Whirlpool Water Heater 6510374 User Manual

Energy Smart Gas  
Water Heater  
with the Flame Lock™  
Safety System  
Installation  
WARNING: If the information in these  
instructions is not followed exactly, a fire  
or explosion may result causing property  
damage, personal injury or death.  
Do not store or use gasoline or other  
flammable vapors and liquids in the  
vicinity of this or any other appliance.  
Instructions and  
Use & Care Guide  
NATURAL GAS MODELS ONLY  
WHAT TO DO IF YOU SMELL GAS  
• Do not try to light any appliance.  
To obtain technical, warranty, or service assistance during or after  
the installation of this water heater, visit our website at:  
• Do not touch any electrical switch;  
do not use any phone in your  
building.  
• Immediately call your gas supplier  
from a neighbor’s phone. Follow  
the gas supplier’s instructions.  
or call toll free  
1-877-817-6750  
When calling for assistance, please have the following  
information ready:  
1.  
2.  
3.  
4.  
5.  
Model number  
7 digit product number  
Serial number  
• If you cannot reach your gas  
supplier, call the fire department.  
Date of installation  
Place of purchase  
Installation and service must be performed  
by a qualified installer, service agency or  
the gas supplier.  
Table of Contents ......................................................  
2
INSTALLER:  
AFFIX THESE INSTRUCTIONS TO OR ADJACENT  
TO THE WATER HEATER.  
OWNER:  
RETAIN THESE INSTRUCTIONS AND WARRANTY  
6510374  
FOR FUTURE REFERENCE. RETAIN THE ORIGINAL  
RECEIPT AS PROOF OF PURCHASE.  
W10100870  
February 2006  
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INSTALLING YOUR GAS WATER HEATER  
instructions, you should not proceed but have a qualified  
Important Information About  
person perform the installation of this water heater.  
Massachusetts code requires this water heater to be  
This Water Heater  
installed in accordance with Massachusetts Plumbing and  
This gas water heater was manufactured to voluntary  
safety standards to reduce the likelihood of a flammable  
vapor ignition incident. New technology used in meeting  
these standards makes this product more sensitive to  
installation errors or improper installation environments.  
Please review the Installation Checklist found at the end of  
the installation instructions section and make any required  
installation upgrades or changes.  
Fuel Gas Code 248 CMR Section 2.00 and 5.00.  
A data plate identifying your water heater can be found next  
to the gas control valve/thermostat. When referring to your  
water heater, always have the information listed on the data  
plate readily available.  
Retain your original receipt as proof of purchase.  
Unpacking the Water Heater  
Consumer Information  
WARNING  
This water heater is design-certified by CSA International  
as a Category I, non-direct vented water heater which takes  
its combustion air either from the installation area or from  
air ducted to the unit from the outside.  
Excessive Weight Hazard  
Use two or more people to move and install  
water heater.  
This water heater must be installed according to all local  
and state codes or, in the absence of local and state codes,  
the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-  
latest edition. This is available from the following:  
Failure to do can result in back or  
other injury.  
CSA America, Inc.  
8501 East Pleasant Valley Road  
Cleveland, OH 44131  
IMPORTANT: Do not remove any permanent instructions,  
labels, or the data label from either the outside of the water  
heater or on the inside of water heater panels.  
National Fire Protection Agency  
1 Batterymarch Park  
Remove exterior packaging and place installation com-  
ponents aside.  
Quincy, MA 02269  
Inspect all parts for damage prior to installation and  
start-up.  
Check your phone listings for the local authorities having  
jurisdiction over your installation.  
Completely read all instructions before attempting to  
assemble and install this product.  
Consumer Responsibilities  
After installation, dispose of/recycle all packaging  
materials.  
This manual has been prepared to acquaint you with the  
installation, operation, and maintenance of your gas water  
heater and provide important safety information in these  
areas.  
Read all of the instructions thoroughly before attempting  
the installation or operation of this water heater.  
Do not discard this manual. You or future users of this  
water heater will need it for future reference.  
Service to the Flame LockSafety System should only be  
performed by a qualified person.  
Examples of a qualified person include: licensed plumbers,  
authorized gas company personnel, and authorized  
service personnel.  
IMPORTANT: This water heater has a resettable thermal  
switch installed as part of the Flame LockSafety System.  
DO NOT attempt to disable or modify this feature in any way.  
IMPORTANT: The manufacturer and seller of this water  
heater will not be liable for any damages, injuries, or  
deaths caused by failure to comply with the installation and  
operating instructions outlined in this manual.  
If you lack the necessary skills required to properly install  
this water heater, or you have difficulty following the  
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Location Requirements  
WARNING  
WARNING  
Carbon Monoxide Poisoning Hazard  
Do not install in a mobile home.  
Doing so can result in death or  
carbon monoxide poisoning.  
FLAMMABLES  
Flammable Vapors  
The Flame Lock™ Safety System is designed to reduce the  
risk of flammable vapor-related fires. The patented system  
protects your family by trapping the burning vapors within  
the water heater combustion chamber through the special  
flame-trap. The burning vapors literally “burn themselves  
out” without escaping back into the room. In the event of a  
flammable vapor incident, the Flame Lock™ Safety System  
shuts off the gas supply to the water heater’s burner and  
pilot, preventing re-ignition of any remaining flammable  
vapors in the area. This will disable the water heater until  
the system is reset. Note: Not following these instructions  
and/or an inadequate air supply can cause the Flame  
Lock™ Safety System to disable the water heater. Please  
make required installation and venting/air supply changes  
prior to resetting the system.  
FIRE AND EXPLOSION HAZARD  
Can result in serious injury or death  
Do not store or use gasoline or other  
flammable vapors and liquids in the  
vicinity of this or any other appliance.  
Storage of or use of gasoline or other  
flammable vapors or liquids in the vicinity  
of this or any other appliance can result in  
serious injury or death.  
IMPORTANT: This water heater has a resettable thermal  
switch installed as part of the Flame LockSafety System.  
DO NOT attempt to disable or modify this feature in any way.  
Read and follow water heater warnings and  
instructions.  
Do not use or store flammable products such as gasoline,  
solvents, or adhesives in the same room or area near the  
water heater. If such flammables must be used, all gas  
burning appliances in the vicinity must be shut off and their  
pilot lights extinguished. Open the doors and windows for  
ventilation while flammable substances are in use.  
If flammable liquids or vapors have spilled or leaked in the  
area of the water heater, leave the area immediately and  
call the fire department from a neighbor’s home. Do not  
attempt to clean the spill until all ignition sources have been  
extinguished.  
Do not store combustible materials (boxes, magazines,  
clothes, etc.) on or in close proximity to the water heater.  
Site Location  
Select a location near the center of the water piping  
system. The water heater must be installed indoors  
and in a vertical position on a level surface. DO NOT  
install in bathrooms, bedrooms, or any occupied room  
normally kept closed.  
Locate the water heater as close to the chimney or gas  
vent as practical. Consider the vent system piping and  
combustion air supply requirements when selecting the  
water heater location. The venting system must be able  
to run from the water heater to termination with minimal  
length and elbows.  
Locate the water heater near the existing gas piping.  
If installing a new gas line, locate the water heater to  
minimize the pipe length and elbows.  
NOTE: This water heater must be installed according to all  
local and state codes or, in the absence of local and state  
codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA  
54)-latest edition.  
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Figure 1  
Air-moving  
Devices  
IMPORTANT: The water heater should be located in  
an area where leakage of the tank or connections  
will not result in damage to the area adjacent to the  
water heater or to lower floors of the structure. Due  
to the normal corrosive action of the water, the tank  
will eventually leak after an extended period of time.  
Also any external plumbing leak, including those from  
improper installation, may cause early failure of the tank  
due to corrosion if not repaired. If the homeowner is  
uncomfortable with making the repair a qualified person  
should be contacted. A suitable metal drain pan should  
be installed under the water heater as shown below,  
to help protect the property from damage which may  
occur from condensate formation or leaks in the piping  
connections or tank. The pan must limit the water level  
to a maximum depth of 1-3/4” and be two inches wider  
than the heater and piped to an adequate drain. NOTE:  
The pan must not restrict combustion air flow. Locate the  
water heater near a suitable indoor drain. Outside drains  
are subject to freezing temperatures which can obstruct  
the drain line. The piping should be at least 3/4” ID and  
pitched for proper drainage. Under no circumstances will  
the manufacturer or seller of this water heater be held  
liable for any water damage which is caused by your  
failure to follow these instructions.  
Exhaust  
Fan  
Reverse flow  
of gases  
Clearances and Accessibility  
NOTE: Minimum clearances from combustible materials  
are stated on the data plate adjacent to the gas control  
valve/thermostat of the water heater.  
The water heater is certified for installation on a  
combustible floor.  
IMPORTANT: If installing over carpeting, the carpeting  
must be protected by a metal or wood panel beneath  
the water heater. The protective panel must extend  
beyond the full width and depth of the water heater by  
at least three inches (76.2mm) in any direction; or if in  
an alcove or closet installation, the entire floor must be  
covered by the panel.  
Figure 2 may be used as a reference guide to locate  
the specific clearance locations. A minimum of 24  
inches of front clearance should be provided for  
inspection and service.  
1 3/4” Maximum  
Pipe to  
adequate  
drain  
Figure 2  
Minimum Clearance  
Locations  
At least 2” greater than the  
diameter of the water heater  
Vent  
Top  
to  
The water heater should be located in an area not  
subject to freezing temperatures. Water heaters located  
in unconditioned spaces (i.e., attics, basements,  
etc.) may require insulation of the water piping and  
drain piping to protect against freezing. The drain and  
controls must be easily accessible for operation and  
service. Maintain proper clearances as specified on the  
data plate.  
Back  
Sides  
ceiling  
Front  
24” minimum  
for service  
Sides  
Top  
View  
Do not locate the water heater near an air-moving  
device. The operation of air-moving devices such as  
exhaust fans, ventilation systems, clothes dryers,  
fireplaces, etc., can affect the proper operation of  
the water heater. Special attention must be given to  
conditions these devices may create. Flow reversal of  
flue gases may cause an increase of carbon monoxide  
inside of the dwelling.  
State of California  
NOTE: The water heater must be braced, anchored, or  
strapped to avoid moving during an earthquake.  
Contact local utilities for code requirements in your area  
or call 1-877-817-6750 and request instructions.  
