A.O. Smith FDV User manual

1
Thank you for buying this energy efficient water heater from
A.O. Smith Water Products Company. We appreciate your
confidence in our products.
CAUTION
TEXT PRINTED OR OUTLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY.
PLEASE READ THOROUGHLY BEFORE
INSTALLING AND USING THIS APPLIANCE.
PART NO. 183310-000
SUPERSEDES PART NO. 182857-000 REV. 1
PRINTED IN U.S.A. 2560 999
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
RESIDENTIAL GAS WATER HEATERS
OWNER'S MANUAL
A DIVISION OF A.O. SMITH CORPORATION
www.hotwater.com
GET TO KNOW YOUR WATER HEATER 2
GENERAL SAFETY INFORMATION 3
INSTALLATION 3 -8
OPERATION 8 -10
MAINTENANCE AND
TROUBLESHOOTING 10 -11
WARRANTY 12
TABLE OF CONTENTS
PAG E
DIRECT VENT
GAS MODELS
FDV

2
GET TO KNOW YOUR WATER HEATER
REPLACEMENT PARTS
Replacement parts may be ordered through authorized servicers
or distributors. Refer to the Yellow Pages for where to call or contact
A. O. Smith Water Products Company, 5621 W. 115th Street, Alsip,
IL 60803, 1-800-433-2545. When ordering parts, provide complete
model and serial numbers (see rating plate), quantity and name of
part desired (as listed in fig. 1). Standard hardware items may be
purchased locally.
WARNING
DO NOT ATTEMPT TO OPERATE WATER HEATER
WITH COLD WATER INLET VALVE CLOSED.
INSERT A

3
INSPECT SHIPMENT
There may be hidden damage caused in transit. Check to be certain
all parts of the venting system, as listed below, are present. Inspect
the upper and lower air inlet boxes, rear air tube and all parts of the
venting system. CAUTION!!! IF THERE ARE ANY DAMAGED
PARTS, DO NOT INSTALL THIS WATER HEATER. REPORT ANY
SHORTAGE TO YOUR DISTRIBUTOR OR DAMAGE TO YOUR
CARRIER.
VENT KIT ASSEMBLY COMPONENTS
1 — 3" 90° steel elbow
1 — 5" 90° aluminum elbow
1 — 3" tube assembly (2-pcs. meshed)
1 — 5" tube assembly (2-pcs. meshed)
1 — Finishing collar (inside)
1 — Finishing collar (outside)
1 — Terminal Vent Cap Assembly
1 — Tube silicone sealant
8 — Sheet metal screws
GENERAL SAFETY INFORMATION
EXTERNAL DAMAGE
Do not operate the water heater until it has been fully checked out
by a qualified technician, if the water heater:
•Has been exposed to fire or damage.
•Displays evidence of sooting.
•Produces steam or unusually hot water.
If the water heater has been flooded it must be replaced.
CHEMICAL VAPOR CORROSION
WARNING
CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY
OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN
CHEMICAL VAPORS. SUCH CORROSION MAY RESULT IN
FAILURE AND RISK OF ASPHYXIATION.
Spray can propellants, cleaning solvents, refrigerator and air
conditioning refrigerants, swimming pool chemicals, calcium and
sodium chloride (water softener salt), waxes and process chemicals
are typical compounds which are potentially corrosive.
Do not store products of this sort near the heater. Also, air which is
brought in contact with the heater should not contain any of these
chemicals. If necessary, uncontaminated air should be obtained
from remote or outside sources. The limited warranty is voided
when failure of water heater is due to a corrosive atmosphere. (Refer
to the limited warranty for complete terms and conditions).
EXTENDED NON-USE PERIODS
WARNING
HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER
SYSTEM SERVED BY THIS HEATER THAT HAS NOT BEEN USED
FOR A LONG PERIOD OF TIME (GENERALLY TWO WEEKS OR
MORE). HYDROGEN GAS IS EXTREMELY FLAMMABLE. To
reduce the risk of injury under these conditions, it is recommended
that the hot water faucet be opened for several minutes at the kitchen
sink before using any electrical appliance connected to the hot water
system. If hydrogen is present, there will probably be an unusual
sound such as air escaping through the pipe as the water begins to
flow. THERE SHOULD BE NO SMOKING OR OPEN FLAME NEAR
THE FAUCET AT THE TIME IT IS OPEN.
