any part of the vent system must main- tain the following clearances from any combusƟ ble materials: • Single-wall vent pipe must main- tain a six inch clearance from combusƟ ble materials. • The clearance from combusƟ ble materials of UL listed Type B dou- ble-wall vent pipe is speciﬁ ed by the manufacturer of the vent pipe. UL listed Type B double-wall vent pipe may pass through walls or par- Ɵ Ɵ ons constructed of combusƟ ble material if the minimum clearance speciﬁ ed by the manufacturer of the vent pipe is maintained. Vent InstallaƟ on To improve the ﬂ ow of exhaust gases, we recommend that a minimum of 12 inches of verƟ cal vent pipe be installed on the draŌ hood prior to any elbow. A porƟ on of the vent pipe (up to 75% of the total verƟ cal height) can be horizontal, but the terminaƟ on must be verƟ cal. For the horizontal secƟ on, install without dips or sags with an upward slope of at least ¼ inch per foot. Install pipe avoiding unnecessary bends. Pipe joints must be fastened by sheet metal screws or other approved means. Support the pipe to maintain clearances and to avoid separaƟ on of joints or other damage. Vent pipe must be accessible for cleaning, inspecƟ on, and replacement. TerminaƟ ons If local codes allow, this water heater may be terminated into an exisƟ ng chimney using the instrucƟ ons below. Otherwise, this water heater’s vent must terminate verƟ cally (sidewall or other horizontal terminaƟ ons are not allowed). Chimney TerminaƟ on Figure 7 - Chimney termination vent system NOTICE: Before connecƟ ng a vent to a chimney, make sure the chimney passageway is clear and free of obstruc- Ɵ ons. The chimney must be cleaned if previously used for venƟ ng solid fuel appliances or ﬁ replaces. Also consult lo- cal and state codes for proper chimney sizing and applicaƟ on or, in the absence of local and state codes, the “NaƟ onal Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current ediƟ on. • The vent pipe must be installed above the extreme boƩ om of the chimney to prevent potenƟ ally blocking the ﬂ ue gases. 12 • ResidenƟ al Standard Gas Water Heater Use and Care GuideGETTING STARTED 12 • ResidenƟ al Standard Gas Water Heater Use and Care Guide GETTING STARTED • The vent pipe must be ﬁ rmly at- tached and sealed to prevent it from falling out. • To aid in removing the vent pipe, a thimble or slip joint may be used. • The vent pipe must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney. Do not terminate the vent pipe in a chimney that has not been cerƟ ﬁ ed for this purpose. Some local codes may prohibit the terminaƟ on of vent con- nectors in a masonry chimney. Common (combined) venƟ ng is allow- able with verƟ cal Type B vent systems and lined masonry chimneys as long as proper draŌ for the water heater is established under all condiƟ ons of operaƟ on. Do not common vent this water heater with any power vented appliance. Ver Ɵ cal TerminaƟ on NOTICE: The gas vent must be termi- nated in a verƟ cal posiƟ on to facilitate the removal of exhaust gases. Ver Ɵ cal exhaust vents must terminate with a listed cap or other roof assem- bly and be installed according to their manufacturer’s instrucƟ ons. An unused chimney ﬂ ue or masonry enclosure may be used as a passageway for the installaƟ on of vent pipe. Do not com- mon vent this water heater with any power vented appliance. The follow- ing ﬁ gures are examples of vent pipe system installaƟ ons and may or may not be suitable for your speciﬁ c appli- caƟ on. Consult the “NaƟ onal Fuel Gas Code”, NFPA 54, ANSI Z223.1-current ediƟ on and local codes. Figure 8 - Vertical gas vent system with type B double wall vent pipe Figure 9 - Venting through a chimney with type B double wall vent pipe Gas Piping Gas piping must be installed accord- ing to local and state codes or, in the absence of local and state codes, the “NaƟ onal Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current ediƟ on. NOTICE: When installing gas piping, apply pipe joint compound or Teﬂ on® tape approved for fuel gases. Figure 10 - Gas Piping 1. Install a readily accessible manual shut-off valve in the gas supply line as recommended by the local uƟ l- ity. Know the locaƟ on of this valve and how to turn off the gas to this unit. 2. Install a Sediment Trap as shown in the Gas Piping ﬁ gure below. The Sediment Trap must be no less than three inches long for the accumula- Ɵ on of dirt, foreign material, and water droplets. 3. Install a ground joint union be- tween the gas control valve and the manual gas shut-off valve. This is to allow easy removal of the gas control valve. 4. Turn the gas supply on and check for leaks. Use a small, soŌ -bristled brush to apply a hand dishwash- ing soap and water mixture (1 part soap to 15 parts water) or children’s soap bubbles to all con- necƟ on points of the gas piping. Saturate all the connecƟ ons and check for gas leaks (which will ap- pear as small bubbles). If any leaks are detected, Ɵ ghten the appropri- ate connecƟ on(s) and re-check. Gas Pressure NOTICE: When tesƟ ng gas pipes with a test pressure of more than ½ psi (3.5 kPa), disconnect the gas line at the manual shut off valve and cap the gas line. Do not subject the water heater’s gas control valve or manual shut off valve to more than ½ psi (3.5 kPa) pressure for any reason. If you are pressure tesƟ ng the gas line with test pressure of ½ psi (3.5 kPa) or less, you may isolate the water heater from the gas line by closing the manual shut off valve. ResidenƟ al Standard Gas Water Heater Use and Care Guide • 13 GETTING STARTEDResidenƟ al Standard Gas Water Heater Use and Care Guide • 13 GETTING STARTED Space HeaƟ ng Some water heater models are equipped with inlet/outlet connecƟ ons for use with space heaƟ ng applicaƟ ons. If this water heater is to be used to supply both space heaƟ ng and domesƟ c potable (drinking) water, the instrucƟ ons listed below must be followed. • This water heater is suitable for combinaƟ on water (potable) heaƟ ng and space heaƟ ng and not suitable for space heaƟ ng applicaƟ ons only. • 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 exisƟ ng boiler installaƟ on. • Do not use with piping that has been treated with chromates, boiler seal or other chemicals and do not add any chemicals to the water heater piping. • If the space heaƟ ng system requires water temperatures in excess of 120°F, install a ThermostaƟ c Mixing Valve in the domesƟ c (potable) hot water supply at each point-of-use to limit the risk of scald injury. Install the mixing valve per its manufacturer’s instruc- Ɵ ons. • Pumps, valves, piping, and ﬁ ƫ ngs must be compaƟ ble with potable water. • A properly installed ﬂ ow control valve is required to prevent thermosiphon- ing. Thermosiphoning is the result of a conƟ nuous ﬂ ow of water through the air handler circuit during the off cycle. • The domesƟ c hot water line from the water heater should be verƟ cal past any mixing valve or supply line to the air handler to remove air bubbles from the system. Otherwise, these bubbles will be trapped in the air handler heat exchanger coil, reducing effi ciency. • Do not connect the water heater to any system or components previously used with non-potable water heat- ing appliances when used to supply potable water. Solar InstallaƟ on If this water heater is used as a solar stor- age heater or as a backup for the solar system, the water supply temperatures to the water heater tank may be in excess of 120°F. A ThermostaƟ c Mixing Valve or other temperature limiƟ ng valve must be installed in the water supply line to limit the supply temperature to 120°F. The unit must be set to Standard Mode (See Operat- ing Modes in OperaƟ on secƟ on on page 24). NOTICE: Solar water heaƟ ng systems can oŌ en supply water with temperatures exceeding 180°F and may result in water heater malfuncƟ on. Figure 11 - Combustion Space Heating and Potable Water (Typical Installation) IN REMOVE A MUST BE VERTICAL TO IR BUBBLES E OUT COIL AIR HANDLER TO AIR HANDLER SHUT-OFF VALVE * EXPANSION TANK VACUUM RELIEF VALVE COLD WATER INLET VAFLOW CONTROL LV PUMP * SHUT-OFFCHECK VALVE † (1/8” HOLE DRILLED IN CLAPPER) VALVECHECK VALVE † TEMP/PRESSURERELIEFVALVE TEMPERED WATER TO FIXTURES (MUST MEET TEMPS LISTED IN MASS. CODE 248 CMR † ) MIXING VALVE (MUST BE INSTALLED BELOW TOP OF WATER HEATER AS PER MANUFACTURER’S RECOMMENDATIONS) UNION UNION HOT WATER OUT * MASSACHUSETTS INSTALLATION REQUIREMENTS: 1.) CONNECT ELECTRONICALLY-CONTROLLED TIMER TO AN ALL-BRONZE PUMP. PUMP MUST ACTIVATE EVERY 6 HOURS FOR 60 SECONDS. TURN PUMP TIMER OFF BEFORE CLOSING PIPING LOOP SHUT-OFF VALVE. 