Residential Gas Water Heater with the Flame Lock® Safety System Installation Instructions and Use & Care Guide WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance.
WATER HEATER SAFETY Your safety and the safety of others are very important. We have provided many important safety messages in this manual and on your appliance. Always read and obey all safety messages. This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others. All safety messages will follow the safety alert symbol and either the word “DANGER” or “WARNING.
INSTALLING YOUR GAS WATER HEATER Important Information About This Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation environments. Please review the Installation Checklist found at the end of the installation instructions section and make any required installation upgrades or changes.
WARNING FLAMMABLES Flammable Vapors FIRE AND EXPLOSION HAZARD Can result in serious injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. 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. Read and follow water heater warnings and instructions. Location Requirements WARNING heater.
IMPORTANT: The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure. Due to the normal corrosive action of the water, the tank will eventually leak after an extended period of time. Also any external plumbing leak, including those from improper installation, may cause early failure of the tank due to corrosion if not repaired.
Gas Supply Figure 3 Gas Piping Manual Gas Shut-off Valve WARNING Ground Joint Union Check with local utility for minimum height 3” Minimum 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. Do not connect an L.P. gas water heater to a natural gas supply. Failure to follow these instructions can result in death, explosion, or carbon monoxide poisoning.
BTU/HR. Combustion Air Supply and Ventilation WARNING Carbon Monoxide Hazard Water heater must be vented to outdoors. Vent must be installed by a qualified person using the installation instructions. Examples of a qualified person include: gas technicians, authorized gas company personnel, and authorized service persons. Failure to follow these instructions can result in death or carbon monoxide poisoning. IMPORTANT: Air for combustion and ventilation must not come from a corrosive atmosphere.
Unconfined Space A water heater in an unconfined space uses indoor air for combustion and requires at least 50 cubic feet for each 1,000 BTU/HR of the total input for all gas appliances. The table below shows a few examples of the minimum square footage (area) required for various BTU/HR inputs.
All Air from Outdoors Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and horizontal ducts. The fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors. Attic or crawl spaces cannot be closed and must be properly ventilated to the outside. Ductwork must be of the same cross-sectional area as the free area of the opening to which they connect.
Figure 9 Draft hood Installation Alternative Opening Location Sheet Metal Screws (four provided) Draft hood Legs Confined Space 1 sq. Inch Per 3000 BTU/HR Legs Slot Jacket top Slot Install the draft hood with the four screws provided. Vent Pipe Size Figure 8B All Air from Outdoors Using a Single Permanent Opening It is important that you follow the guidelines in these instructions for sizing a vent pipe system.
Chimney Connection Listed Lined Chimney IMPORTANT: Before connecting a vent to a chimney, make sure the chimney passageway is clear and free of obstructions. The chimney must be cleaned if previously used for venting solid fuel appliances or fireplaces. Also consult local and state codes for proper chimney sizing and application or, in the absence of local and state codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition.
Water System Piping Piping Installation Piping, fittings, and valves should be installed according to the installation drawing (Figure 13). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation. The water supply pressure should not exceed 80 psi. If this occurs, a pressure reducing valve with a bypass should be installed in the cold water inlet line.
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.
Temperature and Pressure Relief Valve WARNING 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.
Special Applications Combination Space Heating/Potable Water System Some water heater models are equipped with inlet/outlet tappings for use with space heating applications. If this water heater is to be used to supply both space heating and domestic potable (drinking) water, the instructions listed below must be followed. • Be sure to follow the manual(s) shipped with the air handler system. • This water heater is not to be used as a replacement for an existing boiler installation.
Important Information About This Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. The new technology used in meeting these standards makes this product more sensitive to installation errors. Please review the following checklist and make any required installation upgrades or changes. Questions? Call 1-877-817-6750.
OPERATING YOUR WATER HEATER Lighting Instructions WARNING Read and understand these directions thoroughly before Explosion Hazard 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.
L.P.G. (Bottled Propane) Models Burner Flames Liquefied petroleum gas is over 50% heavier than air and in the occurrence of a leak in the system, the gas will settle at floor level. Basements, crawl spaces, skirted areas under mobile homes (even when ventilated), closets and areas below ground level will serve as pockets for the accumulation of gas. Before lighting an L.P. gas water heater, smell all around the appliance at floor level.
Water Temperature Regulation WARNING 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 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 at the “HOT” setting.