INSULATION BLANKETS
Insulation blankets available to the general public for external use
on gas water heaters are not necessary with A. O. Smith products.
The purpose of an insulation blanket is to reduce the standby heat
loss encountered with storage tank water heaters. Your A. O. Smith
water heater meets or exceeds the National Appliance Energy
Conservation Act standards with respect to insulation and standby
loss requirements, making an insulation blanket unnecessary.
WARNING
Should you choose to apply an insulation blanket to this heater,
you should follow these instructions (See Figure 1 for identification
of components mentioned below). Failure to follow these
instructions can restrict the air flow required for proper combustion,
resulting in fire, asphyxiation, serious personal injury or death.
•Do not cover the outer door, thermostat or temperature &
pressure relief valve.
•Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
•Do obtain new warning and instruction labels from A.O. Smith
for placement on the blanket directly over the existing labels.
INSTALLATION
REQUIRED ABILITY
INSTALLATION OR SERVICE OF THIS WATER HEATER
REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED
TRADESMAN IN THE FIELD INVOLVED. PLUMBING, AIR
SUPPLY, VENTING AND GAS SUPPLY ARE REQUIRED.
GENERAL
The installation must conform to these instructions and the local
code authority having jurisdiction. In the absence of local codes,
conform to the latest edition of National Fuel Gas Code ANSI Z223.1
The code manual can be purchased from the American Gas
Association Laboratories, 8501 East Pleasant Valley Road,
Cleveland, OH 44131.
LOCATION OF HEATER
This is a direct vent water heater which draws combustion air from
outside the structure and exhausts all products of combustion to
the outside of the structure. All air for combustion and all products
of combustion are routed through the ducting provided, directly
from and to the outside of the building. It therefore must be located
next to the outside wall within the range of the adjustments illustrated
in fig. 15. DO NOT attempt to extend the air supply tube or inner
flue vent tube beyond the dimensions specified on page 7 vent
connections, steps 6 and 7.
The heater is design certified by the American Gas Association for
installation on combustible flooring in a closet having minimum
clearances from combustible material of: 0" clearance from sides,
rear, and top air tube, 4" from the front and 18" from the top. If
clearances stated on the heater differ from standard clearances,
install water heater according to clearances stated on heater.
A minimum clearance of 4" must be allowed for access to re-
placeable parts such as the thermostats, drain valve and relief valve.
Adequate clearance for servicing this appliance should be
considered before installation, such as changing the anodes, etc.
When installing the heater, consideration must be given to proper
location. The water heater should be located as close to or
centralized to the water piping system as possible. The water heater
should be located in an area not subject to freezing temperatures.

4
THE 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 HEATER OR TO
LOWER FLOORS OF THE STRUCTURE. When such locations
cannot be avoided, a suitable drain pan should be installed under
the heater. Such pans should have a minimum length and width of
at least 2 inches greater than the diameter of the heater and should
be piped to an adequate drain. Drain pans suitable for these heaters
are available from your dealer or A. O. Smith Water Products
Company, 5621 W. 115th Street, Alsip, IL 60803.
Under no circumstances is the manufacturer to be held liable for
any water damage in connection with this water heater.
WARNING
DO NOT INSTALL THIS WATER HEATER DIRECTLY ON A
CARPETED FLOOR. A FIRE HAZARD MAY RESULT. Instead
the water heater must be placed on a metal or wood panel extending
beyond the full width and depth by at least 3 inches (76.2mm) in
any direction. If the heater is installed in a carpeted alcove or
closet, the entire floor shall be covered by the panel.
WATER CONNECTIONS
Refer to figure 1 for typical installation. A suitable pipe thread
sealant must be used to prevent leakage.
WATER (POTABLE) HEATING AND SPACE HEATING
1. All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
2. Toxic chemicals, such as those used for boiler treatment, shall
NEVER be introduced into this system.
3. This unit may NEVER be connected to any existing heating
system or component(s) previously used with a non-potable
water heating appliance.