2.) ALL WATER PIPING MUST BE INSTALLED AND INSULATED IN ACCORDANCE WITH MASSACHUSETTS CODE (248 CMR & 780 CMR). 3.) PIPING LOOP BETWEEN WATER HEATER AND AIR HANDLER MUST BE INSTALLED IN COMPLIANCE WITH 248 CMR. † REQUIRED FOR MASSACHUSETTS. ‡ PIPING FROM THE TOP OF THE WATER HEATER WITH TEES IS ACCEPTABLE. WATER HEATER ACCEPTED BY THE BOARD FOR INSTALLATION IN MASSACHUSETTS. † TYPICAL MIXING VALVE INSTALLATION COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM SEE NOTE ‡ 100’-0” MAXIMUM DISTANCE FROM WATER HEATER TO FAN COIL AND BACK (DEVELOPED LENGTH) NOT INCLUDING COIL IN HEATING UNIT. † 14 • ResidenƟ al Standard Gas Water Heater Use and Care GuideINSTALLATION 14 • ResidenƟ al Standard Gas Water Heater Use and Care Guide INSTALLATION Step 1: ✓Verify that your home is equipped and up-to-date for proper operaƟ on Installing a new water heater is the perfect Ɵ me to examine your home’s plumbing system and make sure the system is up to current code stan- dards. There have likely been plumb- ing code changes since the old water heater was installed. We recommend installing the following accessories and any other needed changes to bring your home up to the latest code requirements. UpdaƟ ng your plumb- ing system can help extend the life of your water heater, avoid damage to your home and property, and reduce the risk of serious injuries or death. Inspect your home and install any de- vices you need to comply with current codes and assure that your new water heater performs at its best. Check with your local plumbing offi cial for more informaƟ on. ✓Water pressure Most codes allow a maximum incoming water pressure of 80 psi (we recommend a working pressure no higher than 50-60 psi). Check your home’s water pressure with a pressure gauge and adjust if necessary. High water pressure can damage the water heater, piping, and other appliances. HOW: Purchase an inexpensive water pressure gauge from Lowe’s®. Con- nect the water pressure gauge to an outside faucet and measure the maximum water pressure experienced throughout a 24-hour period (highest water pressures oŌ en occur at night). Figure 12 - Use a Water Pressure Gauge to make sure your home’s water pressure is not too high. To adjust your home’s water pressure: Locate your home’s Pressure Reduc- ing Valve (PRV) on the main incoming (cold) water supply line and adjust the water pressure control to between 50 and 60 psi. If your home does not have a Pressure Reducing Valve, install a PRV on the home’s main water sup- ply line and set it to between 50 and 60 psi. Pressure Reducing Valves are available at Lowe’s®. BACKGROUND: Over the years, many uƟ liƟ es have increased water supply pressures so they can serve more homes. In some homes today, pressures can exceed 100 psi. High water pressures can damage water heaters, causing premature leaks. If you have replaced toilet valves, had a water heater leak, or had to repair appliances connected to the plumbing system, pay parƟ cular aƩ enƟ on to your home’s water pressure. When purchasing a PRV, make sure the PRV has a built-in bypass. ✓Wa- ter pressure in- crease caused by ther- mal expansion Verify that you have a properly sized Thermal Expansion Tank. We recom- mend installing an expansion tank if your home does not have one. Plumb- ing codes require a properly pressur- ized, properly sized Thermal Expan- sion Tank in almost all homes. Figure 13 - A Thermal Expansion Tank helps protect the home’s plumbing system from pres- sure spikes. HOW: Connect the Thermal Expansion Tank (available from Lowe’s® .) to the cold water supply line near the water heater. The expansion tank contains a bladder and an air charge. To work properly, the Thermal Expansion Tank must be sized according to the water heater’s tank capacity and pressurized to match the home’s incoming water pressure. Refer to the instrucƟ ons provided with the Thermal Expansion Tank for installaƟ on details. BACKGROUND: Water expands when heated, and the increased volume of water must have a place to go, or thermal expansion will cause large increases in water pressure (despite the use of a Pressure Reducing Valve in the home’s main water supply line). The Safe Drinking Water Act of 1974 ResidenƟ al Standard Gas Water Heater Use and Care Guide • 15 INSTALLATIONResidenƟ al Standard Gas Water Heater Use and Care Guide • 15 INSTALLATION requires the use of backﬂ ow preven- ters and check valves to restrict water from your home reentering the public water system. Backﬂ ow preventers are oŌ en installed in water meters and may not be readily visible. As a result, most all plumbing systems today are now “closed,” and almost all homes now need a Thermal Expansion Tank. A Thermal Expansion Tank is a pracƟ - cal and inexpensive way to help avoid damage to the water heater, washing machine, dishwasher, ice maker, and even toilet valves. If your toilet oc- casionally runs for no apparent reason (usually brieﬂ y at night), that may be due to thermal expansion increasing the water pressure temporarily. ✓Water Pipe and Tank Leaks Figure 14 - A metal drain pan piped to an ad- equate drain can help protect flooring from leaks and drips. Leaks from plumbing pipes or from the water heater itself can damage prop- erty and could cause a ﬁ re risk. • Install an automaƟ c leak detecƟ on and shutoff device ( available from Lowe’s®). These devices can detect water leaks and can shut off the water heater’s water supply if a leak occurs. • Install a metal drain pan (available- from Lowe’s® ) under the water heat- er to catch condensaƟ on or leaks from the piping connecƟ ons or tank. Most codes require, and we recom- mend, installing the water heater in a metal drain pan that is piped to an adequate drain. The drain pan must be at least two inches wider than the diameter of the water heater. Install the drain pan so the water level would be limited to a maximum depth of 1-3/4”. The pan must not restrict air ﬂ ow to the burner. ✓Water Tempera- ture RegulaƟ on Install ThermostaƟ c Mixing Valves to regulate the temperature of the water supplied to each point-of-use (for example, kitchen sink, bathroom sink, bath, shower). Install and adjust the mixing valve according to its manufac- turer’s instrucƟ ons. WARNING! Even if the water heater’s thermostat is set to a rela- Ɵ vely low temperature, hot water can scald. Install ThermostaƟ c Mixing Valves at each point-of-use to reduce the risk of scalding. Figure 15 - Thermostatic Mixing Valves installed at each point-of-use can help avoid scalding BACKGROUND: A ThermostaƟ c Mixing Valve, installed at each point-of-use, mixes hot water from the water heater with cold water to more precisely regulate the temperature of hot water supplied to ﬁ xtures. If you aren’t sure if your plumbing system is equipped with properly installed and adjusted ThermostaƟ c Mixing Valves at each point where hot water is used, contact a qualiﬁ ed person. 