If the water heater is located in an area that is  
subjected to lint, dirt, and oil, it may be necessary  
to periodically clean the flame-trap (see “External  
Inspection & Cleaning of the Flame-trap,” Page 22).  
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3. Install a ground joint union between the gas control  
valve/thermostat and the manual shut-off valve. This  
is to allow easy removal of the gas control valve/  
thermostat.  
4. Turn the gas supply on and check for leaks. Test all  
connections by brushing on an approved noncorrosive  
leak-detection solution. Bubbles will show a leak.  
Correct any leak found.  
Gas Supply  
WARNING  
Figure 3  
Gas Piping  
Manual Gas  
Shut-off Valve  
Explosion Hazard  
Use a new CSA approved gas supply line.  
Install a shut-off valve.  
Do not connect a natural gas water heater to  
an L.P. gas supply.  
Ground  
Joint  
Union  
Check with local  
utility for  
minimum height  
Do not connect an L.P. gas water heater to a  
natural gas supply.  
3” Minimum  
Failure to follow these instructions can  
Drip Leg  
result in death, explosion, or  
Gas Pressure  
carbon monoxide poisoning.  
IMPORTANT: 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.  
Gas Requirements  
IMPORTANT: Read the data plate to be sure the water  
heater is made for the type of gas you will be using in  
your home. This information will be found on the data  
plate located near the gas control valve/thermostat. If the  
information does not agree with the type of gas available,  
do not install or light. Call your dealer.  
Gas Pressure Testing  
IMPORTANT: This water heater and its gas connection  
must be leak tested before placing the appliance in  
operation.  
NOTE: 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 time. Do not depend upon this odorant  
as an indication of leaking gas.  
If the code requires the gas lines to be tested at a  
pressure exceeding 14” W.C., the water heater and its  
manual shut-off valve must be disconnected from the  
gas supply piping system and the line capped.  
If the gas lines are to be tested at a pressure less than  
14” W.C., the water heater must be isolated from the  
gas supply piping system by closing its manual shut-off  
valve.  
Gas Piping  
The gas piping must be installed according to all local and  
state codes or, in the absence of local and state codes, the  
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-latest  
edition.  
U.L. recognized fuel gas and carbon monoxide (CO)  
detectors are recommended in all applications and should  
be installed using the manufacturer’s instructions and local  
codes, rules, or regulations.  
Table 1 on page 7 provides a sizing reference for commonly  
used gas pipe materials. Consult the “National Fuel Gas  
Code” for the recommended gas pipe size of other materials.  
Refer to Figure 3  
NOTE: When installing gas piping, apply approved pipe joint  
compound.  
1. Install a readily accessible manual shut-off valve in the  
gas supply line as recommended by the local utility.  
Know the location of this valve and how to turn off the  
gas to this unit.  
NOTE: Air may be present in the gas lines and could  
prevent the pilot from lighting on initial start-up. The gas  
lines should be purged of air by a qualified person after  
installation of the gas piping system.  
2. Install a drip leg (if not already incorporated as part of  
the water heater) as shown. The drip leg must be no  
less than three inches long for the accumulation of dirt,  
foreign material, and water droplets.  
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Table 1  
Natural Gas Pipe Capacity Table (Cu. Ft./Hr.)  
Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity  
of 0.60 (natural gas).  
Nominal Iron Pipe  
Size, in.  
Length of Pipe, Feet  
80  
10  
20  
30  
40  
50  
60  
70  
90 100 125 150 175 200  
40 38 34 31 28 26  
84 79 72 64 59 55  
1/2 132  
92  
73  
63  
56  
3/4 278 190 152 130 115 105  
50  
46  
96  
43  
90  
1
520 350 285 245 215 195 180 170 160 150 130 120 110 100  
1-1/4 1050 730 590 500 440 400 370 350 320 305 275 250 225 210  
1-1/2 1600 1100 890 760 670 610 560 530 490 460 410 380 350 320  
After the length of pipe has been determined, select the pipe size which will provide the minimum cubic feet per hour  
required for the gas input rating of the water heater. By formula:  
Gas Input of Water Heater (BTU/HR)  
Cu. Ft. Per Hr. Required=  
Heating Value of Gas (BTU/FT³)  
The gas input of the water heater is marked on the water heater data plate. The heating value of the gas (BTU/FT3)  
may be determined by consulting the local natural gas utility.  
Additional tables are available in the latest edition of the "National Fuel Gas Code", ANSI Z223.1.  
Combustion air must be free of acid-forming chemicals  
Combustion Air Supply and  
such as sulfur, fluorine, and chlorine. These elements are  
found in aerosol sprays, detergents, bleaches, cleaning  
Ventilation  
solvents, air fresheners, paint, and varnish removers,  
refrigerants, and many other commercial and household  
WARNING  
products. When burned, vapors from these products form  
highly corrosive acid compounds. These products should  
Carbon Monoxide Warning  
not be stored or used near the water heater or air inlet.  
Follow all the local and state codes or, in  
Combustion and ventilation air requirements are  
the absence of local and state codes, the  
determined by the location of the water heater. The water  
“National Fuel Gas Code”, ANSI Z223.1  
heater may be located in either an open (unconfined) area  
(NFPA 54)- latest edition to properly install  
or in a confined area or small enclosure such as a closet or  
small room. Confined spaces are areas with less than 50  
cubic feet for each 1,000 BTUH of the total input for all gas-  
using appliances.  
vent system.  
Failure to do so can result in death,  
explosion, or carbon monoxide poisoning.  
IMPORTANT: Air for combustion and ventilation must not  
come from a corrosive atmosphere. Any failure due to  
corrosive elements in the atmosphere is excluded from  
warranty coverage.  
The following types of installation (not limited to the  
following) will require outdoor air for combustion due to  
chemical exposure and may reduce but not eliminate the  
presence of corrosive chemicals in the air:  
beauty shops  
photo processing labs  
buildings with indoor pools  
water heaters installed in laundry, hobby, or craft rooms  
water heaters installed near chemical storage areas  
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Unconfined Space  
Figure 4  
Opening Locations-  
Confined Spaces  
12” maximum  
A water heater in an unconfined space uses indoor air for  
combustion and requires at least 50 cubic feet for each  
1,000 BTUH of the total input for all gas appliances. The  
table below shows a few examples of the minimum square  
footage (area) required for various BTUH inputs.  
Closet  
or  
other  
Permanent  
openings to  
confined  
space  
the outside or  
additional  
Table 2  
rooms within  
the building  
Minimum Square  
BTUH  
Input  
Typical Room  
with 8' Ceiling  
Feet with  
8' Ceiling  
30,000  
45,000  
60,000  
75,000  
90,000  
105,000  
120,000  
188  
281  
375  
469  
563  
657  
750  
844  
9 x 21  
14 x 20  
15 x 25  
15 x 31  
20 x 28  
20 x 33  
25 x 30  
28 x 30  
12” maximum  
All Air from Inside the Building  
When additional air is to be provided to the confined area  
from additional room(s) within the building, the total volume  
of the room(s) must be of sufficient size to properly provide  
the necessary amount of fresh air to the water heater  
and other gas utilization equipment in the area. If you are  
unsure that the structure meets this requirement, contact  
your local gas utility company or other qualified agency for  
a safety inspection.  
135,000  
Each of the two openings shall have a minimum free area  
of 1 square inch per 1,000 BTUH of the total input rating of  
all gas utilization equipment in the confined area, but not  
less than 100 square inches (Figure 5).  
IMPORTANT:  
The area must be open and be able to provide the  
proper air requirements to the water heater. Areas that  
are being used for storage or contain large objects may  
not be suitable for water heater installation.  
Water heaters installed in open spaces in buildings with  
unusually tight construction may still require outdoor  
air to function properly. In this situation, outside air  
openings should be sized the same as for a confined  
space.  
Confined  
Space  
Modern home construction usually requires supplying  
outside air into the water heater area.  
Permanent  
Openings  
Confined Space  
For the correct and proper operation of this water heater,  
ample air must be supplied for the combustion, ventilation,  
and dilution of flue gases. Small enclosures and confined  
areas must have two permanent openings so that sufficient  
fresh air can be drawn from outside of the enclosure. One  
opening shall be within 12 inches of the top and one within  
12 inches of the bottom of the enclosure as shown in  
Figure 4.  
1 square  
inch/1000  
BTUH  
(minimum  
100 sq. In.)  
Figure 5  
All Air from Inside Building  
Confined Space Installation  
The size of each opening (free area) is determined by the  
total BTUH input of all gas utilization equipment (i.e., water  
heaters, furnaces, clothes dryers, etc.) and the method by  
which the air is provided. The BTUH input can be found on  
the water heater data plate. Additional air can be provided  
by two methods:  
1. All air from inside the building.  
2. All air from outdoors.  
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All Air from Outdoors  
Gable vent  
to outdoors  
Outdoor fresh air can be provided to a confined area either  
directly or by the use of vertical and horizontal ducts. The  
fresh air can be taken from the outdoors or from crawl or  
attic spaces that freely communicate with the outdoors.  
Attic or crawl spaces cannot be closed and must be  
properly ventilated to the outside.  
Install above  
insulation  
Confined  
Space  
Outlet  
air to attic  
1 Sq. inch per  
4000 BTUH  
Ductwork must be of the same cross-sectional area as  
the free area of the opening to which they connect. The  
minimum dimension of rectangular air ducts cannot be less  
than three inches.  
Inlet air  
from the  
crawl  
Alternate  
Air Inlet  
The size of each of the two openings is determined by the  
method in which the air is to be provided. Refer to Table  
3 to calculate the minimum free area for each opening.  
Figures 6, 7, and 8 are typical examples of each method.  
space  
Open  
1 sq. inch per  
4000 BTUH  
Foundation  
Vent  
Louvers and Grilles  
Figure 6  
In calculating free area for ventilation and combustion  
air supply openings, consideration must be given to the  
blocking effect of protection louvers, grilles, and screens.  
These devices can reduce airflow, which in turn may  
require larger openings to achieve the required minimum  
free area. Screens must not be smaller than 1/4” mesh. If  
the free area through a particular design of louver or grille  
is known, it should be used in calculating the specified free  
area of the opening. If the design and free area are not  
known, it can be assumed that most wood louvers will allow  
20 - 25% of free area while metal louvers and grilles will  
allow 60 - 75% of free area.  
