DIRECT VENT USER'S GUIDE GAS WATER HEATE For Your Safety AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER Model Numbers HJ640NBDS HJ640PBDS I-IJ650NBDS HJ650PBDS WARNING: If the information in these instructions are not followed exactly, a fire or explosion may result, causing property damage, personal injury or death. -Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. -WHAT TO DO IF YOU SMELLGAS • Do not try to light any appliance.
Safety Instructions &WARNING The water heater must be properly vented outdoors. Never operate the water heater unless it is vented to the outdoors and has adequate air supply to avoid risks of improper operation, explosion or asphyx ation. _,WARNING HYDROGEN GAS: Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable and explosive.
Table of Contents Safety Instructions ................................................................................................................................ 2-4 Table of Contents ......................................................................................... 5 Customer Information ........................................................................... 6 Product Specifications ................................................................................
Customer Information Thank You for purchasing a Maytag water heater, cannot put everything on the first few pages, READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER. The installation must conform with the instructions in this manual; gas company rules; and Local Codes, or in the absence ofLoca/Codes, with the current edition of the National Fuel Gas code, ANSI Z223.1, also referred to as NFPA 54.
Accessories and Tools Needed Accessories To simplify the installation Maytag has available the installa- tion parts shown below. You may or may not need alI of these accessoriesdependingon yourtypeof installation.Call Maytag Customer Service authorized installer.
Instructions for Installation Removing the Old Water Heater @ Turn "OFF" the gas supply to the water heater. @ iI WARNING If the main gas line shutoff servingall gas appliancesis used, alsoshut "OFF"the gasat eachappliance.Leaveall gasappliancesshut"OFF"untilthe waterheater nsta at on iscomplete, Disconnect the vent pipe from the draft hood, if provided, where they connect to the water heater. In most installations vent pipe(s) canare be removed.
Instructions for Installation (cont'd) Typical Installation CHECK ALL CONNECTIONS PRIETY AND SAFETY. FOR LEAKS.
Instructions for Installation (cont'd) Locating the New Water Heater • The location selection must provide adequateclearancesfor You should carefully choose an indoor location for the new water heater, because the placement is a very important consideration servicing and proper operation of the water heater. &WARNING [ for the safety of the occupants in the building and for the most economical use of the appliance. Thiswater heateris not foruse inmanu_ctured(mobile)homesoroutdoorinstallation.
Instructions for Installation (cont'd) Combustion Air and Ventilation When determining the installation location for a direct vent water heater, snow accumulation and drifting should be considered in areas where applicable. any overhang VENTING CLEARANCES 18"mJn. • 18" minimum in all directions from any obstruction that may interfere. I Figure2 ] • 18" minimum from the ground and 12" from ceiling overhangs. Figure 2.
Instructions for Installation (cont'd) Combustion Air and Ventilation (cont'd) Flue Extensions There are three optional extension kits available. Any combination of the three kits can be chosen; however, only one kit (See Figures 8 & 9.) can be used vertically and/or horizontally. 4_ /36" min.if withid" thisiarea \ e _ 36" min. within a 360° rad_ if vent is a forced air appliante outlet vent. Unless otherwise specified at the time of ordering, a standard shipped within the water heater carton.
Instructions for Installation (cont'd) I A r 66001423 66001424 [ 6600142S HORIZONTAL (EXTENSION KIT) simply plug the dimensions "D" and "G" into the equation ,_v-, [r_ _7_ below.size The answer "E" should then be located in chart the #2.
Instructions for Installation (cont'd) All Installations Furease ofassembly theinstalladon ofthe various kit Standard Vent Kit Installation #1 combinations has been broken into individual sections, The two steps below are common to all installations. Once these have been performed, you need only to refer Standard Vent Kit 66001422 o.ee oo.teoyou , Installation Using Vent Kits: 1. Standard Vent Kit 66001422 ........................... 2. Optional Vertical Vent Kit with Standard Vent Kit ...............