16 • ResidenƟ al Standard Gas Water Heater Use and Care GuideINSTALLATION 16 • ResidenƟ al Standard Gas Water Heater Use and Care Guide INSTALLATION Step 2: Verify that the locaƟ on is appropriate WARNING! Do not store or use ﬂ ammable materials, vapors, or liquids in the same locaƟ on where this water heater is installed. Before installing your water heater, ensure that it will be located: • Indoors in an area with adequate air supply. • In an area that will not freeze. • As close as possible to a chimney or vent. • In a metal drain pan piped to an adequate drain. • In an area suitable for verƟ cal installaƟ on. • In an area with adequate space (clearances) for periodic servicing (there must be a minimum of 24 inches of front clearance). • In an area that allows a minimum clearance from combusƟ ble sur- faces as stated on the data plate. • On a ﬂ oor that can support the weight of a water heater full of water. You will also want to follow these guidelines while considering an appro- priate locaƟ on: • Do not install near air-moving devices such as exhaust fans, venƟ laƟ on systems, or clothes dryers. • Do not obtain venƟ laƟ ng air for the furnace/air handler from the same space as the water heater. Ensure that any return air ducts near the water heater are sealed. • If the water heater is located in an area subject to lint, dust, or oily vapors, at least annually check and clean the air ﬁ lter. See Maintenance secƟ on for steps on cleaning the air ﬁ lter. • Do not install in a bathroom, bedroom, or any occupied room normally kept closed. • If the water heater is installed di- rectly on carpeƟ ng, it shall be in- stalled on a metal or wood panel extending beyond the full width and depth of the water heater by at least 3 in (76.2mm) in any direcƟ on. If the water heater is installed in an alcove or closet, the enƟ re ﬂ oor shall be covered by the aforestated panel. • If your area is prone to earth- quakes, use special straps as required by local building codes. NOTICE: The state of California re- quires bracing, anchoring, or strap- ping the water heater to avoid its moving during an earthquake. Contact local uƟ liƟ es for code requirements in your area, visit hƩ p://www.dsa.dgs. ca.gov, or call 1-916-445-8100 and request instrucƟ ons. Other locaƟ ons may have similar requirements. Check with your local and state authoriƟ es. • Do not install in a locaƟ on prone to physical damage by vehicles, ﬂ ooding, or other risks. Vehicle Stop Drain Drain Pan Figure 16 - In a garage, install a vehicle stop to avoid water heater damage. • Avoid locaƟ ons such as aƫ cs, up- per ﬂ oors, or where a leak might damage the structure or furnish- ings. Due to the normal corrosive acƟ on of water, the tank will eventually leak. To minimize prop- erty damage from leaks, inspect and maintain your water heater in accordance with this manual’s instrucƟ ons. Install a metal drain pan under the water heater piped to an adequate drain. Inspect the drain pan, pipes, and surrounding area regularly and ﬁ x any leaks found. Step 3: Removing the old water heater 1 Read each installaƟ on step and decide if you have the neces- sary skills to install the water heater. Only proceed if you are comfort- able you can safely perform the work. If you are not sure, have a qualiﬁ ed person perform the installaƟ on. ResidenƟ al Standard Gas Water Heater Use and Care Guide • 17 INSTALLATIONResidenƟ al Standard Gas Water Heater Use and Care Guide • 17 INSTALLATION 2 On the old water heater, turn the control knob on the gas control valve to the OFF posiƟ on. Gas control knob Figure 17 - Turn gas control/temperature knob OFF. 3 Turn the manual gas valve for the water heater’s supply line OFF. 4 Open a hot water faucet and let the hot water run unƟ l it is cool (This may take 10 min utes or longer). Figure 18 - Let the hot water run until it is cool. WARNING! Be sure the water runs cool before draining the tank to reduce the risk of scalding. 5 Connect a garden hose to the drain valve and place the other end of the hose in a drain, outside, or in buckets. (Sedi- ment in the boƩ om of the tank may clog the valve and prevent it from draining. If you can’t get the tank to drain, contact a qualiﬁ ed person.) 6 Turn the cold water supply valve OFF. Figure 19 - Cold water supply in off position. 7 Using a standard ﬂ at-blade screwdriver, open the drain valve. Sediment build up in the boƩ om of the water heater may hinder or prevent draining. Figure 20 - Draining the old water heater. 8 Also open a hot water faucet to help the water in the tank drain faster. 9 When the tank is empty, disconnect the Temperature & Pressure (T&P) Relief Valve discharge pipe. You may be able to reuse the discharge pipe, but do not reuse the old T&P Relief Valve. A new T&P Relief Valve comes with your new water heater. Figure 21 - Removing the T&P Relief Valve discharge pipe. 10 Allow the vent pipe and draŌ hood to cool. Once cooled, disconnect the vent pipe from the draŌ hood. You may need to support the vent pipe unƟ l the new water heater is in place. Figure 22 - Disconnect the vent pipe from the draft hood. 11 Disconnect the water pipes. Many water pipes are con- nected by a threaded union which can be disconnected with wrenches. If you must cut the water pipes, cut the pipes close to the water heater’s inlet and outlet connecƟ ons, leaving the water pipes as long as possible. If necessary, you can make them shorter later when you install the new water heater. 12 Conﬁ rm the manual gas valve for the water heater’s supply line is turned off . Disconnect the gas line from the water heater’s gas control valve and cap it. 13 Remove the old water heater. Use an appliance dolly or hand truck to move the water heater. WARNING! Use two or more people to remove or install a water heater. Failure to do so can result in back or other injury. Step 4: Installing the New Water Heater 18 • ResidenƟ al Standard Gas Water Heater Use and Care GuideINSTALLATION 18 • ResidenƟ al Standard Gas Water Heater Use and Care Guide INSTALLATION 1 Completely read all instruc- Ɵ ons before beginning. If you are not sure you can safely complete the installaƟ on, seek assis- tance from any of the following sources: • Lowe’s® Professional InstallaƟ on is available for this product and the work is guaranteed. Call your Lowe’s® store to have this water heater installed. • Schedule an appointment with a qualiﬁ ed person to install your water heater. • Call our Technical Assistance Hotline at 1-877-817-6750. . 2 Install a metal drain pan that is piped to an adequate drain. Figure 23 - Metal drain pan piped to drain. 3 Set the water heater in place taking care not to damage the drain pan. When installing directly on carpet, the water heater must be installed on a wood or metal base that extends beyond the dimen- sions of the water heater (width and depth) by at least 3 inches (76.2 mm) in any direcƟ on. If the water heater is installed on carpet in an alcove or closet, the enƟ re ﬂ oor must be covered by a wood or metal panel. NOTICE: Most codes require seƫ ng the water heater in a metal drain pan piped to an adequate drain. The drain pan helps avoid property damage which may occur from condensaƟ on or leaks in the piping connecƟ ons or tank. The drain pan must be at least two inches wider than the diameter of the water heater. Install the drain pan so the water level is limited to a maximum depth of 1-3/4”. 4 Verify that the water heater is set in place properly. Check that: • There is adequate space to install the T&P Relief Valve discharge pipe and that it can be piped to a separate drain (and not into the drain pan). • There is adequate access and space around the water heater for future maintenance. The water heater is installed verƟ cally. Step 5: Air Filter InstallaƟ on Once you’ve posiƟ oned the water heater in the installaƟ on area, install the wrap-around air ﬁ lter (supplied with the water heater). The wrap-around air ﬁ lter ﬁ ts around the base of the unit. Do not operate the water heater without a clean air ﬁ lter in place. 1 Before installing the Air Filter Assembly, remove any dust, lint or debris (including any packaging materials or tape) from under the water heater. 2 Installation: Wrap the filter around the base of the water heater. Cut to fit around a sensor if present. Trim excess filter material with scissors but allow filter material to overlap a few inches (see Figure 2). 