All Air from Outdoors; Inlet Air from Ventilated  
Crawl Space/Outlet Air to Ventilated Attic  
Gable vent  
to outdoors  
Install above  
insulation  
Outlet air  
Confined  
Space  
to attic  
1 Sq. inch per  
4000 BTUH  
Louvers and grilles must be locked open or interconnected  
with the equipment so that they are opened automatically  
during equipment operation.  
Inlet air duct  
1 sq. inch per  
4000 BTUH  
Keep louvers and grilles clean and free of debris or other  
obstructions.  
12” maximum  
Figure 7  
Table 3  
All Air from Outdoors  
Through Ventilated Attic  
Minimum Free Area of Permanent Openings for Ventilation and  
Combustion Air Supply - All Air from Outdoors Only.  
Based on the total BTUH input rating for all gas utilizing equipment  
within the confined space.  
1 sq. inch  
per  
Minimum Free Area  
Reference  
2000 BTUH  
Opening  
Source  
Per Opening  
(sq. in.)  
Drawing  
Direct to  
outdoors  
1 Square inch per 4000  
Figure 6  
BTUH  
Confined  
Space  
Outlet  
Inlet  
Vertical ducts  
Figure 7  
Figure 8  
1 Square inch per 4000  
BTUH  
Outdoor  
1 Square inch per 2000  
BTUH  
Horizontal ducts  
Air Ducts  
Example: A water heater with an input rate of 50,000 BTUH using  
horizontal ducts would require each opening to have a minimum  
free area of 25 square inches.  
Minimum free area = 50,000 BTUH x 1 sq. in. / 2000 BTUH = 25  
Sq. Inches.  
1 sq. Inch  
Figure 8  
These openings connect directly with the outdoors  
through a ventilated attic, a ventilated crawl space, or  
through an outside wall.  
*
per  
All Air from Outdoors  
Using Horizontal Ducts  
2000 BTUH  
Consult the local codes of your area for specific ventilation  
and combustion air requirements.  
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Vent Pipe System  
Vent Pipe Size  
This water heater uses a non-direct, single-pipe vent  
system to remove exhaust gases created by the burning of  
fossil fuels. Air for combustion is taken from the immediate  
water heater location or is ducted in from the outside (see  
“Combustion Air Supply and Ventilation”).  
It is important that you follow the guidelines in these  
instructions for sizing a vent pipe system. If a transition to  
a larger vent size is required, the vent transition connection  
must be made at the drafthood outlet.  
Vent Connectors  
1. Type B, Double Wall, U.L. Listed Vent Pipe.  
2. Single Wall Vent Pipe.  
This water heater must be properly vented for the removal  
of exhaust gases to the outside atmosphere. Correct  
installation of the vent pipe system is mandatory for the  
proper and efficient operation of this water heater and is an  
important factor in the life of the unit.  
Maintain the manufacturer’s specified minimum clearance  
from combustible materials when using type B double wall  
vent pipe.  
The vent pipe must be installed according to all local and  
state codes or, in the absence of local and state codes, the  
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-latest  
edition. The vent pipe installation must not be obstructed so  
as to prevent the removal of exhaust gases to the outside  
atmosphere.  
Vent connectors made of type B, double wall vent pipe  
material may pass through walls or partitions constructed  
of combustible material if the minimum listed clearance is  
maintained.  
Maintain a six inch minimum clearance from all combustible  
materials when using singlewall vent pipe.  
IMPORTANT: The use of vent dampers is not  
recommended by the manufacturer of this water heater.  
Although some vent dampers are certified by CSA  
International, this certification applies to the vent damper  
device only and does not mean they are certified for use on  
this water heater.  
IMPORTANT: Single wall vent pipe cannot be used for  
water heaters located in attics and may not pass through  
attic spaces, crawl spaces or any confined or inaccessible  
location. A single wall metal vent connector cannot pass  
through any interior wall.  
U.L. recognized fuel gas and carbon monoxide (CO)  
detectors are recommended in all applications and should  
be installed using the manufacturer’s instructions and local  
codes, rules, or regulations.  
When installing a vent connector, please note the following:  
Install the vent connector avoiding unnecessary bends,  
which create resistance to the flow of vent gases.  
IMPORTANT: If you lack the necessary skills required  
to properly install this venting system, you should not  
proceed, but get help from a qualified person.  
Install without dips or sags with an upward slope of at  
least 1/4-inch per foot.  
Joints must be fastened by sheet metal screws or other  
approved means. It must be supported to maintain  
clearances and prevent separation of joints and  
damage.  
Drafthood Installation  
Align the legs of the drafthood with the slots provided.  
Insert the legs and secure the drafthood to the water  
heater’s top with the four screws provided as shown in  
Figure 9. Do not alter the drafthood in any way. If you are  
replacing an existing water heater, be sure to use the new  
drafthood supplied with the water heater.  
The length of the vent connector cannot exceed 75% of  
the vertical vent height.  
The vent connector must be accessible for cleaning,  
inspection, and replacement.  
Vent connectors cannot pass through any ceiling, floor,  
firewall, or fire partition.  
Figure 9  
Drafthood Installation  
IMPORTANT: Existing vent systems must be inspected for  
obstructions, corrosion, and proper installation.  
Sheet Metal Screws (four provided)  
Drafthood  
Legs  
Legs  
Slots  
Slots  
Jacket top  
Install the drafthood with  
the four screws provided.  
10  
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Listed Lined  
Chimney  
Chimney Connection  
IMPORTANT: Before connecting a vent to a chimney,  
make sure the chimney passageway is clear and free of  
obstructions. The chimney must be cleaned if previously  
used for venting solid fuel appliances or fireplaces. Also  
consult local and state codes for proper chimney sizing and  
application or, in the absence of local and state codes, the  
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-latest  
edition.  
2 ft. minimum above any  
object within10 ft.  
horizontally  
3 ft. minimum  
*
The connector must be installed above the extreme  
bottom of the chimney to prevent potentially blocking  
the flue gases.  
Slope up  
1/4 in.  
per ft.  
minimum  
The connector must be firmly attached and sealed to  
prevent it from falling out.  
To aid in removing the connector, a thimble or slip joint  
may be used.  
The connector 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 (Figure 10).  
2 ft. minimum above any  
object within10 ft.  
horizontally  
3 ft. minimum  
Do not terminate the vent connector in a chimney that has  
not been certified for this purpose. Some local codes may  
prohibit the termination of vent connectors in a masonry  
chimney.  
*
Vertical Exhaust Gas Vent  
**  
Vertical exhaust gas vents must be installed with U.L. listed  
type B vent pipe according to the vent manufacturer’s  
instructions and the terms of its listing.  
Vent  
connector  
slope up  
1/4 in. per ft.  
minimum  
It must be connected to the water heater’s drafthood by  
a listed vent connector or by directly originating at the  
drafthood opening.  
Vertical gas vents must terminate with a listed cap or  
other roof assembly and be installed according to their  
manufacturer’s instructions.  
**  
5 in. minimum  
Gas vents must be supported to prevent damage, joint  
separation, and maintain clearances to combustible  
materials (Figures 11 and 12).  
IMPORTANT: This gas vent must be terminated in a vertical  
position to facilitate the removal of the burnt gases.  
*
An unused chimney flue or masonry enclosure may be  
used as a passageway for the installation of a gas vent  
(Figure 12).  
Slope up  
1/4 in.  
Common (combined) venting is allowable with vertical type  
B vent systems and lined masonry chimneys.  
per ft.  
minimum  
Figures 10-12 are examples of vent pipe system  
installations and may or may not be typical for your specific  
application. Consult the “National Fuel Gas Code”, NFPA  
54, ANSI Z223.1-latest edition and the guidelines set forth  
by prevailing local codes.  
Maintain vent pipe clearance requirements to local, state  
and/or the “National Fuel Gas Code”, ANSI Z223.1(NFPA  
54)-latest edition.  
*
** NFPA 211, Standard for Chimneys, Fireplaces, Vents,  
and Solid Fuel-Burning Appliances states that these  
chimneys are intended to be installed in accordance with  
the installation instructions provided with each chimney  
support assembly. Minimum air space clearance to  
combustible materials should be maintained as marked on  
the chimney sections.  
11  
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Figure 13  
Water System Piping  
Water Piping Installation  
Piping Installation  
In a closed system use a  
thermal expansion tank  
Piping, fittings, and valves should be installed according to  
the installation drawing (Figure 13). If the indoor installation  
area is subject to freezing temperatures, the water piping  
must be protected by insulation.  
Cold Water  
Supply to Fixtures  
Hot Water  
Outlet  
Main water supply  
Pressure reducing  
valve with bypass  
Cold Water  
Inlet Valve  
Water supply pressure should not exceed 80% of the  
working pressure of the water heater. The working pressure  
is stated on the water heater’s data plate. If this occurs,  
a pressure limiting valve with a bypass may need to be  
installed in the cold water inlet line. This should be placed  
on the supply to the entire house in order to maintain equal  
hot and cold water pressures.  
Union  
Temperature and  
Pressure Relief Valve  
Discharge line  
6” maximum  
above drain  
Drain line  
3/4” ID  
IMPORTANT: Heat cannot be applied to the water fittings  
on the heater as they may contain nonmetallic parts. If  
solder connections are used, solder the pipe to the adapter  
before attaching the adapter to the hot and cold water  
fittings.  
minimum  
1” Minimum  
Massachussetts:  
Install a vacuum relief  
in cold water line per  
section 19 MGL 142.  
Metal  
Drain Pan  
Drain  
1 3/4” depth maximum  
Figure 14  
Typical Tempering  
Valve Installation  
IMPORTANT: Always use a good grade of joint compound  
and be certain that all fittings are drawn up tight.  
Cold  
Water  
Inlet  
1. Install the water piping and fittings as shown in Figure  
13. Connect the cold water supply (3/4” NPT) to the  
fitting marked “C”. Connect the hot water supply (3/4”  
NPT) to the fitting marked “H”.  
IMPORTANT: Some models may contain energy saving  
heat traps to prevent the circulation of hot water within the  
pipes. Do not remove the inserts within the heat traps.  
Follow the tempering  
valve manufacturer’s  
instructions.  
Hot  
Water  
Outlet  
2. The installation of unions in both the hot and cold water  
supply lines is recommended for ease of removing the  
water heater for service or replacement.  
