® Ultra Low Nox 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 Location Requirements 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 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.
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 WARNING 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. Figure 3 Gas Piping Explosion Hazard Manual Gas Shut-off Valve Use a new CSA approved gas supply line.
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.
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 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.
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.
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” section). It is important that you follow the guidelines in these instructions for sizing a vent pipe system.
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. • Listed Lined Chimney 3 ft.
Water System Piping 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. 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.
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. The Temperature & Pressure Relief Valve: • Must not be in contact with any electrical part. • Must be connected to an adequate discharge line.
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.
White Rodgers Gas Valve - Lighting Instructions FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance has a pilot which is lighted by a piezoelectric igniter. When lighting the pilot, follow these instructions exactly. B. BEFORE LIGHTING smell all around the appliance area for gas.
Burner Flames Inspect burner flames through Figure 18 Flame Characteristics viewport. Flames should be very small Correct flame soft blue with a blue haze and small amounts of yellow or orange at the edges. After several minutes of operation the burner screen may glow red. If large flames are observed at anytime shut-off unit and call a qualified person. IMPORTANT: Adjusting the thermostat past 120°F on the temperature dial will increase the risk of scald injury in the times shown below.
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. Close the cold water inlet valve. 3. Open a nearby hot water faucet. 4.
Natural Gas Burner (Ultra Low Nox) 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. item number 3.
Replacing the Thermocouple 1. Remove the Burner Door 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 assembly (Figure 25). 3. Pull the thermocouple from the pilot assembly (Figure 29). IMPORTANT: Be careful not to bend or alter the position of the pilot assembly components. 4. Push the new thermocouple through the holes in the pilot bracket.
Replacing the Burner Door Assembly WARNING 7. 8. 9. 10. Explosion Hazard 7/16” open end wrench will then be sufficient to seat the lockwasher. Reconnect the igniter wire. Turn gas supply on and refer to the “Lighting Instructions”. Check for leaks by brushing on an approved noncorrosive leak detection solution. Bubbles will show a leak. Correct any leak found. Replace the outer door. Figure 28 Burner Door Assembly Tighten both manifold door screws securely.
Removing and Replacing the Gas Control Valve/Thermostat IMPORTANT: The gas control valve/thermostat is a standard valve with a right-hand thread thermocouple. Use only factory authorized replacement parts. Removing the Gas Valve: 1. Turn the gas control knob on the combination gas control valve/thermostat clockwise to the “OFF” position. NOTE: Depress the dial stop on Robertshaw valves before turning the gas control knob. See Lighting Instructions on the water heater. 2.
PROBLEM POSSIBLE CAUSE(S) PILOT WILL NOT REMAIN LIT 1. 2. 3. 4. 5. 6. 7. CORRECTIVE ACTION 10. Pilot dirty Bleed the air from the gas line Notify utility-install dirt trap in gas line Clean, locate source and correct Finger tighten; then 1/2 turn with wrench Replace thermocouple Locate source and correct Eliminate flammable vapor source(s) Call 1-877-817-6750 8. Check with gas utility company 9. See maintenance section for inspection and cleaning of flame-trap & burner 10.
PILOT LIGHT TROUBLESHOOTING CHART Section A: Pilot light will not light. Is the gas turned on? NO YES Have you bled all the air from the pilot tube and gas supply line? Section B: Pilot light will not remain lit or repeatedly goes out. Check the manual gas shut-off valve to see if it is in the open position, if it is open then contact the gas utility company.
REPAIR PARTS ILLUSTRATION 5 Alternate anode location for top T&P 4 1 6A Anode location for side T&P 6B 2 8 When ordering repair parts always give the following information: 1. Model, serial, and product number 2. Type of gas 3 10A 7 10B 3. Item number 4. Parts description 9 Repair Parts List Item No.
Listed Parts Kits and Illustrations Item 12: Pilot assembly which contains the pilot assembly and igniter electrode. (Natural Gas) Item 13: Burner Door assembly which contains the burner, gasket, door, pilot tube, two piece wire connector with retainer clip, and pilot assembly.