4. When the system requires water for space heating at
temperatures higher than required for domestic water purposes,
a tempering valve must be installed. Please refer to Fig. 2 for
suggested piping arrangement.
CLOSED WATER SYSTEM
A closed system will exist if a back-flow preventer (check valve),
pressure reducing valve, or other similar device is installed in the
cold water line between the water heater and the street main (or
well). Excessive pressure may develop due to the thermal expansion
of heated water causing premature tank failure or intermittent relief
valve operation. This type of failure is not covered by the limited
warranty. An expansion tank may be necessary in the cold water
supply to alleviate this situation, see fig. 1. Contact the local
plumbing authority.
,
If the temperature and pressure relief valve on the appliance
discharges periodically, this may be due to thermal expansion in a
closed water supply system. Contact the water supplier or local
plumbing inspector on how to correct this situation. DO NOT PLUG
THE TEMPERATURE AND PRESSURE RELIEF VALVE.
GAS CONNECTIONS
The minimum gas supply pressure is 4.5" water column for input
adjustment. THE HEATER IS NOT INTENDED FOR OPERATION
AT HIGHER THAN 14" WATER COLUMN (3.5 kPa) SUPPLY
PRESSURE. EXPOSURE TO HIGHER GAS SUPPLY PRESSURE
MAY CAUSE DAMAGE TO THE CONTROL WHICH COULD
RESULT IN FIRE OR EXPLOSION. If overpressure has occurred
such as through improper testing of gas lines or emergency
malfunction of the supply system, the control must be checked for
safe operation.
Make sure that the outside vents on the supply regulators and the
safety vent valves are protected against blockage. These are parts
of the gas supply system not the heater. Vent blockage may occur
during ice storms.
IT IS IMPORTANT TO GUARD AGAINST CONTROL FOULING
FROM CONTAMINANTS IN THE GAS WAYS. SUCH FOULING
MAY CAUSE IMPROPER OPERATION, FIRE OR EXPLOSION.
All piping must comply with local codes and ordinances or with the
latest edition of National Fuel Gas Code (ANSI Z223.1 NFPA-54)
whichever applies.
REFER TO FIG. 1 FOR CONNECTION DETAILS. BEFORE
ATTACHING THE GAS LINE BE SURE THAT ALL GAS PIPE IS
CLEAN ON THE INSIDE.
TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS
SUPPLY LINE, A DIRT LEG (SOMETIMES CALLED DRIP LEG)
MUST BE INCORPORATED IN THE PIPING, FIG. 1. The dirt leg
must be readily accessible. Install in accordance with recom-
mendations of serving gas supplier. Refer to the latest edition of
the National Fuel Gas Code ANSI Z223.1.

5
VENT PIPE TERMINATION
Before installing water heater determine placement of vent pipe
termination.
MAKE CERTAIN TO OBSERVE VENT LOCATION LIMITATION,
SEE FIG'S 3 & 15.
CAUTION
Use only the vent kit assembly supplied with this water heater.
Only supplied kit provides required clearances from combustibles;
both through the wall and the exterior siding. TERMINATION OF A
SIDEWALL VENT SYSTEM WITH A DEVICE OTHER THAN THE
SUPPLIED VENT KIT ASSEMBLY IS NOT RECOMMENDED AND
COULD AFFECT SYSTEM PERFORMANCE AND RESULT IN A
SAFETY HAZARD.
IMPORTANT
The vent system must terminate so that proper clearances are
maintained as cited in local codes or the latest edition of the National
Fuel Gas Code, ANSI Z223.1, 7.3.4e and 7.8c as follows:
1. The vent terminals of a direct vent system shall be not less
than 7 feet above grade when located adjacent to public
walkways (Fig. 3).
2. A venting system shall terminate at least 9 inches above any
forced air inlet located within 10 feet (Fig. 3).
3. The venting system shall terminate at least 9 inches below, 9
inches horizontally from or 9 inches above any door, window
or gravity air inlet into any building.
4. The manufacturer also recommends the vent terminations not
be installed closer than 3 feet from an inside corner of an L
shaped structure, and not less than 1 foot above grade. The
vent shall terminate a minimum 12" above expected snowfall
level to prevent blockage of vent termination.