3. The manufacturer of this water heater recommends  
installing a tempering valve or an anti-scald device  
in the domestic hot water line as shown in Figure 14.  
These valves reduce the point-of-use temperature of  
the water by mixing cold and hot water and are readily  
available for use.  
Tempered water  
to fixtures  
Tempering valve  
(Set to 120°F)  
4. If installing the water heater in a closed water system,  
install an expansion tank in the cold water line as  
specified under “Closed System/Thermal Expansion”  
(Page 13).  
5. Install a shut-off valve in the cold water inlet line. It  
should be located close to the water heater and be  
easily accessible. Know the location of this valve and  
how to shut off the water to the heater.  
6. A temperature and pressure relief valve must be  
installed in the opening marked “Temperature and  
Pressure (T & P) Relief Valve” on the water heater.  
A discharge line must be added to the opening of  
the T & P Relief Valve. Follow the instructions under  
Temperature and Pressure Relief Valve,” page 13.  
7. After piping has been properly connected to the water  
heater, remove the aerator at the nearest hot water  
faucet. Open the hot water faucet and allow the tank  
to completely fill with water. To purge the lines of  
any excess air, keep the hot water faucet open for  
3 minutes after a constant flow of water is obtained.  
Close the faucet and check all connections for leaks.  
Please note the following:  
The system should be installed only with piping that is  
suitable for potable (drinkable) water such as copper,  
CPVC, or polybutylene. This water heater must not be  
installed using iron piping or PVC water piping.  
Use only pumps, valves, or fittings that are compatible  
with potable water.  
Use only full flow ball or gate valves. The use of valves  
that may cause excessive restriction to water flow is  
not recommended.  
Use only 95/5 tin-antimony or other equivalent solder.  
Any lead based solder must not be used.  
Piping that has been treated with chromates, boiler  
seal, or other chemicals must not be used.  
Chemicals that may contaminate the potable water  
supply must not be added to the piping system.  
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Closed System/Thermal Expansion  
Figure 15A  
Temperature and Pressure  
Relief Valve Installation  
Periodic discharge of the temperature and pressure relief  
valve may be due to thermal expansion in a closed water  
supply system. The water utility supply meter may contain a  
check valve, backflow preventer or water pressure reducing  
valve. This will create a closed water system. During  
the heating cycle of the water heater, the water expands  
causing pressure inside the water heater to increase. This  
may cause the temperature and pressure relief valve to  
discharge small quantities of hot water. To prevent this, it  
is recommended that a diaphragm-type expansion tank  
(suitable for potable water) be installed on the cold water  
supply line. The expansion tank must have a minimum  
capacity of 1.5 U.S. gallons for every 50 gallons of stored  
water. Contact the local water supplier or plumbing  
inspector for information on other methods to control this  
situation.  
Optional location  
some models only  
Temperature and  
Pressure Relief Valve  
Discharge line 3/4” maximum  
Do not cap or plug  
6” Maximum  
Drain  
Drain Pan  
IMPORTANT: Do not plug or remove the temperature and  
pressure relief valve.  
For protection against excessive pressures and  
temperatures, a temperature and pressure relief valve must  
be installed in the opening marked “T & P RELIEF VALVE”  
(see Figure 15A). This valve must be design certified by  
a nationally recognized testing laboratory that maintains  
periodic inspection of the production of listed equipment or  
materials as meeting the requirements for Relief Valves and  
Automatic Shut-off Devices for Hot Water Supply Systems,  
ANSI Z21.22. The function of the temperature and pressure  
relief valve is to discharge water in large quantities in the  
event of excessive temperature or pressure developing  
in the water heater. The valve’s relief pressure must not  
exceed the working pressure of the water heater as stated  
on the data plate.  
Temperature and Pressure  
Relief Valve  
WARNING  
IMPORTANT: Only a new temperature and pressure relief  
valve should be used with your water heater. Do not use an  
old or existing valve as it may be damaged or not adequate  
for the working pressure of the new water heater. Do not  
place any valve between the relief valve and the tank.  
Explosion Hazard  
If the temperature and pressure relief valve  
is dripping or leaking, have a qualified  
person replace it.  
Examples of a qualified person include:  
licensed plumbers, authorized gas company  
personnel, and authorized service  
personnel.  
Do not plug valve.  
Do not remove valve.  
Failure to follow these instructions can  
result in death, or explosion.  
The Temperature & Pressure Relief Valve:  
Must not be in contact with any electrical part.  
Must be connected to an adequate discharge line.  
Must not be rated higher than the working pressure  
shown on the data plate of the water heater.  
The Discharge Line:  
Must not be smaller than the pipe size of the relief  
valve or have any reducing coupling installed in the  
discharge line.  
Must not be capped, blocked, plugged or contain any  
valve between the relief valve and the end of the dis-  
charge line.  
Must terminate a maximum of six inches above a floor  
drain or external to the building.  
Must be capable of withstanding 250°F (121°C) without  
distortion.  
Must be installed to allow complete drainage of both  
the valve and discharge line.  
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Pumps, valves, piping and fittings must be compatible  
with potable water.  
Figure 15B  
T&P Relief Valve Insulation  
A properly installed flow control valve is required to pre-  
vent thermosiphoning. Thermosiphoning is the result  
of a continuous flow of water through the air handler  
circuit during the off cycle. Weeping (blow off) of the  
temperature and pressure relief valve (T & P) or higher  
than normal water temperatures are the first signs of  
thermosiphoning.  
T&P Relief Valve Insulation  
Manual Relief Lever  
The domestic hot water line from the water heater  
should be vertical past any tempering 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 the efficiency.  
Do not connect the water heater to any system or  
components previously used with non-potable water  
heating appliances when used to supply potable water.  
T&P Relief Valve  
T&P Relief Valve  
Drain Line  
T&P Relief Valve and Pipe Insulation (Some Models)  
1. Locate the T&P Relief Valve on the water heater.  
2. Locate the slit running the length of the insulation.  
Some jurisdictions may require a backflow preventer  
in the incoming cold water line. This may cause the  
temperature and pressure relief valve on the water heater  
to discharge or weep due to expansion of the heated water.  
A diaphragm-type expansion tank suitable for potable  
water will normally eliminate this weeping condition. Please  
read and follow the manufacturer’s instructions for the  
installation of such tanks.  
3
Spread this slit open and slip it over the T&P Relief Valve.  
See Figure 15B. Apply gentle pressure to the insulation  
to ensure it is fully seated on the T&P Relief Valve. Once  
sealed secure the insulation with a section of tape.  
IMPORTANT: The insulation or tape should not block  
or cover the T&P Relief Valve drain opening. Also the  
insulation or tape should not block or hinder access to the  
T&P Relief valve manual relief lever.  
Also see “Water System Piping” (Page 12) for additional  
instructions on the safe and correct installation and  
operation of this water heater.  
4. Next locate the hot water (outlet) & cold water (inlet) pipes  
to the water heater.  
5. Select one of the sections of pipe insulation and locate the  
slit that runs the length of the insulation.  
Figure 16  
Typical Tempering Valve Installation  
Combination Space Heating/Potable  
Water Heating System  
6. Spread the slit open at the base of the insulation and slip  
it over the cold water (inlet) pipe. Apply gentle  
pressure along the length of the insulation to ensure it is  
fully seated around the cold water pipe. Also ensure that  
the base of insulation is flush with the water heater. Once  
seated, secure the insulation with a section of tape.  
7. Repeat steps 5 through 6 for the hot water (outlet) pipe.  
Domestic  
Hot Water  
Cold  
Out  
Flow Control  
Valve  
Tempering  
Valve  
Water  
Inlet  
Pump  
Hot  
In  
Water  
Out  
Out  
Special Applications  
Unions  
Coil  
To  
Air  
Combination Space Heating/Potable  
Water System  
Handler  
Some water heater models are equipped with inlet/outlet  
tappings for use with space heating applications. If this  
water heater is to be used to supply both space heating  
and domestic potable (drinking) water, the instructions  
listed below must be followed.  
Air  
Shut-off  
Valve  
Handler  
The unit must be set to standard mode (See Operating  
the Temperature Control System section).  
Be sure to follow the manual(s) shipped with the air  
handler system.  
This water heater is not to be used as a replacement  
for an existing boiler installation.  
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 heating system requires water tempera-  
tures in excess of 115°F, a tempering valve or an anti-  
scald device should be installed per its manufacturer’s  
instructions in the domestic (potable) hot water supply  
to limit the risk of scald injury.  
Drain  
Drain Pan  
Massachusetts code  
does not allow this  
type of installation.  
Solar Installation  
If this water heater is used as a solar storage heater or as a  
backup for the solar system, the water supply temperatures  
to the water heater tank may be in excess of 115°F. A  
tempering valve or other temperature limiting valve must  
be installed in the water supply line to limit the supply  
temperature to 115°F. The unit must be set to standard  
mode (See Operating the Temperature Control System  
section). NOTE: Solar water heating systems can often  
supply water with temperatures exceeding 180°F and may  
result in water heater malfunction.  
14  
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Important Information About  
Your Water Heater  
Installation Checklist  
Water Heater Location  
This gas water heater was manufactured to voluntary  
safety standards to reduce the likelihood of a flammable  
vapor ignition incident. New technology used in meeting  
these standards makes this product less tolerant of  
installation errors or improper installation environments.  
Please review the following information and make any  
necessary installation upgrades or changes:  
Centrally located with the water piping system. Located  
as close to the gas piping and vent pipe system as  
possible.  
Located indoors and in a vertical position. Protected  
from freezing temperatures.  
Proper clearances from combustible surfaces  
maintained and not installed directly on a carpeted floor.  
Provisions made to protect the area from water damage.  
Drain pan installed and piped to an adequate drain.  
Installation area free of corrosive elements and  
flammable materials.  
1. Check for insufficient combustion air. Insufficient  
air for the combustion of gas will result in the flame  
becoming “lazy,” thereby allowing heat to build up in  
the combustion chamber. This excessive heat will  
cause a thermal switch on the door assembly to trip.  
Is the water heater installed in a closet or other small,  
enclosed space? If so:  
Sufficient room to service the water heater.  
Water heater not located near an air moving device.  
DO NOT install in bathrooms, bedrooms, or any  
occupied room normally kept closed.  
Are there openings for make-up air to enter and  
exit the room/area?  