3 The filter should fit snugly against base of the water heater with no gaps. The filter must fit flush against the bottom of the drain pan and/or floor. Hold the filter in place, then stretch the filter clip over the overlapped joint and hook in place (see Figure 24). FLUSH FIT AGAINST BOTTOM OF DRAIN PAN AND/OR FLOOR. ATTACH FILTER CLIP AS SHOWN HOLDING THE AIR FILTER ASSEMBLY IN PLACE. NOTE: DRAIN PAN SHOWN REMOVED FOR CLARITY. OVERLAP4” (100 mm) WRAP THE AIR FILTER ASSEMBLY AROUND THE BOTTOM OF THE WATER HEATER (NOTE: CLIP ON TOP EDGE). Figure 24 - Air Filter Installation ResidenƟ al Standard Gas Water Heater Use and Care Guide • 19 INSTALLATIONResidenƟ al Standard Gas Water Heater Use and Care Guide • 19 INSTALLATION 4 Check the filter at least every three months and clean as necessary. After installation, the filter may be cleaned by using a vacuum cleaner with a brush attachment to remove lint and dust. NOTE: because the amount of dust and lint in the air can vary, your filter may need to be inspected/ cleaned more often. In some instances, the filter may need to be removed and washed using mild hand soap and water to remove any oily residue. After washing, allow to dry and properly reinstall. Step 6: Connect the Tempera- ture and Pressure (T&P) Relief Valve/Pipe Most T&P Relief Valves are pre- installed at the factory. In some cases, they are shipped in the carton and must be installed in the opening marked “T&P Relief Valve” and accord- ing to local codes. Figure 25 - Temperature and Pressure Relief Valve WARNING! To avoid serious injury or death from explosion, install a T&P Relief Valve according to the following instrucƟ ons: 1 If the T&P Relief Valve was not factory installed, install the new T&P Relief Valve that came with your water heater. Do not reuse an old T&P Relief Valve. • The discharge pipe should be at least 3/4” inside diameter and sloped for proper drainage. Install it to allow complete drainage of both the T&P Relief Valve and the discharge pipe. Figure 26 - Temperature and Pressure Relief Valve Pipe • The discharge pipe must not be smaller than the pipe size of the T&P Relief Valve. The pipe must also be able to withstand 250°F (121°C) without distorƟ on. Use only copper or CPVC pipe. Do not use any other type of pipe, such as PVC, iron, ﬂ exible plasƟ c pipe, or any type of hose. • Terminate the discharge pipe a maximum of six inches above a ﬂ oor drain or outside the building. Do not drain the discharge pipe into the drain pan; instead pipe it separately to an adequate drain. In cold climates, terminate the dis- charge pipe inside the building to an adequate drain. Outside drains could freeze and obstruct the drain line—protect the discharge pipe from freezing. • Do not place any valve or other restricƟ on between the tank and T&P Relief Valve. Do not cap, block, plug, or insert any valve between the T&P Relief Valve and the end of the discharge pipe. Do not insert or install any reducer in the discharge pipe. Step 7: Install Shutoff and Ther- mostaƟ c Mixing Valves 1 If one is not already installed, install a manual shutoff valve in the cold water line that supplies the water heater. Install the shutoff valve near the water heater so that it is readily accessible. Only use a full-ﬂ ow ball or gate valve compaƟ ble with potable water. 2 Install a ThermostaƟ c Mixing Valve at each point-of-use (for example, kitchen sink, bathroom sink, bath, shower) per the valve manufacturer’s instrucƟ ons. Figure 27 - Install Thermostatic Mixing Valves at each point where hot water will be used. WARNING! Even if the water heater’s thermostat is set to a rela- Ɵ vely low temperature, hot water can scald. Install ThermostaƟ c Mixing Valves at each point-of-use to reduce the risk of scalding. 20 • ResidenƟ al Standard Gas Water Heater Use and Care GuideINSTALLATION 20 • ResidenƟ al Standard Gas Water Heater Use and Care Guide INSTALLATION 3 For water heaters that are fed by a solar water heaƟ ng system (or any other pre- heaƟ ng system), always install a ThermostaƟ c Mixing Valve or other temperature limiƟ ng device in the inlet water supply line to limit water supply inlet temperature to 120°F. Solar water heaƟ ng systems can supply water with temperatures exceeding 180°F and may result in water heater malfuncƟ on. WARNING! Hot water provided by solar heaƟ ng systems can cause severe burns instantly, resulƟ ng in severe injury or death. Step 8: Connect the Water Supply Note that all piping and components connected to the water heater must be suitable for use with potable water. 1 Determine the type of water pipes in your home. Most homes use copper water pipes, but some use CPVC or cross- linked polyethylene (PEX). Use ﬁ ƫ ngs appropriate for the type of pipe in your home. Do not use iron or PVC pipe. 2 Connect the cold water supply using 3/4 inch NaƟ onal Pipe Thread “NPT” to the ﬁ ƫ ng marked “C” (COLD). For ease of removing the water heater for service or replacement, connect the water pipes with a coupling called a union. We recommend using a dielectric-type union (available from Lowe’s ). Dielectric unions can help prevent corrosion caused by Ɵ ny elec- tric currents common in copper water pipes and can help extend the life of the water heater. IF YOU HAVE COPPER PIPES: If your home has copper water pipes, you can solder the water pipe connec- Ɵ ons or use compression ﬁ ƫ ngs which don’t require soldering. Compression ﬁ ƫ ngs are easier to install than solder- ing pipe. Check with local plumbing offi cials to determine what types of pipe materials are suitable for your locaƟ on. Do not use lead-based solder. NOTICE: Do not solder pipes while they are aƩ ached to the water heater. The water heater’s inlet and outlet connecƟ ons contain non-metallic parts which could be damaged. The proper way to connect the water heater to copper water pipes is as follows: • Solder a short length of pipe (about a foot or so) to a threaded adapter using only 95/5 Ɵ n-anƟ mony or equivalent solder. AƩ ach the thread- ed adapters to the water heater’s connecƟ ons (using Teﬂ on® tape or pipe joint compound). Connect the home’s water pipes by soldering, keeping the connecƟ ons at the water heater cool with wet rags. Compression ﬁ ƫ ngs don’t require soldering. ResidenƟ al Standard Gas Water Heater Use and Care Guide • 21 INSTALLATIONResidenƟ al Standard Gas Water Heater Use and Care Guide • 21 INSTALLATION NOTICE: Most water heater models contain energy saving heat traps in the inlet and outlet connecƟ ons. Do not remove the heat traps. 3 Connect the hot water supply using 3/4 inch NPT to the ﬁ ƫ ng marked “H” (HOT). 4 Install insulaƟ on (or heat tape) on the water pipes especially if the indoor installaƟ on area is subject to freezing temperatures. InsulaƟ ng the hot water pipes can increase energy effi ciency. 5 Adjust (or install) the home’s Pressure Reducing Valve to 50-60 psi and install a Thermal Expansion Tank. Figure 28 - A Pressure Reducing Valve is required if your home’s water pressure is above 80 psi. Figure 29 - The Thermal Expansion Tank should be pressurized with air, using a hand pump, to match the home’s incoming water pressure. Step 9: Verify ConnecƟ ons and Completely Fill Tank To remove air from the tank and allow the tank to ﬁ ll completely with water, follow these steps: 1 Remove the aerator at the nearest hot water faucet. This allows debris in plumbing system to be washed out of the pipes. 2 Turn the cold water supply back on and ﬁ ll the tank. 3 Open a hot water faucet and allow the water to run unƟ l it ﬂ ows with a full stream. 4 Let the water run full stream for three minutes. 5 Close the hot water faucet and replace the aerator. 6 Check inlet and outlet connec- Ɵ ons and water pipes for leaks. Dry pipes connecƟ ons so that any drips or leaks will be apparent. Repair any leaks. Almost all leaks occur at connecƟ ons and are not a tank leak. Step 10: Install DraŌ Hood 1 Install the new draŌ hood by aligning the legs and inserƟ ng them into the slots provided on top of the water heater. Do not reuse the draŌ hood from the old water heater, but rather use the new one that came with your new water heater. 2 Secure the draŌ hood using the four screws provided. AƩ ach the home’s exisƟ ng vent pipe to the draŌ hood outlet using an approved vent adapter (not supplied). Figure 30 - Install the new draft hood and secure with screws. 