5. In cold climates, it is recommended that vent termination not
be mounted directly above or within 3 feet horizontally from an
oil tank vent or gas meter to avoid potential freeze-up from
condensation.
Plan the vent system layout so that proper clearances are
maintained from plumbing and wiring.
Required clearances from combustible materials must be provided
in accordance with information in this manual under LOCATION
OF HEATER and with the National Fuel Gas Code and local codes.
Carefully read through these installation instructions before you
start your installation. The figures provided will give the necessary
views to complete this installation. Self drilling screws are provided,
but it may be necessary to use a 1/8" drill for a starting hole as
called for in the instructions.
NOTE: IN SOME LOCALITIES, LOCAL CODE REQUIRES AN
ADDITIONAL VENT COVER.
NOTE: The four fasteners that are required to secure the vent cap
to the external wall are not provided. These should be screw type
(not nails) chosen for the type of construction and obtained locally.
To prevent damage, care must be taken not to apply too much
torque when attaching gas supply pipe to thermostat gas inlet. The
thermostat inlet has a pad for use with a backup wrench.
Apply joint compounds (pipe dope) sparingly and only to the male
threads of pipe joints. Do not apply compound to the first two
threads. Use compounds resistant to the action of liquefied
petroleum gases. Do not use teflon tape on thermostat fittings.
DISCONNECT THE APPLIANCE FROM THE GAS SUPPLY
PIPING SYSTEM DURING ANY SUPPLY PRESSURE TESTING
EXCEEDING 1/2 PSI (3.5 kPa). GAS SUPPLY LINE MUST BE
CAPPED WHEN DISCONNECTED FROM THE HEATER. FOR
TEST PRESSURES AT 1/2 PSI (3.5 kPa) OR LESS, THE
APPLIANCE NEED NOT BE DISCONNECTED, BUT MUST BE
ISOLATED FROM THE SUPPLY PRESSURE TEST BY CLOSING
THE MAIN MANUAL GAS VALVE.
BEFORE PLACING THE HEATER IN OPERATION, CHECK FOR
GAS LEAKAGE. USE SOAP AND WATER SOLUTION OR OTHER
MATERIAL ACCEPTABLE FOR THIS PURPOSE. DO NOT USE
MATCHES, CANDLES, FLAME OR OTHER SOURCES OF
IGNITION TO LOCATE GAS LEAKS.
RELIEF VALVE
A NEW TEMPERATURE AND PRESSURE RELIEF VALVE
COMPLYING WITH THE STANDARD FOR RELIEF VALVES AND
AUTOMATIC GAS SHUT OFF DEVICES FOR HOT WATER
SUPPLY SYSTEMS, ANSI Z21.22 (LATEST EDITION) MUST BE
INSTALLED IN THE HEATER IN THE MARKED OPENING
PROVIDED (SEE FIGURE 1). THE VALVE MUST BE OF A SIZE
(INPUT RATING) THAT WILL BE ADEQUATE FOR YOUR SIZE
HEATER.
Check the metal tag on the relief valve and compare it to the heater’s
rating plate. The pressure rating of the relief valve must not exceed
the working pressure shown on the rating plate of the heater. In
addition, the hourly BTU rated temperature steam discharge
capacity of the relief valve shall not be less than the input rating of
the heater. NO VALVE IS TO BE PLACED BETWEEN THE RELIEF
VALVE AND TANK. DO NOT PLUG THE RELIEF VALVE.
The drain line connected to this valve must not contain a reducing
coupling or other restriction and must terminate near a suitable
drain to prevent water damage during valve operation. The
discharge line shall be installed in a manner to allow complete
drainage of both the valve and line. DO NOT THREAD, PLUG OR
CAP THE END OF THE DRAIN LINE.
VENTING
WARNING
NEVER OPERATE THE HEATER UNLESS IT IS VENTED TO THE
OUTDOORS AND HAS ADEQUATE AIR SUPPLY TO AVOID
RISKS OF IMPROPER OPERATION, FIRE, EXPLOSION OR
ASPHYXIATION.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND
VENTILATING AIR. ADEQUATE AIR FOR COMBUSTION AND
VENTILATION MUST BE PROVIDED FOR SAFE OPERATION.