Instructions for Installation (cont'd) 3. Using the tube of sealant supplied, run an ample amount 6. The standard vent kit includes a 6° diameter extension around the oval flare of the jacket, pipe which is used when "E" dimension is over 6V2". 4. First remo e the 3 honzontaI extension from the elbow. X Starting with the long end (with four securing holes), place the 6" diameter vent elbow over the 3" diameter elbow. Bend the round end "oval_ to fit the flared oval end of the jacket top.
Instructions for Installation (cont'd) Standard Vent Kit (cont'd) 9. Place the water heater at the opening in the wall, at the predetermined clearance, 12. We have supplied 4 wood screws to temporarily attach the collar to the exterior wall of the building. However, other types of screws may have to be substituted depending on \\ \\ \\ \\ '\ \ 13.
Instructions for Installation (cont'd) 15. The vent cap has 4 holes around the outer edge. Remove the 4 screws used to temporarily attach the collar to the exterior wall. Then secure the vent cap assembly with the vent collar assembly to the exterior wall using the same 4 screws. NOTE: Screws are suppfied; however, substitution may be necessary depending on the exterior wall material.
Instructions for Installation (cont'd) Optional Vertical Vent Kit (Cont'd) Use the chart, drawing and simple equation below to find the length of expansion of the telescoping flue sections, Because of manufacturing tolerances, place the telescoping extension on the water heater and adjust the height ("X" Dimension) and mark the point. Once the length has been determined, lock the two sections together by 3. drilling holes (180" apart) in the pipe and securing with the two screws supplied.
Instructions for Installation (cont'd) 7. Place the 3" elbow on the flue extension. 10. If"E" Dimension is less than 61/2# move to next step. NOTE: Make sure elbow is properly aligned to opening If "E" dimension is over 6V:', assemble the 6" diameter in the outside wail. extension pipe to the 6" diameter vent elbow and secure Mark the 3" dia. end of the flue extension at the slots the using two sheet metal screws. Using the tube of sealant elbow.
Instructions for Installation (cont'd) Optional Vertical Vent Kit (cont'd) 13. Move outdoors with all the remaining vent pans. Using the tube of sealant supplied, run an ample amount on the inside surface of the collar assembly that will contact the exterior wall and also fill the bead on the end of the 6" diameter vent 16. Insert the 3" diameter flue extension pipe into the vent collar assembly (flared &.
Instructions for Installation (cont'd) Optional Horizontal Installation #3 19. Go back indoors to attach inside collar to the inside wall. Vent Kit Any Optional Vent Kit NOTE: supplied; however, substitution may lottgPlace 4sheet theScrews collaragainstthewaU.Secureto metaJ,are screws. waUbyusing be necessary depending on the interior wall material. ___ _ _ _ parts are not used These _ *Each part is stamped with a part number The opening through the wall should be cut at this time.
Instructions for Installation (cont'd) Optional (Cont'd) Horizontal Vent Kit 3. Using the mbe ofsealant supplied, run an ample amount around the oval flare of the jacket, 6. The standard kit includes a single piece of3" flue and 6" vent pipe which will not be used in conjunction with the horizontal kit. 4. First remove the 3" horizontal extension from the elbow. 7. Slide the vent collar (to be installed later) over the 6" vent elbow.
Instructions for Installation (cont'd) 9. Slide the 6" telescoping vent section apart to reveal the 12. Install the vent collar assembly through the wall, connect- beads, ing it to the 6" telescoping extension. Remember, the extension is not connected yet and it may be necessary to go back indoors and push it back up for a tight fit to the coUar. NOTE: The section of 6" pipe with beads will connect to the elbow. Using the caulking supplied, fill the beads, 10.
Instructions for Installation (cont'd) Optional Horizontal Vent Kit (cont'd) 15. The vent cap has 4 holes around the outer edge. Remove the 4 screws used to temporarily attach the collar to the exterior wall. Then secure the vent cap assembly with the vent coUar assembly to the exterior wall using the same 4 18. Using a #22 drill bit, drill holes 180 ° apart at the connection point of the two 3" flue extensions. Then using 2 screws provided, lock these pipes together. screws.