3 Secure the vent adapter to the draŌ hood with sheet metal screws. Read the VenƟ ng secƟ on on page 11. Make sure your home’s venƟ ng system complies with the instrucƟ ons in this manual and is in good condiƟ on. 22 • ResidenƟ al Standard Gas Water Heater Use and Care GuideINSTALLATION 22 • ResidenƟ al Standard Gas Water Heater Use and Care Guide INSTALLATION Step 11: Make Gas ConnecƟ ons The Gas Water Heater Hook-Up Kit (available at Lowe’s®) includes a ﬂ ex- ible gas connector with compression ﬁ ƫ ngs to connect the home’s gas line to the water heater’s gas control valve. Follow the kit’s installaƟ on instrucƟ ons to aƩ ach the ﬂ exible gas connector. Figure 31 - Flexible gas line connector. Once you’ve made the gas connec- Ɵ ons, use a small, soŌ -bristled brush to apply a hand dishwashing soap and water mixture or children’s soap bubbles (1 part soap to 15 parts water) to all connecƟ on points of the gas line and ﬂ exible gas connector (if used). Make sure to generously coat all the connecƟ ons and check for gas leaks (which will appear as small bubbles). If any leaks are detected, turn the gas supply off , Ɵ ghten the leaking connec- Ɵ on and re-check. BEFORE LIGHTING THE WATER HEATER... Make sure all checklist items have been completed. Water Heater LocaƟ on ✓ InstallaƟ on area free of corrosive or ﬂ ammable materials, liquids or vapors. ✓ Proper clearances from combusƟ ble surfaces maintained and suffi cient room to service the water heater. ✓ Not installed directly on a carpeted ﬂ oor. ✓ Metal drain pan installed and piped to an adequate drain. ✓ Water heater not located near an air moving device (fan, clothes dryer). ✓ Not in a locaƟ on with large amounts of lint, dust, etc. (If so, the air ﬁ lter or ﬂ ame arrestor located on the boƩ om of the water heater will need to be cleaned more oŌ en.) CombusƟ on Air Supply and Ven Ɵ laƟ on ✓ Adequate air supply for water heater and any other nearby gas appliances. If the water heater is installed in a closet or other small, enclosed space or within the living space of the house, air supply openings needed. ✓ Are the openings of suffi cient size? ✓ Ductwork is the same cross-sec- Ɵ onal area as the openings? ✓ Outside air openings are preferred and may be required in Ɵ ghtly built homes. Vent Pipe System ✓ New draŌ hood, properly installed. ✓ Vent pipe securely fastened to draŌ hood with screws and sup- ported properly. ✓ Vent pipe made of approved mate- rial and either 2” or 3” in diameter. ✓ Vent system installed according to local and state codes or, in the absence of local and state codes, the “NaƟ onal Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current ediƟ on. ✓ Check exisƟ ng vent system for rust, restricƟ ons/obstrucƟ ons. Water System Piping ✓ Temperature and pressure relief valve properly installed with a discharge line run to an adequate drain and protected from freezing. ✓ Water pipes free of leaks. ✓ Water heater completely ﬁ lled with water. ✓ Thermal Expansion Tank installed ✓ Water Pressure Reducing Valve installed and adjusted to 50-60 psi. ✓ ThermostaƟ c Mixing Valves in- stalled at each point-of-use. Gas Supply and Piping ✓ Gas type is the same as that listed on the water heater’s data plate. ✓ Gas line equipped with shut-off valve. ✓ Adequate gas pipe size and ap- proved gas pipe material. ✓ All gas connecƟ ons and ﬁ ƫ ngs leak checked and any leaks corrected. ResidenƟ al Standard Gas Water Heater Use and Care Guide • 23 OPERATIONResidenƟ al Standard Gas Water Heater Use and Care Guide • 23 OPERATION LighƟ ng InstrucƟ ons WARNING! Explosion Hazard – Replace viewport if glass is missing or damaged. Failure to do so can result in death, explosion or ﬁ re. Read and understand these direcƟ ons thoroughly before aƩ empƟ ng to light or re-light the pilot. Make sure the viewport is not missing or damaged. Make sure the tank is completely ﬁ lled with water before lighƟ ng the pilot. Check the data plate near the gas control valve to ensure the correct gas type. Do not use this water heater with any gas other than the one listed on the data plate. If you have any quesƟ ons or doubts, consult your gas supplier or gas uƟ lity company. NOTICE! A newly installed water heater will have air in the gas line. It may take several lighƟ ng aƩ empts to clear all the air from the gas line and light the pilot. Follow these steps to light the pilot: 1 Make sure the manual gas valve for the water heater’s supply line is ON. Figure 32 - Gas valve in “on” position 2 Turn the gas control knob to the PILOT posiƟ on. Figure 33 - Gas control/valve. 3 Press the gas control knob in fully and hold it in. While holding in the gas control knob, repeatedly click the igniter buƩ on (approximately once per second) for up to 90 seconds or unƟ l the Status Light starts to ﬂ ash. You can tell the pilot is lit when the Status Light ﬂ ashes once every three seconds. Figure 34 - Status light. 4 Once the Status Light starts ﬂ ashing, release the gas control knob. Adjust the gas control knob to the desired tempera- ture seƫ ng. 5 If the Status Light doesn’t start ﬂ ashing aŌ er 90 seconds, release the gas control knob and wait 10 minutes. 6 Repeat lighƟ ng steps 2 through 5 at least two addiƟ onal Ɵ mes or unƟ l the Status Light starts ﬂ ashing once every three seconds. Wait 10 minutes between lighƟ ng aƩ empts. 7 A solid Status Light means the pilot was lit but is now off . Release the gas control knob and wait 10 minutes. Once the Status Light goes out, repeat lighƟ ng steps 2 through 5. 8 If the Status Light doesn’t start ﬂ ashing aŌ er three lighƟ ng aƩ empts, turn the gas control knob to the OFF posiƟ on and refer to the “TroubleshooƟ ng-No Hot Water” secƟ on (see page 25). 9 When a gas water heater is ﬁ rst lit and the tank is cold, conden- saƟ on oŌ en forms inside the water heater. You may hear drips or a sizzling sound when the water heater is ﬁ rst lit or, you may see a small puddle on the ﬂ oor. CondensaƟ on is not a leak and will go away once the tank reaches normal operaƟ ng temperature. 10 The air ﬁ lter at the boƩ om of the water heater must be cleaned from Ɵ me to Ɵ me. See the Maintenance secƟ on for steps on cleaning the air ﬁ lter. If the air ﬁ lter is not cleaned as needed, the water heater’s pilot may go out. Shut down InstrucƟ ons Turn the gas control/temperature knob counterclockwise to the “OFF” seƫ ng. The status light will stop blinking and stay on for a short Ɵ me aŌ er the water heater is turned off . Emergency Shut down Should overheaƟ ng occur or the gas supply fail to shut off , turn off the water heater’s manual gas control valve and call a qualiﬁ ed person. Checking the Vent System and Air Supply Once the water heater is lit and the gas control knob is set to the desired temper- ature, the burner will light (if the tank is cold). Perform an air supply and vent test to make sure the unit is venƟ ng properly and the air supply is adequate: 1 The main burner must be on for this test. With a newly installed water heater full of cold water, turning the temperature control knob to HOT should cause the main burner to come on. You can view the burner through the sight glass at the base of the water heater. 2 Close all windows and doors and turn on all gas appliances and air-moving devices (range hoods, bathroom exhaust fans, ceiling fans, etc.) in your home. Also, close any ﬁ replace dampers. 24 • ResidenƟ al Standard Gas Water Heater Use and Care GuideOPERATION3Allow the water heater’s main burner to operate for ﬁ ve minutes. Pass a newly exƟ n- guished match approximately one inch from the draŌ hood’s relief opening. Smoke from the match should be steadily drawn into the opening indicat- ing the water heater is geƫ ng adequate air and the vent system is working. Figure 35 - Test the air supply and vent to make sure the water heater has adequate air and is venting properly. 