A. O. Smith Standard ResidentialGas Installation Manual

ManualsBrandsAO Smith ManualsPlumbingSMI GCG-50LP ProMax 300/301 50 Gallon Liquid Propane Water Heater

100263112

January 2015

Residential Gas

Water Heater

Installa on Instruc ons and

Use & Care Guide

Keep this manual in the pocket on heater for future reference whenever maintenance, adjustment or service is required.

Retain your original receipt as proof of purchase.

Residen al Atmospheric Gas Water Heater

with the Flammable Vapor Igni on Resistant

Safety System

Read this manual and the labels on the water heater before you install,

operate, or service it. If you have diﬃ culty following the direc ons, or

aren’t sure you can safely and properly do any of this work yourself:

• Call our Technical Assistance Hotline at 1-800-527-1953 . We can help you with in-

stalla on, opera ons, troubleshoo ng, or maintenance. Before you call, write down

the model and serial number from the water heater’s data plate.

Incorrect installa on, opera on, or service can damage the water heater, your house

and other property, and present risks including ﬁ re, scalding, electric shock, and

explosion, causing serious injury or death.

Do not store or use gasoline or other

ﬂ ammable vapors and liquids in the

vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch;

do not use any phone in your build-

ing.

• Immediately call your gas supplier

from a neighbor’s phone. Follow the

gas supplier’s instruc ons.

• If you cannot reach your gas sup-

plier, call the ﬁ re department.

Installa on and service must be per-

formed by a qualiﬁ ed installer, service

agency or the gas supplier.

WARNING: If the informa on in

these instruc ons is not followed

exactly, a ﬁ re or explosion may

result causing property damage,

personal injury or death.

LOW LEAD

CONTENT

Table of Contents Page

IMPORTANT SAFETY INFORMATION ............................................. 3

GETTING STARTED ........................................................................ 7

INSTALLATION ............................................................................. 14

OPERATION ................................................................................. 23

TROUBLESHOOTING ................................................................... 25

MAINTENANCE ........................................................................... 28

NOTES ......................................................................................... 31

REPAIR PARTS ............................................................................. 35

Summary of content (36 pages)