Instructions for Installation (cont'd) 21. Lock the 6" vent extension to the vent elbow by using Use the chart, drawing and simple equation below to find two screws provided, placiag them 1800 apart, the length of expansion of the telescoping flue sections. Because of manufacturing tolerances, place the telescop- _"/_' ("X" Dimension) and mark the point.
Installation Instructions (cont'd) Optional Vertical and Horizontal Vent Kits (cont'd) 3. Slide the 6" vent telescoping section apart to reveal the beads. Using the caulking supplied, fdl the beads, 6. Bend the round end of the 6" vent extension oval at the jacket tip and secure it using four sheet metal screws. 4. Uslng the tube of sealant supplied, run an ample amount around the oval flare of the jacket. _._ 7. Place the 3" elbow on the flue extenmon." in the outside wall. Mark the 3" dia.
Installation Instructions (cont'd) 9. Making sure the 6" diameter elbow is centered around the 3" diameter flue, secure the 6" diameter vent pipe using two sheet metal screws at the connection of the elbow and 6 M vertical extension. . . 11. Place the water heater at the opening in the waU, at the predetermined clearance. I 10. Slide the vent collar (to be installed later) over the 6" vent elbow. ¢ _ 12.
Instructions for Installation (cont'd) Optional Vertical and Horizontal Vent Kits (Cont'd) the tube of sealant supplied, run an ample amount on the inside surface of the collar assembly that will contact the / • , diameter vent collar, s // / _ _i t/ It exterior wall and also fiLlthe bead on the end of the 6" ////7 7.?/_--_/-2/L',-- / / N"_ }l_/_// _ I _\/7"x / / i 17. Place the vent cap in the vent collar assembly. it tothe thevent 6" telescoping extension. the 15.
Instructionsfor Installation (cont'd) 20. Collapse the 6" vent extension pipes as shown below and install the 3" extension by first sfipping the end with the O-ring approximately 1_/," into the end of the vent cap. 22. Now the 6" vent extension pipes can be expanded to connect at the vent elbow. Lock the other end of the 3" extension assembly to the ease ofasserably vent cap to the 3" pipe, a soap solution can be appfied to the O-ring gasket. studs in the NOTE: elbOW.
Instructions for Installation (cont'd) Water Piping AWARNING • Look at the top cover of the water heater. The water outlet is marked hot. Put two or three turns of teflon tape around the threaded end of the threaded-to-sweat coupling and around both ends of the 3/, ,, threaded nipple. Using flexible HOTTER WATER CAN SCALD: Water heaters are intended to produce hot water.
Instructions for Installation (cont'd) Temperature-Pressure Relief Valve AWARNING At the time of manufacture this water heater was provided with a combination temperature-pressuresrelief valve certified by a nationally recognizedtesting laboratory that maintains periodic inspection of production of listed equipment or materials, as meeting the requirements for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, and the current edition of ANSI z21.
Instructions for Installation (cont'd) Filling the Water Heater A CAUTION Never use this water heater unless it is completely filled with water. Toprevent damage to the tank, [ the tank must be filledwith water.
Instructions for Installation (cont'd) AWARNING I GAS PIPING Use pipe joint compound or teflon tape marked as ' being resistant to the action of petroleum [Propane (LR)]gases. I SEDIMENT FLEXIBLE heater CONNECTOR GAS SI. PPLY PIPING TRAP MANUAL SHUTOFF A sediment trap shall be installed as close to the inlet of the water WITH as practical at the time of water heater _ _ VALVE instaUa- tion.
Instructions for Installation (cont'd) Installation Checklist BEFORE LIGHTING THE PILOT: CHECK FOR LEAKS Check the gas lines for Ieaks. Be sure to check all your gas pipes for leaks before lighting a. Use a soapy water solution. using a match DO NOT test for gas leaks c. Check for bubbling on all gas pipes, joints Turn "OFF" gas and make the necessary d. Recheck for leaks, e. Rinse offsoapy soiution and wipe dry. "Temperature-Pressure • soapy water solution repairs.