Combustion Air Supply and Ventilation  
Are the openings of sufficient size? Remember,  
if there are other gas-fired or air-consuming  
appliances in the same room, you need more  
make-up air. Refer to the Location Requirements  
section of this water heater manual for specific  
requirements.  
Sufficient fresh air supply for proper water heater  
operation.  
Fresh air not taken from areas that contain negative  
pressure producing devices such as exhaust fans,  
fireplaces, etc.  
Fresh air supply free of corrosive elements and  
Is there a furnace/air handler in the same room/  
space as the water heater? If so, has a return air  
duct system been attached that exits the room?  
If so, check for leaks on the air duct system. If no  
air duct system is present, correct immediately  
by contacting a local Heating, Ventilation, Air-  
Conditioning & Refrigeration (HVAC-R) authorized  
service provider.  
flammable vapors.  
Fresh air openings sized correctly with consideration  
given to the blocking effect of louvers and grilles.  
Ductwork is the same cross-sectional area as the  
openings.  
Vent Pipe System  
Drafthood properly installed.  
2. Check for proper drafting at the water heater draft  
hood. Refer to the “Checking the Draft” section of this  
manual for the test procedure. If the procedure shows  
no draft is present:  
Vent connectors securely fastened with screws and  
supported properly to maintain six inch clearance.  
Vent connector made of approved material and sized  
correctly.  
Recheck #1.  
Vent pipe system must be installed according to all  
local and state codes or, in the absence of local and  
state codes, the “National Fuel Gas Code”, ANSI  
Z223.1(NFPA 54)-latest edition.  
Flue baffle engaged in slots provided in the flue tube.  
Flue way, drafthood, or vent pipe system not obstructed  
in any way.  
Check the vent system for restrictions/obstructions  
and check the vent termination height. Refer to  
the Air Supply and Ventilation section of this water  
heater manual for specific requirements.  
3. Is the installed environment dirty (excessive amounts  
of lint, dirt, dust, etc.)? If so, make sure the flame  
arrestor located on the bottom of the water heater  
has been cleaned. Refer to the Maintenance of your  
Water Heater section of this manual for information on  
cleaning the flame-trap.  
4. Is it possible that flammable vapors entered the  
water heater and were ignited in the burner area (a  
flammable vapor incident)? If a flammable vapor  
incident has occurred or if you are unsure whether it  
has, call the number below immediately.  
Water System Piping  
Temperature and pressure relief valve properly installed  
with a discharge line run to an open drain and protected  
from freezing.  
All piping properly installed and free of leaks.  
Heater completely filled with water.  
Closed system pressure build-up precautions installed.  
Tempering valve installed per manufacturer’s  
instructions, when applicable (See Water Temperature  
Regulation section.)  
Proper installation will ensure the safe, effective and  
efficient operation of the water heater. Make sure that  
you review and follow the instructions in this manual.  
Questions? Call 1-877-817-6750.  
Gas Supply and Piping  
Gas supply is the same type as listed on the water heater  
data plate.  
Gas line equipped with shut-off valve, union, and drip leg.  
Approved pipe joint compound used.  
Adequate pipe size and of approved material.  
An approved noncorrosive leak detection solution to  
check all connections and fittings for possible gas leaks.  
Correct any leak found.  
15  
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OPERATING YOUR WATER HEATER  
Lighting Instructions  
WARNING  
Replace viewport if glass is  
missing or damaged.  
Failure to do so can result in  
death, explosion or fire.  
Read and understand these directions thoroughly before  
attempting to light or re-light the pilot. Make sure the  
viewport is not missing or damaged. (See Figure 23)  
Make sure the tank is completely filled with water before  
lighting the pilot. Check the data plate near the gas control  
valve/thermostat for the correct gas. Do not use this water  
heater with any gas other than the one listed on the data  
plate. If you have any questions or doubts, consult your gas  
supplier or gas utility company.  
Explosion Hazard  
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Checking the Draft  
Water Temperature Regulation  
WARNING  
WARNING  
Burn Hazard  
Do not touch vent.  
Doing so can result in burns.  
After successfully lighting the water heater, allow the unit  
to operate for 15 minutes and check the drafthood relief  
opening for proper draft. Make  
sure all other appliances in  
Figure 17  
Drafthood  
Water temperature over 125°F can cause  
severe burns instantly or death from scalds.  
Children, disabled and elderly are at highest  
risk of being scalded.  
Feel water before bathing or showering.  
Temperature limiting valves are available.  
the area are operating and  
Relief  
Opening  
all doors are closed when  
Match  
performing the draft test. Pass  
a match flame around the relief  
opening of the drafthood. A  
steady flame drawn into the  
opening indicates proper draft.  
If the flame flutters or is blown  
out, combustion products are escaping from the relief  
The thermostat is adjusted to the pilot position when it  
is shipped from the factory. Water temperature can be  
regulated by moving the temperature dial to the preferred  
setting. The preferred starting point is 120°F. Align the knob  
with the desired water temperature as shown in Figure 19A.  
There is a hot water scald potential if the thermostat is set  
too high.  
opening. If this occurs,  
Figure 18  
do not operate the  
Flame Characteristics  
Tips may have  
water heater until proper  
a yellow tint  
adjustments or repairs  
Yellow inner  
are made to the vent  
cones are  
pipe system and/or air  
satisfactory  
IMPORTANT: Adjusting the thermostat past the 120°F bar  
on the temperature dial will increase the risk of scald injury.  
Hot water can produce first degree burns within:  
supply requirements.  
Correct flame  
Burner Flames  
Inspect the burner  
soft blue  
120°F (49°C) more than 5 minutes  
130°F (54°C) at 20 seconds  
140°F (60°C) at 3 seconds  
flames through the viewport and compare them to the  
drawings in Figure 18. A properly operating burner should  
produce a soft blue flame. Blue tips with yellow inner cones  
are satisfactory. The tips of the flame may have a slight  
yellow tint. The flame should not be all yellow or have a  
sharp blue-orange color. Contaminated air may cause an  
orange colored flame. Contact a qualified person if the  
flame is not satisfactory.  
150°F (66°C) at 1-1/2 seconds  
Figure 19A  
Honeywell Gas Valve/Thermostat  
120°  
Mark  
Settings  
Gas Control/Temperature Knob  
150°  
Mark  
Status  
Light  
Stacking  
Stacking occurs when a series of short draws of hot water  
(3 gallons or less) are taken from the water heater tank.  
This causes increased cycling of the burner and can result  
in increased water temperatures at the hot water outlet. An  
anti-scald device is recommended in the hot water supply  
line to reduce the risk of scald injury.  
120°  
Mark  
Index  
Mark  
Igniter  
NOTE: During low demand periods when hot water is not  
being used, a lower thermostat setting will reduce energy  
losses and may satisfy your normal hot water needs.  
If hot water use is expected to be more than normal, a  
higher thermostat setting may be required to meet the  
increased demand. When leaving your home for extended  
periods (vacations, etc.) turn the temperature dial to the  
vacation (VAC) setting. This will maintain the water at low  
temperatures with minimum energy losses and prevent the  
tank from freezing during cold weather.  
Emergency Shut Down  
IMPORTANT: Should overheating occur or the gas supply  
fails to shut off, turn off the water heater’s manual gas  
control valve and call a qualified person.  
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Operating the Temperature Control System  
NOTE: If the pilot lights, but will only stay lit with the knob  
depressed in the pilot position, look for the following status  
light codes.  
Figure 19B  
Temperature Control System  
STATUS LIGHT CODE  
6 Second Solid Light followed by:  
4 Flashes  
7 Flashes  
8 Flashes  
The unit will not relight because it detects an  
overheat failure.  
The unit will not relight because it detects an  
electronic control failure.  
Flashes are displayed 1 second apart at 3 second intervals  
120°  
Mark  
The unit will not relight because it detects a  
valve failure.  
150°  
STATUS LIGHT CODE  
Mark  
Flashes are displayed 1 second apart at 3 second intervals  
6 Second Solid Light with combinations of:  
4 + 7 Flashes*  
4 + 8 Flashes*  
7 + 8 Flashes*  
The unit will not relight because it  
detects an overheat failure and an  
electronic control failure.  
The unit will not relight because it  
detects an overheat failure and a valve  
failure.  
The unit will not relight because it  
detects an electronic control failure and  
a valve failure.  
Index  
Mark  
120°  
Mark  
Water Temperature Adjustment  
The water temperature can be adjusted from 110°F to  
150°F. Turn the Gas Control/Temperature Knob to the  
desired setting/temperature.  
4 + 7 + 8 Flashes* The unit will not relight because  
it detects an overheat failure, an  
electronic control failure and a valve  
failure.  
Operating Modes and Settings  
* Flashes are displayed at 1 second apart and a 3 second  
pause between combinations.  
Standard Mode - The controller adjusts the water  
heater to maintain the temperature set by the user.  
Energy Smart Mode - The controller adjusts the water  
temperature to the lowest temperature required to  
meet the household demands. This mode minimizes  
operating costs. The controller will not adjust the  
temperature higher than the user’s selected set point or  
lower than 115°F.  
Vacation Setting - The controller adjusts the water  
temperature to approximately 80°F. This setting is  
recommended when the water heater is not in use for  
a long period of time. This effectively turns the water  
heater down to a setting that prevents the water from  
freezing.  
Diagnostic Status Light Code  
No status light indicates a control off or the pilot is out.  
Standard Flashes:  
1 Flashes Indicates Normal Operation  
2 Flashes Indicates Thermopile Voltage Low  
3 Flashes Indicates Valve or Sensor Failure  
4 Flashes Indicates Overheat Failure  
5 Flashes Indicates Lower Sensor Failure  
6 Flashes Indicates Upper Sensor Failure  
7 Flashes Indicates Electronic Control Failure  
8 Flashes Indicates Valve Failure  
Continuous Solid Flash indicates system shutdown  
18  
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A high temperature limit switch or ECO (Energy Cut Off) in  
the tank is used to shut off the unit if the water temperature  
exceeds 180°F (83°C). The ECO is a single use switch and  
requires complete replacement of the entire gas control  
valve/thermostat. If the ECO should function, the water  
heater cannot be used until the gas control valve/thermostat  
is replaced by a qualified person. Contact your local dealer  
for service information.  
Operational Conditions  
Condensation  
Moisture from the products of combustion condenses on  
the tank surface and the outside jacket of the water heater  
and forms drops of water which may fall onto the burner or  
other hot surfaces. This will produce a “sizzling” or “frying”  
noise. NOTE: This condensation is normal and should not be  
confused with a leaking tank. Condensation may increase or  
decrease at different times of the year.  