PAGE 1
Installa on Instruc ons and Use & Care Guide Residential Gas Water Heater Residen al Atmospheric Gas Water Heater with the Flammable Vapor Igni on Resistant Safety System Read this manual and the labels on the water heater before you install, operate, or service it. If you have diﬃculty following the direc ons, or aren’t sure you can safely and properly do any of this work yourself: • Call our Technical Assistance Hotline at 1-800-527-1953.
PAGE 2
COMPLETED INSTALLATION TYPICAL Vent pipe Cold water shut oﬀ Expansion tank (Connect to cold water supply) Hot water line Cold water line Dra hood T&P relief valve T&P discharge pipe Gas supply shut oﬀ Drain valve Gas supply Drain pan discharge pipe Gas control valve/thermostat Sediment Trap Metal drain pan
PAGE 3
Read and follow all safety messages and instruc ons in this manual. This is the safety alert symbol. It is used to alert you to poten al physical injury hazards. Obey all safety messages that follow this symbol to avoid possible property damage, serious injury or death. Do not remove any permanent instruc ons, labels, or the data plate from either the outside of the water heater or on the inside of the access panels. Keep this manual near the water heater.
PAGE 4
SAFETY IMPORTANT SAFETY INFORMATION T o reduce the risk of property damage, serious injury or death, read and follow the precau ons below, all labels on the water heater, and the safety messages and instruc ons throughout this manual. RISKS DURING INSTALLATION AND MAINTENANCE Li ing Risk WARNING! The water heater is heavy. Follow these precauons to reduce the risk of property damage, injuries from li ing or impact injuries from dropping the water heater.
PAGE 5
• • If the water supplied to the water heater is pre-heated (for example, by a solar system) the temperature in the tank may be higher than the water heater’s temperature se ng. Should overhea ng occur or the burner fail to shut oﬀ, turn oﬀ the manual gas supply valve to the water heater and call a qualified person. To reduce the risk of unusually hot water reaching the fixtures in the house, install Thermosta c Mixing Valves at each point-of-use.
PAGE 6
SAFETY IMPORTANT SAFETY INFORMATION if the T&P Relief Valve or discharge pipe is blocked. Do not cap or plug the T&P Relief Valve or discharge pipe. instruc ons. When the installa on is complete, check the vent’s dra using the instruc ons on pages 23-24. Fire and Explosion Risk if Hot Water is Not Used for Two Weeks or More. • Install a fuel gas and carbon monoxide detector in the living areas of your home.
PAGE 7
GETTING STARTED This water heater is designcer fied by CSA Interna onal as a Category I, non-direct vented water heater which takes its combus on air either from the installaon area or from air ducted to the unit from the outside. This water heater must be installed according to all local and state codes or, in the absence of local and state codes, the “Na onal Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edi on. This is available from the following: 2 CSA America, Inc.
PAGE 8
GETTING STARTED Example: GETTING STARTED Gas Burning Appliance BTU/HR Ra ng Gas Water Heater 40,000 Furnace 75,000 Dryer 20,000 Total 135,000 Your Appliances: Gas Burning Appliance BTU/HR Ra ng Gas Water Heater Total Table 2 provides examples of minimum square footage (area) required for various BTU/HR totals. Areas used for storage or which contain large objects containing less air than is assumed for the room sizes in Table 2 – see Op on A for more specific calcula ons.
PAGE 9
GETTING STARTED A water heater installed in an unconfined a c or garage requires that the space be at least 50 cubic feet per 1,000 BTU/ HR of the total input for all gas burning appliances in the same area. [Total BTU/HR/1000] x 50 = Cubic feet of air required. Example: (135,000 / 1000) x 50 = 6,750 If the air volume of the room is less than the required air volume, you must provide two permanent outside air openings that draw in suﬃcient air. Use Op on B. mum free area is sized according to Table 3.
PAGE 10
GETTING STARTED GETTING STARTED covering (in decimals – e.g., 60% = .6) For example, an installa on area that requires openings with 100 square inches of free area would need 134 square inch openings if using metal louvers rated at 75% free area (100 sq. in. ÷ .75 = 134 sq. in.).
PAGE 11
Ven ng Installing a New Vent System WARNING! Carbon Monoxide Hazard. This water heater must be supplied with adequate air and vented to outdoors. The vent system must be installed by a qualified person. Examples of a qualified person include gas technicians, authorized gas company personnel, and authorized service technicians. Failure to properly vent the water heater can result in severe injury or death from carbon monoxide poisoning.
PAGE 12
GETTING STARTED GETTING STARTED • The vent pipe must be firmly attached and sealed to prevent it from falling out. • To aid in removing the vent pipe, a thimble or slip joint may be used. • The vent pipe must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney. Ver cal Termina on NOTICE: The gas vent must be terminated in a ver cal posi on to facilitate the removal of exhaust gases.
PAGE 13
GETTING STARTED Space Hea ng TYPICAL MIXING VALVE INSTALLATION COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM EXPANSION TANK TEMPERED WATER TO FIXTURES (MUST MEET TEMPS LISTED IN MASS. CODE 248 CMR † ) CHECK VALVE † The domes c hot water line from the water heater should be ver cal past any mixing valve or supply line to the air handler to remove air bubbles from the system. Otherwise, these bubbles will be trapped in the air handler heat exchanger coil, reducing eﬃciency.
PAGE 14
INSTALLATION Step 1: ✓ INSTALLATION Verify that your home is equipped and up-to-date for proper opera on Installing a new water heater is the perfect me to examine your home’s plumbing system and make sure the system is up to current code standards. There have likely been plumbing code changes since the old water heater was installed. We recommend installing the following accessories and any other needed changes to bring your home up to the latest code requirements.
PAGE 15
INSTALLATION A Thermal Expansion Tank is a prac cal and inexpensive way to help avoid damage to the water heater, washing machine, dishwasher, ice maker, and even toilet valves. If your toilet occasionally runs for no apparent reason (usually briefly at night), that may be due to thermal expansion increasing the water pressure temporarily. ✓ Water Pipe and Tank Leaks • Install an automa c leak detecon and shutoﬀ device (available at your local plumbing supplier).
PAGE 16
INSTALLATION Step 2: Verify that the loca on is appropriate INSTALLATION WARNING! Do not store or use flammable materials, vapors, or liquids in the same loca on where this water heater is installed. Before installing your water heater, ensure that it will be located: • Indoors in an area with adequate air supply. • In an area that will not freeze. • As close as possible to a chimney or vent. • In a metal drain pan piped to an adequate drain. • In an area suitable for ver cal installa on.