6
2. Move the water heater to its final installed location. Make certain
clearances from combustible material are observed. See figure 6.
FIGURE 5
3. Apply high temperature silicone sealant around flue extension
inside of flared end.
WARNING: IF YOU RUN OUT OF HIGH TEMPERATURE
SILICONE SEALANT, USE NATIONAL POLYMER PRO-
DUCTS, SEALCON II, RTV ADHESIVE SEALANT OR
EQUIVALENT MUST CONFORM TO MIL-A46106A TYPE 1.
DO NOT USE ANY OTHER KIND.
Place the 3 inch steel elbow on the water heater flue pipe and
press it firmly downward until sealed and pointed in the desired
direction. See figure 7.
FIGURE 6
4. Install the 5 inch aluminum elbow over the 3 inch steel elbow.
Be certain both are pointed in the desired direction with the 3
inch centered inside the 5 inch elbow. See figure 8.
VENT CONNECTIONS
Before proceeding, refer to figure 4 for schematic of how venting
must be installed. Please note that the centerline of opening for
the vent termination must be 67-7/8" above the surface upon which
the water heater will be resting. If the heater will be placed on a
stand, be sure to measure the 67-7/8" from the level of the stand
upon which the heater will be resting. .
FIGURE 4
After the location for the vent terminal has been selected:
1. Cut a clearance hole, (BEWARE OF CONCEALED WIRING
AND PIPING INSIDE OF WALL), approximately 6 inches in
diameter, through the exterior wall for the 5 inches diameter air
tube. See figure 5.
Basement installations generally require an additional leg stand
kit (18" water heater stand) or a job fabricated stand to raise
the heater to the proper height for exterior venting. Outside
terminal vent cap must not be less than 12" above the ground.
In heavy snow areas, the minimum 12" clearance should be
increased accordingly.
RECOMMENDED CLEARANCE
NOT REQUIRED BY CODE.
POSSIBLE PILOT OUTAGE
IF LESS THAN 3' AND WINDY
CONDITIONS EXIST.

7
FIGURE 7
5. As an aid to leveling the 5 inch elbow, temporarily place the 5
inch sliding tube onto the elbow. When leveled, drill a 1/8
diameter hole through the elbow into the collar at the front and
back. Secure with the two #8 sheet metal screws provided.
See figure 9.
Place the finishing collar on the 5 inch elbow, as it will be
positioned later.
FIGURE 8
6. Extend the 3 inch tube assembly to its maximum installed
length, 20-3/4 inches. A minimum of 1-1/4" overlap is required
at all 3" vent pipe joints. Place the larger main section through
the hole in the external wall to the outside. Place the inner
sliding section fully onto the 3 inch elbow. Apply high
temperature silicone sealant as shown in fig. 10.
FIGURE 9
7. Attach the 5 inch main tube to the vent terminal base. Drill a
1/8 inch hole through the tube into the collar of the base. Secure
with a #8 sheet metal screw, furnished. Repeat with a second
hole and screw approximately 180° from the first. Reinstall
the 5 inch inner sliding section at its maximum extended length,
19-3/4 inches. See figure 11.
FIGURE 10
8. From the outside of the building, insert the 5 inch tube/base
assembly through the hole in the exterior wall and onto the 5
inch elbow. Then seal the base onto the wall. See figure 12.
FIGURE 11
9. Next place the 3 inch main tube fully onto the collar of the vent
cap. Then seat the cap against the base.
FIGURE 12
10. Secure the vent cap/base assembly to the exterior wall with
four screw anchors appropriate for the type of wall construction.
The 5 inch tube should be essentially level. However, a small
amount of upward or downward pitch will not affect operation.
11. Apply silicone caulking compound around the junction of the
vent terminal base and the exterior wall.
12. Position and fasten the finishing collar, previously installed
on the 5 inch elbow, against the wall to close the opening
around the tube.