Anode Rod/Water Odor  
Each water heater contains at least one anode rod, which  
will slowly deplete while protecting the glass-lined tank  
from corrosion and prolonging the life of the water heater.  
Once the anode is depleted, the tank will start to corrode,  
eventually developing a leak. Certain water conditions will  
cause a reaction between this rod and the water. The most  
High efficient energy saver water heaters will produce  
larger amounts of condensation on initial start-up or when  
a large amount of hot water is being used. NOTE: Do not  
confuse this with a “tank leak”. Once the water reaches a  
temperature of 120°F and the tank warms up (usually 1-2  
hours), the condensation will stop.  
IMPORTANT: It is always recommended that a suitable drain common complaint associated with the anode rod is a “rotten  
pan be installed under the water heater to protect the area  
from water damage resulting from normal condensation  
production, a leaking tank or piping connections. Refer to  
“Location Requirements” on page 4. Under no circumstances  
is the manufacturer to be held responsible for any water  
damage in connection with this water heater.  
egg smell” produced from the presence of hydrogen sulfide  
gas dissolved in the water. IMPORTANT: Do not remove  
this rod permanently as it will void any warranties. The parts  
list includes a special anode that can be ordered if water  
odor or discoloration occurs. NOTE: This rod may reduce  
but not eliminate water odor problems. The water supply  
system may require special filtration equipment from a water  
conditioning company to successfully eliminate all water odor  
problems.  
Artificially softened water is exceedingly corrosive because  
the process substitutes sodium ions for magnesium and  
calcium ions. The use of a water softener may decrease the  
life of the water heater tank.  
Water Heater Sounds  
During the normal operation of the water heater, sounds or  
noises may be heard. These noises are common and may  
result from the following:  
1. Normal expansion and contraction of metal parts during  
periods of heat-up and cool-down.  
2. Condensation causes sizzling and popping within the  
burner area and should be considered normal.  
The anode rod should be removed from the water heater  
tank every 3 years for inspection. The following are typical  
(but not all) signs of a depleted anode rod:  
3. Sediment buildup in the tank bottom will create varying  
amounts of noise and may cause premature tank failure.  
Drain and flush the tank as directed under “Draining and  
Flushing”.  
Smoke/Odor  
The majority of the rods diameter is less than 3/8”.  
Significant sections of the support wire (approx. 1/3 or  
more of the anode rod’s length) are visible.  
The water heater may give off a small amount of smoke  
and odor during the initial start-up of the unit. This is due to  
the burning off of oil from metal parts of a new unit and will  
If the anode rod show signs of either or both it should be  
replaced. NOTE: Whether re-installing or replacing the  
anode rod, check for any leaks and  
immediately correct if found.  
disappear after a few minutes of operation.  
Safety Shut-off  
In replacing the anode:  
This water heater is designed to automatically shut-off in the  
1. Turn off gas supply to the water  
heater.  
event of the following:  
1. The pilot flame is extinguished for any reason.  
2. The water temperature exceeds 180°F (83°C).  
3. Excessive combustion chamber temperatures.  
4. The ignition of flammable vapors.  
2. Shut off the water supply and  
open a nearby hot water faucet to  
depressurize the water tank.  
3. Drain approximately 5 gallons  
of water from tank (Refer to  
A thermopile is used to determine if a pilot flame is present,  
and will shut off the gas supply to the main burner and the  
pilot if the flame is absent. This unit is also equipped with a  
thermal switch, designed to shut off the gas supply in the  
event the water heater has been exposed to flammable  
vapors (eg, spilled gasoline), poor combustion caused by a  
blocked vent or insufficient combustion air. If the  
thermal switch opens:  
“Draining and Flushing” for proper  
procedures). Close drain valve.  
4. Remove old anode rod.  
5. Use Teflon® tape or approved pipe  
sealant on threads and install new  
anode rod.  
6. Turn on water supply and open  
nearby hot water faucet to purge  
air from water system. Check for  
any leaks and immediately correct  
any if found.  
1. Check the flame-trap for signs of high temperature  
(blue or black discoloration) See Figure 28A.  
2. If there are signs of high temperature, correct any  
issues before you reset the thermal switch. Contact the  
Product Service and Support Department for service  
information at: 1-877-817-6750.  
7. Restart the water heater as directed under “Operating  
Your Water Heater.” See the “Repair Parts Illustration”  
for anode rod location on page 27.  
3. Inspect your installation for any problems with venting  
or combustion air.  
4. Reset the thermal switch by depressing the small  
button in the center of the thermal switch.  
TEFLON is a registered trademark of E.I. Du Pont De Nemours and Company.  
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MAINTENANCE OF YOUR WATER HEATER  
Draining and Flushing  
Temperature and Pressure  
Relief Valve  
It is recommended that the tank be drained and flushed  
every 6 months to remove sediment which may build up  
during operation. The water heater should be drained if  
being shut down during freezing temperatures. To drain the  
tank, perform the following steps:  
WARNING  
1. Turn off the gas to the water heater at the manual gas  
shut-off valve.  
2. Close the cold water inlet valve.  
3. Open a nearby hot water faucet.  
Explosion Hazard  
4. Connect a hose to the drain valve and terminate it to an  
adequate drain.  
If the temperature and pressure relief valve  
is dripping or leaking, have a qualified  
person replace it.  
Examples of a qualified person include:  
licensed plumbers, authorized gas company  
personnel, and authorized service  
personnel.  
NOTE: The drain hose should be rated for at least 200°F.  
If the drain hose does not have this rating, open the cold  
water inlet valve and a nearby hot faucet until the water is  
no longer hot.  
5. Open the water heater drain valve and allow all the  
water to drain from the tank. Flush the tank with water  
as needed to remove sediment.  
6. Close the drain valve, refill the tank, and restart the  
heater as directed under “Operating Your Water  
Heater”.  
Do not plug valve.  
Do not remove valve.  
Failure to follow these instructions can  
result in death, or explosion.  
If the water heater is going to be shut down for an extended  
period, the drain valve should be left open.  
IMPORTANT: Condensation may occur when refilling the  
tank and should not be confused with a tank leak.  
Manually operate  
Figure 21  
the temperature  
and pressure relief  
valve at least once  
a year to make  
Temperature and Pressure  
Relief Valve  
Routine Preventive  
Maintenance  
Manual Relief  
Valve  
sure it is working  
properly. To prevent  
water damage,  
the valve must be  
properly connected  
to a discharge line  
which terminates  
at an adequate  
drain. Standing clear of the outlet (discharged water may  
be hot), slowly lift and release the lever handle on the  
temperature and pressure relief valve to allow the valve to  
operate freely and return to its closed position. If the valve  
fails to completely reset and continues to release water,  
immediately shut off the manual gas control valve and the  
cold water inlet valve and call a qualified person.  
At least annually, a visual inspection should be made of  
the venting and air supply system, piping systems, main  
burner, pilot burner, and flame-trap. Check the water heater  
for the following:  
Obstructions, damage, or deterioration in the venting  
system. Make sure the ventilation and combustion air  
supplies are not obstructed.  
Discharge line to drain  
Build up of soot and carbon on the main burner and  
pilot burner. Check for a soft blue flame.  
Leaking or damaged water and gas piping.  
Presence of flammable or corrosive materials in the  
installation area.  
Presence of combustible materials near the water  
heater.  
After servicing this water heater, check to make sure it  
is working properly. (See Operating Your Water Heater  
section of this manual.)  
IMPORTANT: If you lack the necessary skills required to  
properly perform this visual inspection, you should not  
proceed, but get help from a qualified person.  
20  
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Removing the Burner from the  
Manifold Assembly  
Natural Gas Burner (Low Nox)  
Replacement Parts  
IMPORTANT: The following maintenance procedures  
are for the Flame LockSafety System components and  
should be performed by a qualified person.  
1. Take off the burner by removing the two (2) screws  
Replacement parts may be ordered through your plumber  
or the local distributor. Parts will be shipped at prevailing  
prices and billed accordingly. When ordering replacement  
parts, always have the following information ready:  
located underneath the burner.  
2. Check the burner to see if it is dirty or clogged. The  
burner may be cleaned with soap and hot water (Figure  
24).  
1. model, serial, and product number  
2. type of gas  
Manifold Door  
Figure 24  
Natural gas (Low NOx)  
Manifold Assembly  
Thermal Switch  
3. item number  
Door Gasket  
4. parts description  
Burner  
Two Piece Wire  
Connector  
Manifold Tube  
See pages 27-28 for a list of available repair parts.  
Pilot Tube  
Removing the Manifold Assembly  
1. Turn off the gas to the water heater at the manual gas  
shut-off valve (Figure 3).  
Thermopile  
Igniter Wire  
2. Turn the gas control/temperature knob to the “OFF”  
Pilot Bracket  
position (Figure 19).  
Figure 22  
Viewport  
Gas Control Valve/  
3. Remove the outer door.  
Thermostat  
Pilot Assembly  
Thermopile Connector  
4. Remove the two screws  
securing the manifold door  
to the combustion chamber  
(Figure 23).  
Pilot Tube  
Manifold Tube  
5. Disconnect the thermopile,  
pilot tube, the igniter wire  
from the igniter button, the  
two connectors attached  
to the thermal switch, and  
manifold tube at the gas  
control valve/thermostat.  
(Figures 22 & 23.)  
Burners  
Igniter  
Button  
Manifold  
Tube  
Manifold Door  
Screws  
Pilot Assembly  
Igniter  
Wire  
Thermopile Wire  
Pilot Tube  
6. Grasp the manifold tube  
and push down slightly to  
free the manifold tube, pilot tube, and thermopile.  
7. Carefully remove the manifold assembly from the  
combustion chamber. NOTE: Be sure not to damage  
internal parts.  
Figure 23  
Manifold Assembly  
Removal  
Gas Valve/Thermostat  
Piezo Igniter Button  
Pilot Tube  
Manifold Tube  
Thermal Switch  
Thermopile  
Viewport  
Manifold Door  
Manifold Screw (2)  
Two Piece Wire Connector  
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Replacing the Pilot Assembly  
External Inspection & Cleaning of the  
Flame-trap  
1. Remove the manifold assembly as directed previously.  
2. Remove the retainer clip from the back of the two  
piece wire connector and remove the two piece wire  
connector from the manifold door (Figure 25).  