4 If the main burner has been operaƟ ng for ﬁ ve minutes but the match smoke driŌ s around or is blown away from the opening, turn the gas control knob OFF. Inspect the vent system and repair if necessary. In many cases, failure to pass the air supply and vent test indicates the water heater is not geƫ ng enough air or there is a problem with the vent system. It may be necessary to increase the air supply by geƫ ng air from outside (see page 7). WARNING! Burn Hazard. Do not touch the vent, doing so can cause burns. If the draŌ hood does not draw in smoke from a match aŌ er ﬁ ve minutes of main burner operaƟ on, shut the gas supply off , and do not operate the water heater unƟ l the vent system and air supply have been checked by a qualiﬁ ed person and repaired if necessary. ConƟ nuing to operate the water heater in this condiƟ on could lead to serious injury or death from carbon monoxide poisoning. Temperature Control System AdjusƟ ng the Temperature With the installaƟ on steps completed, you may adjust the water heater’s tem- perature seƫ ng if desired. 1 Set the gas valve to the desired temperature. The “HOT” seƫ ng sets the water tem- perature to approximately 120°F, reducing the risk of scald injury. You may wish to set a higher temperature to provide hot water for automaƟ c dishwashers or laundry machines, to provide more hot water capacity, and to reduce bacterial growth. Higher tank temperatures (140° F) kill bacteria that cause a condiƟ on known as “smelly water” and can reduce the levels of bacteria that cause water-borne diseases. Water usage paƩ erns, as well as heat from sources such as solar collectors, ambient air, and the pilot light can result in temperatures higher than the thermostat set-point. WARNING! Higher temperatures increase the risk of scalding, but even at 120°F, hot water can scald (see Table 1). Install ThermostaƟ c Mixing Valve(s) at each point-of-use to reduce the risk of scalding. 2 To adjust the water heater’s thermostat: Figure 36 - Adjust the gas control knob to “HOT”. Turn the gas control knob on the gas control valve to the right to the follow- ing seƫ ngs. • “A” 128°F • “B” 138°F • “C” 147°F • “VERY HOT” 160°F NOTICE: The temperatures above are approximates. The actual temperature of the heated water may vary. 3 Wait for the water to heat up. If you have no hot water aŌ er two hours, refer to the TroubleshooƟ ng SecƟ on (see page 25). NOTICE: If the tank is full of cold water, condensaƟ on may form inside the water heater. This condensaƟ on may drop on the burner causing a sizzling sound. In some cases, you may see a small puddle on the ﬂ oor. Condensa- Ɵ on is normal and should go away once the tank reaches its normal operaƟ ng procedure. WARNING! If you have increased the temperature seƫ ng and the ThermostaƟ c Mixing Valves are not set properly (or not installed) you could scald yourself while checking the temperature. 4 Check water temperature at several points of use in your home (for example, bathtub faucet, shower, or lavatory sink) and adjust the ThermostaƟ c Mixing Valves as needed. If you aren’t sure how to adjust the ThermostaƟ c Mixing Valve seƫ ngs, or aren’t sure if you have ThermostaƟ c Mixing Valves, contact a qualiﬁ ed person. OperaƟ ng Modes The gas control valve has two diff er- ent operaƟ ng modes: Standard and Vaca Ɵ on. The Standard mode allows you to adjust the water temperature to your desired seƫ ng. The VacaƟ on (VAC) mode sets the thermostat at approximately 55°F and is recom- mended when not using hot water for an extended period of Ɵ me. The VAC seƫ ng also reduces energy losses and 24 • ResidenƟ al Standard Gas Water Heater Use and Care Guide OPERATION ResidenƟ al Standard Gas Water Heater Use and Care Guide • 25 TROUBLESHOOTINGResidenƟ al Standard Gas Water Heater Use and Care Guide • 25 TROUBLESHOOTING keeps the tank from freezing during cold weather but can cause a Hydrogen gas build up. See cauƟ on on page 6. No Hot Water Use the following step-by-step plan as a guide to help determine why you have no hot water: 1 Check the Status Light The Status Light on the gas control valve ﬂ ashes once every three seconds if the pilot is lit and the gas control valve has not detected any problems. Figure 37 - Status light. If the Status Light is ﬂ ashing once ev- ery three seconds and you have no hot water, make sure the gas control knob is set to HOT. If the Status Light ﬂ ashes more than once every three seconds, refer to the Status Light Code TroubleshooƟ ng Chart on page 27. If the Status Light is not ﬂ ashing, go to step 2. 2 Status Light is Not Flashing If the Status Light isn’t ﬂ ashing, try lighƟ ng the pilot using the lighƟ ng instrucƟ ons on page 23. If you have tried lighƟ ng the pilot and the Status Light does not ﬂ ash, go to step 3. If the Status Light ﬂ ashes, go to Step 1. 3 Checking the Pilot Light Check the spark igniter. Dim the room lights and look through the viewport while clicking the igniter buƩ on. If you don’t see a spark through the viewport, check to make sure the igniter wire is ﬁ rmly inserted into the white connector. If you see a spark, make sure the gas supply valve is turned on, and try light- ing the pilot using the lighƟ ng instruc- Ɵ ons on page 23. If the pilot sƟ ll does not light, call a qualiﬁ ed person. Insuffi cient Hot Water or Slow Hot Water Recovery WARNING! Because of the increased risk from scalding, if you set the water heater’s gas control knob higher than 120°F, install ThermostaƟ c Mixing Valves at each point-of-use. Due to the increased risk of scalding, do not set the temperature of the ThermostaƟ c Mixing Valves above 120°F. If the hot water is simply not warm enough, there are several possible causes: • Faulty ThermostaƟ c Mixing Valve in a faucet or shower control (check other faucets in the house for hot water). • Water heater’s capacity too small (or usage too high). • Reversed plumbing connecƟ ons or melted dip tube (usually found soon aŌ er new installaƟ on). • Plumbing leak. • Sediment or lime build up in the boƩ om of the tank. ThermostaƟ c Mixing Valves. If the hot water is simply not warm enough, make sure the faucet you are checking doesn’t have a defecƟ ve ThermostaƟ c Mixing Valve. Many shower controls now have built-in mixing valves. If these devices fail, they can reduce the amount of hot water the shower or faucet delivers even though there is plenty of hot water in the tank. Always check the water temperature at several faucets to make sure the problem is not in a faucet or shower control. Undersized Water Heater. If your water heater runs out of hot water quickly, it may be too small for your needs. If the water heater is old, consider replacing it with a larger model. If the water heater is in good condiƟ on, you may be able to meet your family’s hot water needs with the exisƟ ng water heater by install- ing ThermostaƟ c Mixing Valves at each point-of-use and then turning the gas control knob to a higher seƫ ng. You can also reduce your home’s hot water needs by washing clothes in cold water, installing ﬂ ow restrictors on shower heads, repairing leaky faucets, and taking other conservaƟ on steps. Reversed ConnecƟ ons or Melted Dip Tube. Check the hot and cold water connecƟ ons and make sure your home’s hot water pipe is connected to the hot water outlet on the water heater. Usually, reversed connecƟ ons are found soon aŌ er the installaƟ on of a new unit. If copper pipes were soldered while they were aƩ ached to the water heater, the dip tube may have melted. The dip tube is a long, plasƟ c tube inside the tank aƩ ached to the cold water inlet. If the dip tube has melted, it can be replaced by removing the cold water inlet connecƟ on, re- moving the old dip tube and installing a new one. Plumbing Leak. Even a small leak in the hot water side of the home’s 26 • ResidenƟ al Standard Gas Water Heater Use and Care GuideTROUBLESHOOTING 26 • ResidenƟ al Standard Gas Water Heater Use and Care Guide TROUBLESHOOTING plumbing system can make it appear that the water heater is producing liƩ le to no hot water. In this case, the burner will be on all or almost all the Ɵ me, yet you will have very liƩ le hot water. Locate and repair the