Instructions for Operation AWARNING BEFORE LIGHTING [PROPANE (L.P.) GAS WATER HEATERS]: Propane (L.P.) gas is heavier than air. Should there be a leak in the system, the gas will settle near the ground. Basements, crawl spaces, skirted areas under manufactured (mobile) homes (even when ventilated), closets and areas below for the accumulato light or relight the water heater's pilot or turning on a nearby electrical light switch, be absolutely sure there is no accumulated gas in the area.
Instructions for Operation (cont'd) Lighting label on the water heater as it appears above the thermostat FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may resultcausing propertydamage, WARNING personal injury or loss of life. I A. Thisappliancehasa pilotwhichmustbe lightedby hand.Whenlighting thepilot,followtheseinstructions exactly. B.BEFORE LiGHTiNG smellallaroundtheappliance area for gas.
Instructions for Operation (cont'd) Temperature Regulation Due to the nature of the typical gas water heater, the water temperature in certain situations may vary up to 30°F higher or Turn the water temperature dial clockwise (_-"%) to decrease the temperature, or counterclockwise (("_) to lower at the point of use such as, bathtubs, showers, sink, etc. increase the temperature.
Service and Maintenance Venting System Inspection Burner Inspection AWARNING At least once a year a visual inspection should be made of the venting system.You should look for: Flood damage to a water heater may not be readily visible or immediately detectible. However, over a • Obstructions which could cause improper venting. The combustion and exhaust air flow must not be obstructed.
Serviceand Maintenance (cont'd) L.R Gas Control Valve & Burner Assembly Replacement Draining The water heater should be drained if being shut down during Information freezing temperatures. Also periodic draining and cleaning of AWARNING sediment from the tank may be necessary. PROPANE (L.P.) GAS CONTROL VALVE AN BURNER ASSEMBLY REPLACEMENT INFORMATION. • Turn tl_e gas control knob to the "OFF" position. For Propane (L.R) Gas Models Only: Your water heater is equipped with a Propane (L.
Service and Maintenance (cont'd) Temperature-Pressure Relief Valve Operation Drain Valve Washer Replacement The temperature-pressure ated at least once a year. NOTE: For replacement, use a W_"x Wd'x ½" thick washer available at your nearest hardwa_ store. For ordering replacement washers, refer to the "Repair Parts List" section. rellef valve must be manually oper- TEMPERATURE-PRESSURE 1. Turn "OFF" gassupply to water heater. 3. Turning counter clockwise, remove the hex cap below the screw handle, 4.
Troubleshooting Start Up Conditions CONDENSATION THERMAL Whenever the water heater is ftUedwith cold water, a certain amount of condensation will form while the burner is on. A water heater may appear to be leaking when in fact the water is condensation. This usually happens when: When a new water heater is filled with cold water for the first time.
Troubleshooting (cont'd) Operational Conditions SMELLY WATER HIGH TEMPERATURE SHUT OFF SYSTEM In each glasslined water heater there is installed at least one anode rod (see parts section) for corrosion protection of the tank. Certain water conditions will cause a reaction between This water heater is equipped with an automatic gas shut off system. The high temperature shut offis built into the gas control valve. This system shuts offthe gas supply to the this rod and the water.
Troubleshooting (cont'd) WATER IS TOO HOT 1. The temperature adjustment dial may be set too high, See the "Temperature Adjustment" section. NOTE: A period of time is necessary after an adjustment has been made for the water temperature m reach the new temperatu_ setting. 2. If lower temperature settings wil/not lower the water temperature, call Mayt'ag Customer Service (1-800-788-8899) for an authorized servicer.
Troubleshooting (cont'd) Leakage Checkpoints Use this guide to check a "Leaking" water heater. Many suspected "Leakers" are not leaking tanks. Often the source of IRead this manual _efore checking the | ]water heater make sure the gas supply hasbeen] I turned "OFF", and never turn the gas "ON" before the water can be found and corrected.