13. Make certain the 5 inch tube sliding section has been fully
engaged onto the 5 inch elbow. Drill two each 1/8 inch holes
(180° apart) in the junction of the two joints in the five inch
tube. Fasten with four #8 sheet metal screws, furnished.

8
OPERATION
NEVER OPERATE THE HEATER WITHOUT FIRST BEING CER-
TAIN IT IS FILLED WITH WATER AND A TEMPERATURE AND
PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE
OPENING OF THE HEATER. DO NOT ATTEMPT TO OPERATE
HEATER WITH COLD WATER INLET VALVE CLOSED.
FILLING
1. Close the heater drain valve (Fig. 1) by turning handle clockwise.
2. Open a nearby hot water faucet to permit the air in the system
to escape.
3. Fully open the cold water inlet pipe valve (Fig. 1) allowing the
heater and piping to be filled.
4. Close the hot water faucet as water starts to flow.
5. The heater is ready to be operated.
HIGH ALTITUDE INSTALLATIONS
WARNING
INSTALLATIONS ABOVE 2,000 FT. REQUIRE REPLACEMENT
OF THE BURNER ORIFICE IN ACCORDANCE WITH THE
NATIONAL FUEL GAS CODE (ANSI Z 223.1/NFPA 54). FAILURE
TO REPLACE THE ORIFICE COULD RESULT IN IMPROPER AND
INEFFICIENT OPERATION OF THE APPLIANCE, PRODUCING
CARBON MONOXIDE GAS IN EXCESS OF SAFE LIMITS, WHICH
COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
CONTACT YOUR GAS SUPPLIER FOR ANY SPECIFIC
CHANGES WHICH MAY BE REQUIRED IN YOUR AREA.
A. O. Smith builds models specifically for high altitude service.
Please check the rating plate before making changes.
TEMPERATURE REGULATION
DANGER
THIS WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE
THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT
WATER TEMPERATURES REQUIRED FOR AUTOMATIC
DISHWASHER AND LAUNDRY USE CAN CAUSE PAINFUL
SCALDING WITH POSSIBLE SERIOUS AND PERMANENT IN-
JURY. THE TEMPERATURE AT WHICH INJURY OCCURS VARIES
WITH THE PERSON’S AGE AND THE TIME OF THE EXPOSURE.
THE SLOWER RESPONSE TIME OF CHILDREN, AGED OR
DISABLED PERSONS INCREASES THE HAZARDS TO THEM.
NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER TAP,
OR TO DRAW THEIR OWN BATH WATER. NEVER LEAVE A
CHILD OR DISABLED PERSON UNATTENDED IN A BATHTUB
OR SHOWER.
THE WATER HEATER SHOULD BE LOCATED IN AN AREA
WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS. IF
A SUITABLE AREA IS NOT AVAILABLE, A COVER SHOULD BE
INSTALLED OVER THE THERMOSTAT TO PREVENT
TAMPERING. Suitable covers are available through A.O. Smith
Water Products Company, 5621 W. 115th Street, Alsip, IL 60803.
FIGURE 13
14. Seal all the 5 inch tube joints with silicone sealant including
the elbow joint to the collar on the heater's air supply box.
FIGURE 14
15. The fixed installation height is 67-7/8 inches from the surface
that the heater rests on to the center of the vent tube.
Do not attempt to extend the air supply tube beyond the
dimensions shown (10" max.).
Contact your supplier if additional information is needed before
starting installation.
E - REAR VENTING F - SIDE VENTING**
GAL. MIN. MAX. MIN. MAX.
40 4-1/8" 14-1/8" 9-1/8" 20-1/8"
50 3-1/8" 13-1/8" 8-1/8" 18-1/8"
FIGURE 15

9
1. Set the thermostat to lowest setting.
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.
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH
WATER AND AIR PURGED FROM ALL LINES.
A. This appliance has a pilot which must be lighted by hand.
When lighting the pilot, follow these instructions exactly.
B. BEFORE LIGHTING smell all around the appliance area
for gas. Be sure to smell next to the floor because some
gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electric 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.
• If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or turn
by hand, don’t try to repair it, call a qualified service
technician. Force or attempted repair may result in a fire
or explosion.