3. Locate and remove the screws on the underside of the  
burner. Remove the screw securing the pilot assembly  
to the manifold.  
4. Using a wrench loosen the nut securing the pilot tube  
to the pilot assembly. NOTE: To prevent any bending of  
the pilot bracket, use pliers to hold the pilot assembly  
bracket while loosening the pilot nut.  
Inspect the wrap around filter periodically to check for lint,  
dust, or other debris that may have accumulated on it. If the  
water heater is installed in an easily accessible location,  
remove the wrap around filter and clean with soap and  
warm water. If the installation is not easily accessible use a  
vacuum with a brush attachement to clean the wrap around  
filter. Rotate the filter around the base of the water heater,  
vacuuming each exposed section until the wrap around  
filter is clean. Although not likely to occur, if debris collects  
on the flame-trap, use a vacuum, compressed air, or a soft  
bristle brush to remove it. Note: If unable to inspect or  
clean the flame trap from underneath, follow the “Cleaning  
the Combustion Chamber and Flame-trap” instructions.  
5. Pull the pilot tube from the pilot assembly (Figure 26).  
IMPORTANT: Be careful not to bend or alter the position of  
the pilot assembly components.  
6. Push the new pilot assembly connectors through the  
hole in the manifold door (See Figure 25). Reconnect  
the pilot tube and tighten the nut securing it to the pilot  
assembly. IMPORTANT: Keep the pilot orifice in the  
pilot when making the connection. DO NOT operate the  
water heater without the pilot orifice installed. Reattach  
the pilot assembly to the manifold.  
Figure 27  
Flame-trap visual inspection  
and cleaning  
7. Reattach the burner and secure with the screws  
removed earlier. Note: See figure 24 for correct burner  
orientation.  
Flashlight  
8. Position the new thermopile wires through the lower  
opening of the two piece wire connector (Figure 25).  
Be sure igniter wire is positioned through the upper  
opening of the two piece wire connector.  
9. See “Replacing Manifold Assembly” Page 23.  
Figure 25  
Burner and other fittings  
not show for clarity.  
Mirror  
Two Piece Wire  
Connector Assembly  
Thermopile  
Connector  
Retainer Clip  
Igniter  
Wire  
Vacuum with  
brush attachement  
Pilot Tube  
Two Piece  
Manifold Door  
Wire Connector  
Cleaning the Combustion Chamber and  
Flame-trap  
1. Follow procedure outlined in “Removing the Manifold  
Assembly”.  
Figure 26  
Pilot Assembly  
Pilot  
Thermopile  
Pilot  
2. Use a vacuum cleaner/shop vac to remove all loose  
debris in the combustion chamber (Figure 28A). Use  
compressed air to clear any dust or debris that may  
have accumulated in the flame-trap.  
Assembly  
Igniter Connector  
Thermopile  
Connector  
3. Reassemble following the procedure under “Replacing  
the Manifold Assembly”.  
Thermal  
Switch  
Connectors  
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9. Check for leaks by brushing on an approved  
noncorrosive leak detection solution. Bubbles forming  
indicate a leak. Correct any leak found. IMPORTANT:  
All leaks must be fixed immediately.  
Replacing the Manifold Assembly  
WARNING  
10. Replace the outer door.  
Figure 28A  
Combustion Chamber  
Flame-trap  
Bracket  
Door Gasket  
Explosion Hazard  
Tighten both manifold door screws  
securely.  
Remove any fiberglass between gasket  
and combustion chamber.  
Replace viewport if glass is missing or  
damaged.  
Figure 28B  
Close-up inside view of  
the combustion chamber.  
Manifold Assembly Close-up  
Replace two piece wire connector if missing  
or removed.  
Replace door gasket if damaged.  
Failure to follow these instructions can  
result in death, explosion, or fire.  
Tab  
1. Check the door gasket for damage or imbedded debris  
prior to installation.  
Slot  
Bracket  
Manifold Tube  
WARNING  
Replace viewport if glass is  
missing or damaged.  
Piezoelectric Igniter System  
Explosion Hazard  
The piezoelectric igniter system consists of the igniter  
button, electrode, and wire. The pilot is ignited by an  
electric spark generated when the igniter button is pressed.  
The spark gap of 0.125 inch is set when the electrode is  
installed at the factory. (See Figure 29). Use only factory  
authorized piezoelectric igniter parts for replacement.  
Failure to do so can result in  
death, explosion or fire.  
2. Inspect the viewport for damage and replace as  
Figure 29  
required.  
Natural Gas Igniter Assembly  
3. Insert the manifold assembly into the combustion  
chamber making sure that the tab of the manifold  
tube engages in the slot of the bracket inside the  
combustion chamber (Figure 28B).  
Pilot  
S
A
0
R
T
Y
G
M
O
R
E
D
N
E
E
O
O
N
O
W
T
°
0
5
H
Thermopile  
O
M
0
M
R
4. Inspect the door gasket and make sure there is no  
fiberglass insulation between the door gasket and the  
combustion chamber.  
O
L
V
F
A
F
C
O
P
I
LO  
T
.125”  
5. Replace the two screws which secure the manifold  
assembly door to the combustion chamber. Tighten  
securely. There should be no space between the  
gasket part of the manifold door and combustion  
chamber. IMPORTANT: Do not operate the water  
heater if the door gasket does not create a seal  
between the manifold door and the combustion  
chamber.  
Electrode  
Wire to Electrode  
Pilot Bracket  
Igniter Button  
Testing the Igniter System  
Turn off the gas to the water heater at the manual gas shut-  
off valve. Watch the electrode tip while activating the igniter.  
A visible spark should jump from the electrode. To avoid  
shock, do not touch the burner or any metal part on the  
pilot or pilot assembly. If no spark is visible, check the wire  
connections and make sure the electrode is not broken.  
Replace the igniter if defective. Dirt and rust on the pilot or  
electrode tip can prevent the igniter spark. Wipe clean with  
a damp cloth and dry completely. Rust can be removed  
from the electrode tip and metal surfaces by lightly sanding  
with an emery cloth or fine grit sandpaper.  
6. Reconnect the two wire leads to the thermal switch,  
the manifold tubing, pilot tubing, and thermopile to the  
gas control valve/thermostat. IMPORTANT: DO NOT  
attempt to disable or modify the thermal switch in any  
way. Do not cross-thread or apply any thread sealant to  
these fittings.  
7. Reconnect the igniter wire.  
8. Turn gas supply on and refer to the “Lighting  
Instructions” on page 16.  
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Replacing the Gas Valve:  
Removing and Replacing the Gas  
Control Valve/Thermostat  
To replace the gas control valve/thermostat, reassemble in  
reverse order. IMPORTANT: This water heater has a  
resettable thermal switch installed. DO NOT attempt to disable  
or modify this feature in any way. When replacing the gas  
valve, thread a correctly sized pipe into the inlet and use it to  
turn the gas valve (clockwise.) DO NOT OVER TIGHTEN,  
damage may result.  
IMPORTANT: The gas control valve/thermostat is a standard  
valve with wire leads that connect to a thermal switch.  
Removing the Gas Valve:  
1. Turn the gas control/temperature knob to the “OFF”  
position (Figure 19).  
Be sure to use approved Teflon® tape or pipe joint  
compound on the gas piping connections and fitting 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/thermostat.  
Turn the gas supply on and check the gas supply and  
gas valve for leaks. Test the supply connections by  
brushing on an approved noncorrosive leak detection  
solution. Bubbles forming indicate a leak. Correct any  
leak found.  
2. Turn off the gas at the manual shut-off valve on the gas  
supply pipe (Figure 3).  
3. Drain the water heater. Refer to the section of “Draining  
and Flushing” on page 20 and follow the procedure.  
4. Disconnect the igniter wire from the igniter button.  
Disconnect the thermopile, pilot tube, two wire leads at  
the thermal switch, and manifold tube at the gas control  
valve/thermostat (Figure 22).  
5. Refer to “Gas Piping” (Figure 3) and disconnect the  
ground joint union in the gas piping. Disconnect the  
remaining pipe from the gas control valve/thermostat.  
6. To remove the gas valve, thread a correctly sized  
pipe into the inlet and use it to turn the gas valve  
(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  
connections. Damage to the gas valve may result.  
Be sure tank is completely filled with water before  
lighting and activating the water heater. Follow the  
“Lighting Instructions” on page 16. With the water heater  
lit check for leaks at the manifold and pilot connections.  
Bubbles forming indicate a leak. Correct any leak found.  
If additional information is required, contact the Service  
Department at: 1-877-817-6750.  
TEFLON is a registered trademark of E.I. Du Pont De Nemours and Company.  