Notes 45
Repair Parts List MAYTAG GAS WATER HEATERS MODEL NUMBERS: HJ640NBDS HJ640PBDS 40 Gallon Natural Gas 40 Gallon Propane (L.R) Gas 6" I.D. VENT PIPE 6" O.D. VENT EXTENSIONPIPE 27 29 37 43 HJ650NBDS HJ650PBDS O-RINGGASKET 30 35 41 3_ FLUEPIPE 24 33 39 45 Standard Vent Kit: 6,,,° I 50 Gallon Natural Gas 50 Gallon Propane (L.R) Gas 3" FLUEEXTENSIONPIPE 31 36 42 ROPEGASKET 25 28 34 40 26 32 38 44 66001422]--_ EXTENSION / _ 6" O.D. VENT PIPE _ _:_'_.
Repair Parts List (cont'd) MAYTAG GAS WATER HEATERS MODEL NUMBERS: HJ640NBDS 40 Gallon Natural Gas HJ640PBDS 40 Gallon Propane (L.P.) Gas HJ650NBDS HJ650PBDS 50 Gallon Natural Gas 50 Gallon Propane (LR) Gas Model Number KEY NO. HJ640NBDS PARTDESCRIPTION HJ640PBDS HJ650NBDS PARTNUMBERS HJ6SOPBDS 1. 2. 3. AccessDoor Clips (Pkg. 2) Right AccessDoor w/Gasket Left Access Door w/Gasket 66001204 66001205 66001206 66001204 66001205 66001206 66001204 66001205 66001206 66001204 66001205 66001206 4.
Repair Parts List (cont'd) MAYTAG GAS WATER HEATERS MODEL NUMBERS: HJ640NBDS HJ640PBDS 6" I.D. VENT PIPE 40 Gallon Natural Gas 40 Gallon Propane (L.P.) Gas 6" O.D. VENT EXTENSIONPIPE 27 29 37 43 HJ650NBDS HJ650PBDS O-RINGGASKET 30 35 41 3"FLUEPIPE 24 33 39 45 Standard Vent Kit: 6 ID 25 28 34 40 II_i__/_ '_1_=4 t49 _1 _-,_1_ \'_ _ _)1 _f_'_47 _ _ _1_ _J, _ I _<_1 _ _' • .
Repair Parts List (cont'd) MAYTAG GAS WATER HEATERS MODEL NUMBERS: HJ640NBDS HJ640PBDS 40 Gallon Natural Gas 40 Gallon Propane (L.R) Gas HJ650NBDS HJ650PBDS 50 Gallon Natural Gas S0 Gallon Propane (L.R) Gas Model Number KEY NO HJ640NBDS PARTDESCRIPTION Standard Kit No. 66001422 HJ640PBDS HJ650NBDS PARTNUMBERS HJ650PBDS 24. 25. O-Rin_ Gasket 3" I.D. x 9½" Flue Extension Pipe w/Gaskets 66001207 66001208 66001207 66001208 66001207 66001208 66001207 66001208 26.
Repair Parts List (cont'd) MAYTAG GAS WATER HEATERS M AYTAG/STATE PART NUMBER CONVERSION KEY MAYTAG STATE 66001004 9002123 66001011 9001609 66001012 9001608 66001013 ETC2X 66001014 ETC5X 66001021 9001584 66001025 0230120 66001027 9002411 66001029 9000281 66001035 0230141 66001037 9002413 66001040 0230223 66001041 0230224 66001044 9002415 66001068 9001453 66001105 9002769 66001157 9000029 66001159 0230125 66001172 0230225 66001181 9000058 66001183 9000249 66001185 9000349 66001188 9000278 66001192 9000285 6
Notes 51
Warranty FULL ONE YEAR WARRANTY For One Year from the date of Original Retail Purchase, any part which fails in normal home use will be repaired or replaced free of charge. If a leak occurs in the Tank, a new water heater of the closest capacity and quality then available, will be replaced flee of charge. The warranty of the replacement is the balance of the original water heater's Warranty.