PAGE 17
INSTALLATION 2 On the old water heater, turn the control knob on the gas control valve to the OFF posi on. drain, outside, or in buckets. (Sediment in the bo om of the tank may clog the valve and prevent it from draining. If you can’t get the tank to drain, contact a qualified person.) Turn the cold water supply valve OFF. 6 Figure 21 - Removing the T&P Relief Valve discharge pipe. Gas control knob 3 4 Turn the manual gas valve for the water heater’s supply line OFF.
PAGE 18
INSTALLATION line is turned oﬀ. Disconnect the gas line from the water heater’s gas control valve and cap it. 13 Remove the old water heater. Use an appliance dolly or hand truck to move the water heater. WARNING! Use two or more people to remove or install a water heater. Failure to do so can result in back or other injury. Step 4: Installing the New Water Heater Completely read all instrucons before beginning.
PAGE 19
INSTALLATION Step 7: Step 6: Install Shutoﬀ and Thermosta c Mixing Valves Connect the Temperature and Pressure (T&P) Relief Valve/Pipe Figure 26 - Temperature and Pressure Relief Valve Pipe • • Figure 25 - Temperature and Pressure Relief Valve WARNING! To avoid serious injury or death from explosion, install a T&P Relief Valve according to the following instruc ons: If the T&P Relief Valve was not factory installed, install the new T&P Relief Valve that came with your water heater.
PAGE 20
INSTALLATION For water heaters that are fed by a solar water hea ng system (or any other prehea ng system), always install a Thermosta c Mixing Valve or other temperature limi ng device in the inlet water supply line to limit water supply inlet temperature to 120°F. Solar water hea ng systems can supply water with temperatures exceeding 180°F and may result in water heater malfunc on.
PAGE 21
INSTALLATION NOTICE: Most water heater models contain energy saving heat traps in the inlet and outlet connec ons. Do not remove the heat traps. Connect the hot water supply using 3/4 inch NPT to the fi ng marked “H” (HOT). Install insula on (or heat tape) on the water pipes especially if the indoor installa on area is subject to freezing temperatures. Insula ng the hot water pipes can increase energy eﬃciency.
PAGE 22
INSTALLATION Step 11: Make Gas Connec ons INSTALLATION The Gas Water Heater Hook-Up Kit (available at your local plumbing supplier) includes a flexible gas connector with compression fi ngs to connect the home’s gas line to the water heater’s gas control valve. Follow the kit’s installa on instruc ons to a ach the flexible gas connector. surfaces maintained and suﬃcient room to service the water heater.
PAGE 23
OPERATION WARNING! Explosion Hazard – Replace viewport if glass is missing or damaged. Failure to do so can result in death, explosion or fire. Read and understand these direc ons thoroughly before a emp ng to light or re-light the pilot. Make sure the viewport is not missing or damaged. Make sure the tank is completely filled with water before ligh ng the pilot. Check the data plate near the gas control valve to ensure the correct gas type.
PAGE 24
OPERATION Allow the water heater’s main burner to operate for five minutes. Pass a newly ex nguished match approximately one inch from the dra hood’s relief opening. Smoke from the match should be steadily drawn into the opening indicating the water heater is ge ng adequate air and the vent system is working. 3 Temperature Control System Adjus ng the Temperature With the installa on steps completed, you may adjust the water heater’s temperature se ng if desired.
PAGE 25
TROUBLESHOOTING No Hot Water Use the following step-by-step plan as a guide to help determine why you have no hot water: 1 Check the Status Light The Status Light on the gas control valve flashes once every three seconds if the pilot is lit and the gas control valve has not detected any problems. 3 Checking the Pilot Light Check the spark igniter. Dim the room lights and look through the viewport while clicking the igniter bu on.
PAGE 26
TROUBLESHOOTING plumbing system can make it appear that the water heater is producing li le to no hot water. In this case, the burner will be on all or almost all the me, yet you will have very li le hot water. Locate and repair the leak. Sediment or Lime in Tank. With an exis ng water heater, if you have some hot water but not as much as you’re used to, there may be a build up of sediment or lime on the bo om of the tank. Sediment or lime build up can reduce the eﬃciency of your water heater.
PAGE 27
TROUBLESHOOTING TROUBLESHOOTING Residen al Standard Gas Water Heater Use and Care Guide • 27
PAGE 28
MAINTENANCE Rou ne Maintenance Rou ne maintenance will help your water heater last longer and work better. If you can’t perform these rou ne maintenance tasks yourself, contact a qualified person. 3 Open a hot water faucet and let the hot water run un l it is cool (This may take 10 min utes or longer). Remove and inspect the anode rod and replace if depleted. The anode rod requires a 1-1/16” socket.
PAGE 29
MAINTENANCE discharge pipe, turn the gas control knob to the OFF posi on and call a qualified person to determine the cause. Relight the pilot using the instruc ons on page 23 and adjust the gas control knob to the desired temperature. It may take an hour or more for the tank of cold water to heat up. 11 Visual Inspec on • Figure 44 - Burner Flames • Leaking or damaged water and gas piping. • Remove any flammable, corrosive or combus ble materials near the water heater.
PAGE 30
MAINTENANCE Removing and Replacing the Gas Control Valve/Thermostat gas control valve/thermostat. NOTE: L.P. Gas systems use reverse (le -hand) threads on the manifold tube. 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: Turn the gas control/temperature knob to the “OFF” posi on. Figure 56 - Gas control/valve with threaded pipe. 1 B C D A Figure 52 - Gas valve connections.
PAGE 31
NOTES NOTES Residen al Standard Gas Water Heater Use and Care Guide • 31
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NOTES NOTES 32 • Residen al Standard Gas Water Heater Use and Care Guide
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NOTES NOTES Residen al Standard Gas Water Heater Use and Care Guide • 33
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NOTES NOTES 34 • Residen al Standard Gas Water Heater Use and Care Guide
PAGE 35
REPAIR PARTS Replacement parts may be ordered through your plumber or the local distributor. Parts will be shipped at prevailing prices and billed accordingly.
PAGE 36
REPAIR PARTS Listed Parts Kits and Illustrations Item 12: Pilot assembly kit, which contains the pilot assembly, thermopile, and retainer clip (Natural Gas or L.P.) Item 13: Final burner assembly which contains the burner, orifice, manifold tube, gasket, door, pilot tube, thermopile, manifold component block with retainer clip, thermal switch, and pilot assembly. (Natural Gas/Low Nox or L.P.) REPAIR PARTS Item 14: Contains manifold door gasket Item #12 Item #13 (Natural Burner) Item #13 (L.P.