Flame LockSafety System Operational Checklist  
5. No leaks at pilot and manifold connection.  
6. Manifold door screws securely tightened.  
7. Depress the button on the thermal switch.  
1. Manifold door gasket properly sealed.  
2. Viewport not damaged or cracked.  
3. Flame-trap free of debris and undamaged.  
4. Two piece wire connector properly installed.  
TROUBLESHOOTING CHART  
PROBLEM  
POSSIBLE CAUSE(S)  
CORRECTIVE ACTION  
BURNER WILL NOT IGNITE 1. Pilot not lit  
1. Light pilot  
2. Thermostat set too low  
2. Turn temp. dial to desired temperature  
3. Check with gas utility company  
4. Notify utility-install trap in gas line  
5. Clean, locate source and correct  
6. Clean, locate source and correct  
7. Replace thermopile  
3. No gas  
4. Dirt in the gas lines  
5. Pilot line clogged  
6. Main burner line clogged  
7. Non-functioning thermopile  
8. Non-functioning thermostat  
8. Replace thermostat  
9. Heater installed in a confined area  
1. Sulfides in the water  
9. Provide fresh air ventilation  
SMELLY WATER  
1. Replace the anode with a special anode  
BURNER FLAME YELLOW- 1. Insufficient secondary air  
1. Provide ventilation to water heater  
2. Check with gas utility company  
3. Clean, locate source and correct  
4. Clean, locate source and correct  
5. Proper fresh air ventilation  
LAZY  
2. Low gas pressure  
3. Flue clogged  
4. Main burner line clogged  
5. Heater installed in a confined area  
6. Obstruction in main burner orifice  
6. Clean or replace orifice  
PILOT WILL NOT LIGHT OR 1. Non-functioning igniter  
1. Replace igniter pilot assembly  
2. See Pilot Light Troubleshooting Flowchart  
section  
REMAIN LIT  
2. The thermal switch tripped  
3. Thermopile connection loose  
4. Air in gas line  
3. Seat connector firmly in socket  
4. Bleed the air from the gas line  
5. Check with gas utility company  
6. Check with gas utility company  
7. Notify utility-install dirt trap in gas line  
8. Locate source and correct  
9. Replace thermostat  
5. Low gas pressure  
6. No gas  
7. Dirt in gas lines  
8. Cold drafts  
9. Thermostat ECO switch open  
10. Pilot line or orifice clogged  
11. Non-functioning thermopile  
12. Air for combustion obstructed  
10. Clean, locate source and correct  
11. Replace thermopile  
12. See maintenance section for inspection and  
cleaning of flame trap  
13. Flammable vapors incident, Flame Lock™  
function utilized  
13. Replace water heater, eliminate flammable  
vapors source. Call 1-877-817-6750  
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PROBLEM  
POSSIBLE CAUSE(S)  
CORRECTIVE ACTION  
HIGH OPERATION COSTS  
1. Thermostat set too high  
1. Set temperature dial to lower setting  
2. Drain/flush-provide water treatment if needed  
3. Install adequate heater  
2. Sediment or lime in tank  
3. Water heater too small for job  
4. Wrong piping connections  
5. Leaking faucets  
4. Correct piping-dip tube must be in cold inlet  
5. Repair faucets  
6. Gas leaks  
6. Check with utility-repair at once  
7. Advise customer  
7. Wasted hot water  
8. Long runs of exposed piping  
9. Hot water piping in exposed wall  
8. Insulate piping  
9. Insulate piping  
INSUFFICIENT HOT WATER 1. Thermostat set too low  
2. Sediment or lime in tank  
3. Water heater too small  
1. Turn temperature dial to desired setting  
2. Drain/flush-provide water treatment if needed  
3. Install adequate heater  
4. Wrong piping connections  
5. Leaking faucets  
4. Correct piping-dip tube must be in cold inlet  
5
Repair faucets  
6. Wasted hot water  
6. Advise customer  
7. Long runs of exposed piping  
8. Hot water piping in outside wall  
9. Low gas pressure  
7. Insulate piping  
8. Insulate piping  
9. Check with gas utility company  
SLOW HOT WATER  
RECOVERY  
1. Insufficient secondary air  
1. Provide ventilation to water heater. Check flue  
way, flue baffle, and burner  
2. Flue clogged  
2. Clean flue, locate source and correct  
3. Check with gas utility company  
4. Replace thermostat  
3. Low gas pressure  
4. Improper calibration  
5. Thermostat set too low  
6. Water heater too small  
7. Wrong piping connections  
8. Wasted hot water  
5. Turn temperature dial to desired setting  
6. Install adequate heater  
7. Correct piping-dip tube must be in cold inlet  
8. Advise customer  
DRIP FROM RELIEF VALVE 1. Excessive water pressure  
2. Heater stacking  
1. Use a pressure reducing valve and relief valve  
2. Lower the thermostat setting  
3. Closed water system  
3. See “Closed System/Thermal Expansion”  
THERMOSTAT FAILS TO  
SHUT-OFF  
1. Thermostat not functioning properly  
2. Improper calibration  
1. Replace thermostat  
2. Replace thermostat  
COMBUSTION ODORS  
1. Insufficient secondary air  
1. Provide ventilation to water heater. Check flue  
way, flue baffle, and burner  
2. Flue clogged  
2. Clean, locate source and correct  
3. Provide fresh air ventilation  
3. Heater installed in a confined area  
SMOKING AND CARBON  
FORMATION (SOOTING)  
1. Insufficient secondary air  
1. Provide ventilation to water heater. Check flue  
way, flue baffle, burner  
2. Low gas pressure  
2. Check with gas utility company  
3. Clean, locate source and correct  
4. Replace thermostat  
3. Flue clogged  
4. Thermostat not functioning properly  
5. Heater installed in a confined area  
6. Burner flame yellow-lazy  
5. Provide fresh air ventilation  
6. See “Burner Flame Yellow-Lazy”  
CONDENSATION  
1. Temperature setting too low  
1. Increase the temperature setting  
BURNER FLAME FLOATS  
AND LIFTS OFF PORTS  
1. Orifice too large  
2. High gas pressure  
3. Flue clogged  
4. Cold drafts  
1. Replace with correct orifice  
2. Check with gas utility company  
3. Clean flue and burner-locate source and correct  
4. Locate source and correct  
BURNER FLAME TOO HIGH 1. Orifice too large  
1. Replace with correct orifice  
FLAME BURNS AT ORIFICE 1. Thermostat not functioning properly  
2. Low gas pressure  
1. Replace thermostat  
2. Check with gas utility company  
PILOT FLAME  
TOO SMALL  
1. Pilot line or orifice clogged  
2. Low gas pressure  
1. Clean, locate source and correct  
2. Check with gas utility company  
25  
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PILOT LIGHT TROUBLESHOOTING CHART  
Section A: Pilot light will not light (new installation).  
Section C: Pilot light will not remain lit.  
Check for insufficient combustion air.  
Is the manual gas shut-off valve,  
located in the supply line to the  
water heater, in the on position?  
Turn the manual gas shut-off valve to  
the on position and follow the lighting  
instructions on the front of the water heater.  
NO  
Are the combustion air supply and ventilation openings  
of sufficient size? See Combustion Air Supply and  
Ventilation section in this manual for requirements.  
Correct size of  
openings to allow  
sufficient air.  
NO  
YES  
While repeatedly depressing the igniter  
button, push in and hold the gas control/  
temperature knob until the pilot is lit and  
maintains a stable flame, (status light  
will blink) then release the gas control/  
temperature knob.  
YES  
Have you bled all the air  
from the pilot tube and  
gas supply line?  
NO  
Is there a furnace/air handler in the same room as the water heater?  
NO  
YES  
YES  
Does the return air duct for the furnace/  
Contact a local Heating,  
Is the igniter producing a  
spark?  
NO  
air handler draw its air from a separate  
YES  
Ventilation, Air-Conditioning  
location than the water heater? See the  
Location Requirements section and the  
Combustion Air Supply section.  
NO  
& Refrigeration authorized  
service provider to correct  
the combustion air supply/  
ventilation issue.  
Follow the Testing the Igniter System  
section in this manual.  
Set thermostat to desired temperature.  
YES  
Check the vent  
Is there proper drafting at the  
system for restrictions/  
obstructions and check  
the vent termination  
height. Refer to the  
drafthood? See Checking the  
Draft section in this manual.  
NO  
NO  
Section B: Pilot light repeatedly goes out.  
Installation Instructions  
section of this manual for  
specific requirements.  
Refer to the Use &  
Remove the burner door  
Care Guide section  
of this manual for  
information on  
assembly. Are the flame-trap and  
burner free from debris due to  
excessive lint, dirt, dust or oil?  
Contact Customer Service at the number  
located on the front of this manual.  
NO  
cleaning the flame-  
trap and burner.  
YES  
NOTE: If you are still experiencing difficulties  
after following the steps in sections A, B, and C,  
please use the number located on the front of  
this manual to contact Customer Service.  
Does the flame-trap  
Reassemble the heater, press the thermal  
switch, and attempt to return the heater to  
service. Does the pilot remain lit?  
NO  
show signs of  
discoloration?  
YES  
YES  
NO  
Shut-off the gas supply to the water heater at the  
manual gas shut-off valve, and contact Customer  
Service using the number on the cover of this manual.  
Set to desired temperature.  
Thermal Switch Location  
Does the diagnostic status light on the  
gas control valve/thermostat give  
a two flash error code?  
YES  
NO  
Refer to the Replacing the Pilot  
Assembly instructions in the manual.  
Go to section C.  
Reassemble and restore to service.  
Thermal  
Switch  
26  
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REPAIR PARTS ILLUSTRATION  
1
5
4
2
3
8
6
When ordering repair parts always give the following  
information:  
1. Model, serial, and product number  
10  
2. Type of gas  
3. Item number  
4. Parts description  
7
9
11  
Repair Parts List  
Item  
Parts Description  
No.  
1
2
3
4
5
6
7
8
DRAFTHOOD  
REDUCER RING - SOME MODELS  
FLUE BAFFLE  
HEAT TRAP (COLD) - SOME MODELS  
HEAT TRAP (HOT) - SOME MODELS  
COLD WATER DIP TUBE  
ANODE ROD  
TEMPERATURE & PRESSURE RELIEF VALVE  
(LOCATED TOP OR SIDE)  
9
DRAIN VALVE  
10  
11  
GAS CONTROL VALVE/THERMOSTAT(with wire leads)  
OUTER DOOR  
12* PILOT ASSEMBLY KIT  
(Natural Gas)  
13  
BURNER (Natural Gas/Low Nox)  
14* MANIFOLD DOOR ASSEMBLY  
(Natural Gas/Low Nox)  
15* TWO PIECE WIRE CONNECTOR  
WITH RETAINER CLIP  
16* MANIFOLD DOOR GASKET  
17* VIEWPORT ASSEMBLY  
18* THERMISTORS  
LEGEND  
Special anode rod (see page 19)  
Temperature and Pressure Relief Valve is required,  
but may not be factory installed  
*Pictured on next page.  
Unique: Flame LockSafety System parts  
27  
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Listed Parts Kits and Illustrations  
Item 12: Pilot assembly kit, which contains the pilot assembly, thermopile, and retainer clip (Natural Gas)  
Item 13: Burner (Natural Gas/Low Nox)  
Item 14: Manifold door assembly which contains the manifold tube, gasket, door, pilot tube, thermopile, two piece wire  
connector with retainer clip, thermal switch, and pilot assembly. (Natural Gas/Low Nox)  
Item 15: Contains two piece wire connector and retainer clip  
Item 16: Contains manifold door gasket  
Item 17: Contains viewport  
Item 18: Contains replacement thermistors  
Item #18  
WHIRLPOOL, FLAME LOCK & DESIGN, and FLAME LOCK are trademarks of Whirlpool, U.S.A. © 2006 Whirlpool Corporation. All rights reserved.  
Manufactured under license by American Water Heater Company, Tennessee.  
28  
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