leak. Sediment or Lime in Tank. With an ex- isƟ ng water heater, if you have some hot water but not as much as you’re used to, there may be a build up of sediment or lime on the boƩ om of the tank. Sediment or lime build up can reduce the effi ciency of your water heater. Heavy deposits can damage the water heater. See the Mainte- nance secƟ on for steps on draining and ﬂ ushing the water heater. Temperature Too High Adjust the thermostat on the water heater to a lower seƫ ng. Install or adjust ThermostaƟ c Mixing Valves for each point-of-use (see the valve manufacturer’s instrucƟ ons). Low Water Pressure Check both the cold and hot water at a sink to determine if the lower pressure is only on the hot water side. If both hot and cold faucets have low pressure, call your local water uƟ lity. If the low pressure is only on the hot water side, the primary causes are: • Melted heat traps or dip tube. Sol- dering copper pipes while they are connected to the water heater can melt the heat traps inside the hot and cold water connecƟ ons or the dip tube (cold water side). Melted heat traps or a melted dip tube can restrict the ﬂ ow of hot water. If that’s the case, replace the heat traps or dip tube. • ParƟ ally closed supply valve. Open the water heater’s supply valve fully. Drips from T&P Relief Valve Discharge Pipe A small amount of water dripping from the Temperature and Pressure (T&P) Relief Valve usually means the home’s water pressure is too high and/or you need a Thermal Expan- sion Tank. See Step 1 in the Installa- Ɵ on secƟ on of this manual for more informaƟ on. A large amount of hot water coming from the T&P discharge pipe may be due to the tank overheaƟ ng. If the T&P relief valve is discharging large amounts of very hot water, turn the gas supply valve off and call a quali- ﬁ ed person. WARNING! Do not cap or plug the T&P Relief Valve or discharge pipe, and do not operate the water heater without a funcƟ oning T&P Relief Valve—this could cause an explosion. Water Pressure too High. High water pressure can cause the T&P Relief Valve to drip. Install a Pressure Re- ducing Valve (PRV) on the main cold water supply line. Adjust the PRV to between 50 and 60 psi. Thermal Expansion Tank. Install a Thermal Expansion Tank. If a Thermal Expansion Tank is already installed and the T&P Relief Valve discharge pipe drips, the home’s water pressure may be too high or the Thermal Ex- pansion Tank may be defecƟ ve. Refer to the instrucƟ ons that came with the Thermal Expansion Tank for more informaƟ on. Debris. In rare cases, debris can sƟ ck inside the T&P Relief Valve prevenƟ ng the valve from sealing fully. In that case, the T&P Relief Valve discharge pipe will drip. You may be able to clear debris from the T&P Relief Valve by manually operaƟ ng the valve, allowing small quanƟ Ɵ es of water to ﬂ ush out the debris. See the label on the T&P Relief Valve for instrucƟ ons. WARNING! When manually operaƟ ng the temperature-pressure relief valve, make sure that no one is in front of or around the discharge outlet. The water may be extremely hot and could cause severe burns. Also ensure that the water discharge will not cause property damage. If the water pressure is between 50 and 60 psi, a Thermal Expansion Tank is installed and properly pressurized, and the valve has been cleared of any debris, and it sƟ ll drips, the valve may be broken—have a qualiﬁ ed person replace the T&P Relief Valve. Water Odor Harmless bacteria normally present in tap water can mulƟ ply in water heat- ers and give off a “roƩ en egg” smell. Although eliminaƟ ng the bacteria that causes “smelly water” is the only sure treatment, in some cases, the stan- dard anode rod that came with your water heater can be replaced with a special zinc anode rod which may help reduce or eliminate the odor. Contact a qualiﬁ ed person. NOTICE: To protect the tank, an anode rod must be installed in the water heater at all Ɵ mes or the warranty is void. In cases where the “roƩ en egg” smell is very strong, you could increase the tank temperature to 140°F in order to reduce bacterial growth in the tank. WARNING! Because higher temperatures increase the risk of scalding, if you set the thermostat(s) higher than 120°F, ThermostaƟ c Mixing Valves at each point-of-use are parƟ cularly important. ResidenƟ al Standard Gas Water Heater Use and Care Guide • 27 TROUBLESHOOTINGResidenƟ al Standard Gas Water Heater Use and Care Guide • 27 TROUBLESHOOTING 28 • ResidenƟ al Standard Gas Water Heater Use and Care GuideMAINTENANCE 28 • ResidenƟ al Standard Gas Water Heater Use and Care Guide MAINTENANCE Rou Ɵ ne Maintenance RouƟ ne maintenance will help your water heater last longer and work bet- ter. If you can’t perform these rouƟ ne maintenance tasks yourself, contact a qualiﬁ ed person. Draining and Flushing the Water Heater Tap water contains minerals that can form sediment in the boƩ om of the tank. The amount of sediment formed depends on the hardness of your tap water, the temperature seƫ ngs, and other variables. We recommend drain- ing and ﬂ ushing the water heater aŌ er the ﬁ rst six months of operaƟ on to de- termine the amount of sediment build up. If there is liƩ le sediment, drain and ﬂ ush the tank annually. If there is a lot of sediment, drain and ﬂ ush the tank more oŌ en. Draining sediment extends the life of the water heater. To Drain and Flush the Tank: 1 Turn the gas control knob on the gas control valve to the OFF posiƟ on. Figure 40 - Turn gas control/temperature knob OFF. 2 Turn the manual gas valve for the water heater’s supply line OFF. 3 Open a hot water faucet and let the hot water run unƟ l it is cool (This may take 10 min utes or longer). Figure 41 - Let the hot water run until it is cool. WARNING! Be sure the water runs cool before draining the tank to reduce the risk of scalding. 4 Connect a garden hose to the drain valve and place the other end of the hose in a drain, outside, or in buckets. Note that sediment in the boƩ om of the tank may clog the valve and prevent it from draining. If you can’t get the tank to drain, contact a qualiﬁ ed person. 5 Turn the cold water supply valve OFF. 6 Open the drain valve on the water heater. Figure 42 - Draining the water heater. 7 Also open a hot water faucet to help the water in the tank drain faster. 8 Remove and inspect the anode rod and replace if depleted. The anode rod requires a 1-1/16” socket. Figure 43 - Anode rods from new (top) to par- tially depleted (middle) to fully depleted stage (bottom). Anode Rod. The anode rod is a sacriﬁ - cial metal rod that helps avoid corro- sion and premature failure (leaks) in the tank. The anode rod is a consum- able item. Inspect the anode rod aŌ er the ﬁ rst six months of operaƟ on when you drain and ﬂ ush the tank. Replace the anode rod if it is substanƟ ally worn out or depleted. ThereaŌ er, inspect the anode rod annually or more frequently if needed. If you use a water soŌ ener, your anode rod will deplete faster than normal. Inspect the anode rod more frequently, replacing the anode rod if it is depleted. Obtain a new anode rod from Lowe’s® or have a qualiﬁ ed person replace it. (Anode rods are a consumable item and are not covered under warranty). 9 If a large amount of sediment was present when the tank was drained, ﬂ ush the tank by opening the cold water supply valve and leƫ ng the water run unƟ l no more sediment drains from the tank. Close the drain valve when you are done. ResidenƟ al Standard Gas Water Heater Use and Care Guide • 29 MAINTENANCEResidenƟ al Standard Gas Water Heater Use and Care Guide • 29 MAINTENANCE 10 Reﬁ ll the tank by opening the cold water supply valve. Make sure a hot water faucet is open and the drain valve is closed. Allow a hot water faucet to run full for at least three minutes to make sure the tank has all the air removed and is complete- ly full of water. Once you are certain the tank is completely full of water, close the hot water faucet. 