Operating the Temperature Control System Figure 19B: Status Codes List of status codes are shown at top of gas control valve/thermostat. Status Light Code Normal Flashes: • 0 Flashes Indicates Control Off/Pilot Out. • 1 Flash Indicates Normal Operation. • Continuous Light indicates the gas control valve/thermostat is shutting down. Diagnostic Flashes: If the water heater is not working look for the following diagnostic flashes after lighting the pilot.
Operational Conditions Condensation Moisture from the products of combustion condenses on the tank surface and the outside jacket of the water heater and forms drops of water which may fall onto the burner or other hot surfaces. This will produce a “sizzling” or “frying” noise. NOTE: This condensation is normal and should not be confused with a leaking tank. Condensation may increase or decrease at different times of the year.
MAINTENANCE OF YOUR WATER HEATER Draining and Flushing It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during operation. The water heater should be drained if being shut down during freezing temperatures. To drain the tank, perform the following steps: Temperature and Pressure Relief Valve WARNING 1. Turn off the gas to the water heater at the manual gas shut-off valve. 2. Open a nearby hot water faucet until the water is no longer hot. 3.
Replacement Parts IMPORTANT: The following maintenance procedures are for the Flame Lock® Safety System components and should be performed by a qualified person. Replacement parts may be ordered through your plumber or the local distributor. Parts will be shipped at prevailing prices and billed accordingly. When ordering replacement parts, always have the following information ready: 1. model, serial, and product number 2. type of gas 3. item number 4.
Replacing the Pilot/Thermopile Assembly 1. Remove the manifold assembly as directed previously. 2. Lift the retainer clip straight up from the back of the manifold component block (using a flat-blade screwdriver), then remove the manifold component block from the manifold door (Figure 25). Thermopile Connector Figure 25 Manifold Component Block Assembly Burner and other fittings not show for clarity. White Wire Igniter Wire Manifold Component Block Red Wire Pilot Tube Manifold Door 4.
Cleaning the Combustion Chamber and Flame-trap 1. Follow procedure outlined in “Removing the Manifold Assembly”. 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. 3. Reassemble following the procedure under “Replacing the Manifold Assembly”. 9. Check for leaks by brushing on an approved noncorrosive leak detection solution. Bubbles forming indicate a leak.
Removing and Replacing the Gas Control Valve/Thermostat IMPORTANT: The gas control valve/thermostat is a standard valve with wire leads that connect to a thermal switch. Removing the Gas Control Valve/Thermostat: 1. Turn the gas control/temperature knob to the “OFF” position (Figure 19A). 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” and follow the procedure. 4.
PROBLEM PILOT WILL NOT LIGHT OR REMAIN LIT (continued) POSSIBLE CAUSE(S) 14. Flammable vapors incident, Flame Lock® function utilized 11. Clean, locate source and correct 12. Replace thermopile 13. See maintenance section for inspection and cleaning of flame trap 14. Replace water heater, eliminate flammable vapors source. Call 1-877-817-6750 1. 2. 3. 4. 5. 6. 7. 8. 9.
STATUS LIGHT CODE TROUBLESHOOTING CHART LED STATUS 0 FLASHES (LED NOT LIT) PROBLEM CORRECTIVE ACTION Pilot light is not lit. Not enough power (millivolts) to keep it lit. Follow the lighting instructions on the front of the water heater and record any diagnostic codes. See Diagnostic Status Light Code section. 1 FLASH (EVERY 3 SECONDS) Normal operation. No corrective action necessary. 2 FLASHES Insufficient power (millivolts) to the 1. gas control valve/thermostat. 2. Check all wiring connections.
PILOT LIGHT TROUBLESHOOTING CHART Section A: Pilot light will not light (new installation). Is the manual gas shut-off valve, located in the supply line to the water heater, in the on position? YES Have you bled all the air from the pilot tube and gas supply line? YES NO 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.
REPAIR PARTS ILLUSTRATION 1 5 4 2 8 3 6 When ordering repair parts always give the following information: 1. 2. 3. 4. Model, serial, and product number Type of gas Item number Parts description 10 9 Repair Parts List Item No.
Listed Parts Kits and Illustrations Item 12: Pilot assembly kit, which contains the pilot assembly, thermopile, and retainer clip (Natural Gas) Item 12: Pilot assembly kit, which contains the pilot assembly, thermopile, and retainer clip (L.P. Gas) Item 13: Burner (Natural Gas/L.P. Gas) Item 13: Burner (L.P. Gas) Item 14: Manifold door assembly which contains the manifold tube, gasket, door, pilot tube, thermopile, manifold component block with retainer clip, thermal switch, and pilot assembly.
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