11 Relight the pilot using the instrucƟ ons on page 23 and adjust the gas control knob to the desired temperature. It may take an hour or more for the tank of cold water to heat up. Visual InspecƟ on On an annual basis, visually inspect the venƟ ng and air supply system, piping systems, main burner, pilot burner, and the air ﬁ lter. Check the water heater for the following: • ObstrucƟ ons, damage, or deterio- raƟ on in the venƟ ng system. Make sure the venƟ laƟ on and combus- Ɵ on air supplies are not obstruct- ed. Check the air ﬁ lter for dust or other debris and clean if needed. • Build up of soot and carbon on the main burner and pilot burner. The burner may be cleaned with soap and hot water. • Inspect the burner ﬂ ames through the viewport and compare them to the drawing below. A properly operaƟ ng burner should produce a soŌ blue ﬂ ame. Blue Ɵ ps with yellow inner cones are saƟ sfactory. The Ɵ ps of the ﬂ ame may have a slight yellow Ɵ nt. The ﬂ ame should not be all yellow or have a sharp blue-orange color. Contaminated air may cause an orange colored ﬂ ame. Contact a qualiﬁ ed technician if the ﬂ ame is not saƟ sfactory. Figure 44 - Burner Flames • Leaking or damaged water and gas piping. • Remove any ﬂ ammable, corrosive or combusƟ ble materials near the water heater. If you lack the necessary skills required to properly perform this visual inspec- Ɵ on or if the burner needs to be cleaned, get help from a qualiﬁ ed person. T&P Relief Valve Maintenance Figure 45 - T&P Relief Valve. Read and follow the operaƟ ng and an- nual maintenance instrucƟ ons provided by the manufacturer of the T&P Relief Valve (yellow label aƩ ached to T&P Relief Valve). Minerals in the water can form deposits that cause the valve to sƟ ck or create blocked passages, mak- ing the T&P Relief Valve inoperaƟ ve. Follow these guidelines: • At least annually, operate the T&P Relief Valve manually to ensure the waterways are clear and the valve mechanism moves freely (above). Before operaƟ ng the valve manually, check that it will discharge in a place for secure disposal. WARNING! Hot water will be released. Before operaƟ ng the T&P relief valve manually, check that it will discharge in a safe place. If water does not ﬂ ow freely from the end of the discharge pipe, turn the gas control knob to the OFF posiƟ on and call a qualiﬁ ed person to determine the cause. • At least every ﬁ ve years, have a qualiﬁ ed person inspect the T&P Relief Valve and discharge pipe. Damage caused by corrosive water condiƟ ons, mineral deposits, or other problems can only be de- termined when a qualiﬁ ed person removes and inspects the valve and its components. A dripping T&P Relief Valve is usually caused by the home’s water pressure being too high or the lack of a Thermal Expansion Tank. If your T&P Relief Valve drips, see page 26. A T&P relief valve that has been al- lowed to drip for an appreciable period of Ɵ me should be inspected for mineral buildup. See T&P relief valve tag for more informaƟ on. Inspect and Clean the Air Filter Figure 46 - Clean air filter periodically. An air ﬁ lter should be installed around the base of the water heater. At least annually inspect the air ﬁ lter and check for a build-up of dust or debris. Vacuum the ﬁ lter to remove any dust or debris. If an oily residue is present on the ﬁ lter, wash it in soap and water, then dry the ﬁ lter. 30 • ResidenƟ al Standard Gas Water Heater Use and Care GuideMAINTENANCE 30 • ResidenƟ al Standard Gas Water Heater Use and Care Guide 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 Control Valve/ Thermostat: 1 Turn the gas control/tem- perature knob to the “OFF” posiƟ on. Figure 48 - Gas control/valve. 2 Turn off the gas at the manual shut-off valve on the gas supply pipe. Figure 50 - Gas valve in “off” position. 3 Drain the water heater. Refer to the “Draining and Flushing the Water Heater” secƟ on (see page 28) and follow the procedure. 4 Disconnect the A igniter wire from the igniter lead wire. Use needle nose pliers to disconnect the B red (+) and white (-) thermopile wires. Disconnect C pilot tube (7/16” wrench) and D manifold tube (3/4” wrench) at the gas control valve/thermostat. NOTE: L.P. Gas systems use reverse (leŌ -hand) threads on the manifold tube. A C D B Figure 52 - Gas valve connections. 5 Disconnect the ground joint union in the gas piping. Disconnect the remaining pipe from the gas control valve/ thermostat. Figure 54 - Ground joint union connection. 6 To remove the gas control valve/thermostat, thread a 4” secƟ on of gas pipe into the inlet and use it to turn the FVIR Safety System OperaƟ onal Checklist TROU- BLESHOOTING CHART gas control valve/thermostat (counterclockwise.) Do not use pipe wrench or equivalent to grip body. Damage may result, causing leaks. Do not insert any sharp objects into the inlet or outlet connec- Ɵ ons. Damage to the gas control valve/ thermostat may result. Figure 56 - Gas control/valve with threaded pipe. Replacing Gas Control Valve/Thermostat: To replace the gas control valve/thermo- stat, reassemble in reverse order. When replacing the gas control valve/ thermostat, thread a 4” secƟ on of gas pipe into the inlet and use it to turn the gas control valve/thermostat (clockwise.) DO NOT OVER TIGHTEN, damage may result. • Be sure to use approved Teﬂ on® tape or pipe joint compound on the gas piping connecƟ ons and ﬁ ƫ ng on the back of the gas control valve that screws into tank. • Be sure to remove the pilot ferrule nut from the new gas control valve/thermo- stat. Figure 58 - Gas valve in “on” position. • Turn the gas supply on and check for leaks. Test the water heater by brushing on an approved noncorrosive leak detecƟ on soluƟ on. Bubbles forming indicate a leak. Correct any leak found. • Be sure tank is completely ﬁ lled with water before lighƟ ng and acƟ vaƟ ng the water heater. Follow the “LighƟ ng InstrucƟ ons” on page 23. • If addiƟ onal informaƟ on is required, contact the Service Department at: 1- 877-817-6750. MAINTENANCE ResidenƟ al Standard Gas Water Heater Use and Care Guide • 31 NOTESNOTES 32 • ResidenƟ al Standard Gas Water Heater Use and Care GuideNOTESNOTES ResidenƟ al Standard Gas Water Heater Use and Care Guide • 33 NOTESNOTES 34 • ResidenƟ al Standard Gas Water Heater Use and Care GuideNOTESNOTES ResidenƟ al Standard Gas Water Heater Use and Care Guide • 35 REPAIR PARTSREPAIR PARTS Item No.Parts Description 1 DRAFT HOOD 2 REDUCER RING - SOME MODELS (NOT SHOWN) 3 FLUE BAFFLE (NOT SHOWN) 4 COMBINATION DIP TUBE/HEAT TRAP NIPPLE 5 HEAT TRAP/NIPPLE 6 ANODE ROD - SOME MODELS 7 COMBINATION HEAT TRAP NIPPLE/ANODE - SOME MODELS 8 TEMPERATURE & PRESSURE RELIEF VALVE (LOCATED TOP OR SIDE) 9 DRAIN VALVE 10 GAS CONTROL VALVE/THERMOSTAT (with thermal switch wire lead) 11 OUTER DOOR 12 PILOT/THERMOPILE ASSEMBLY KIT 13 FINAL BURNER ASSEMBLY 14 MANIFOLD DOOR GASKET 15 WRAP AROUND AIR FILTER REPAIR PARTS LIST Replacement parts may be ordered through your plumber or the local distributor. Parts will be shipped at prevailing prices and billed accordingly. NOTICE: When ordering replacement parts, have the following informaƟ on ready: • Model and serial number • Type of gas used • Item number • Parts descripƟ on Legend ·Special anode rod (see page 26) µTemperature and Pressure Relief Valve is required but may be factory installed ®Unique: Flammable Vapor IgniƟ on Resistant Safety System parts 36 • ResidenƟ al Standard Gas Water Heater Use and Care GuideREPAIR PARTS 36 • ResidenƟ al Standard Gas Water Heater Use and Care Guide REPAIR PARTS Listed Parts Kits and Illustrations Item 12: Pilot assembly kit, which contains the pilot assembly, thermopile, and retainer clip (Natural Gas or L.P.) Item 13: Final burner assembly which contains the burner, orifice, manifold tube, gasket, door, pilot tube, thermopile, manifold component block with retainer clip, thermal switch, and pilot assembly. (Natural Gas/Low Nox or L.P.) Item 14: Contains manifold door gasket Item #12 Item #13 (L.P. Burner)Item #14 Item #13 (Natural Burner) ®Te ﬂ on is a registered trademark of E.I. Du Pont De Nemours and Company A.O. Smith Corporation. All Rights Reserved. Limited Warranty provided by Manufacturer.