D. Do not use this appliance if any part has been under
water. Immediately call a qualified service technician to
inspect the appliance and to replace any part of the
system and any gas control which has been under water.
1. STOP! Read safety information above on
this label.
2. Set the thermostat to lowest setting. Turn thermostat dial
fully clockwise until it stops.
3. Push in gas control knob slightly and turn clockwise
to “OFF”. SEE FIGURE ‘A’.
NOTE: Knob cannot be turned from “PILOT” to “OFF” unless
knob is pushed in slightly. Do not force.
4. Remove the outer burner door located below and behind
the gas control unit.
5. Remove two screws from right side of hinged inner
door, then open.
6. Wait five (5) minutes to clear out any gas. If you
then smell gas, STOP! Follow “B” in the
safety information above on this label. If you
don’t smell gas, go to next step.
7. Find pilot–follow metal tube from gas control through door
openings. The pilot is between the burner tube and
thermocouple behind the burner access door. SEE
FIGURE ‘D’.
8. Turn knob on gas control counter clockwise to
“PILOT”. SEE FIGURE ‘B’.
LIGHTING INSTRUCTIONS
TOP KNOB
TO TURN OFF GAS TO APPLIANCE
2. Push in gas control knob slightly and turn clockwise
to “OFF”. Do not force. SEE FIGURE ‘A’.
9. Push in control knob all the way and hold in.
Immediately light the pilot with a match. Continue
to hold the control knob in for about (1) minute
after the pilot is lit. Release knob and it will pop
back up. Pilot should remain lit. If it goes out, repeat
steps 3 through 10. It may take several seconds
for air to clear the lines before the pilot will light.
• If knob does not pop up when released, stop and
immediately call your service technician or gas supplier.
• If the pilot will not stay lit after several tries, turn the gas
control knob clockwise to “OFF” and call your
service technician or gas supplier. SEE FIGURE ‘A’.
10.Once the pilot flame is established, replace and tighten
the (2) screws in the right hand side of the hinged door.
11. Replace outer burner door.
12.At arms length away, turn gas control counter clockwise
to “ON”. SEE FIGURE ‘C’.
13.Set thermostat to desired setting.
CAUTION: Hotter water increases the risk
of scald injury. Consult the instruction
manual before changing temperature.

10
It is recommended that lower water temperatures be used to avoid
the risk of scalding. It is further recommended, in all cases, that
the water temperature dial, Figure 16, be set for the lowest
temperature which satisfies your hot water needs. This will also
provide the most energy efficient operation of the water heater.
The water temperature adjusting dial was factory set at the lowest
temperature; all the way clockwise to the mechanical stop. Turning
the dial counterclockwise increases temperature and clockwise
reduces temperature.
SETTING THE WATER HEATER TEMPERATURE AT 120°F (AP-
PROX. "V"MARK ON FACE OF THERMOSTAT) WILL REDUCE
THE RISK OF SCALDS. Some states require settings at specific
lower temperatures.
Figure 16 below shows the approximate water temperatures
produced at various thermostat dial settings. Short repeated heating
cycles caused by small hot water uses can cause temperatures at
the point of use to exceed the thermostat setting by up to 30°F. If
you experience this type of use you should consider using lower
temperature settings to reduce scald hazards.
Time to Produce 2nd & 3rd
Temperature Setting Degree Burns on Adult Skin
VERY HOT = approx. 160°F About 1/2 second
C = approx. 150°F about 1-1/2 seconds
B = approx. 140°F Less than 5 seconds
A = approx. 130°F About 30 seconds
V= approx. 120°F More than 5 minutes
LOW = approx. 80°F
FIGURE 16
Valves for reducing point-of-use temperature by mixing cold and
hot water are available (See Fig. 2). Also available are inexpensive
devices that attach to faucets to limit hot water temperatures.
Contact a licensed plumber or the local plumbing authority.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL
TO SHUT OFF, TURN OFF THE MAIN MANUAL GAS CONTROL
VALVE TO THE APPLIANCE. SEE FIGURE 1.
MAINTENANCE
FOR YOUR SAFETY AND SATISFACTORY OPERATION, IT IS
RECOMMENDED THAT THIS HEATER BE CHECKED ONCE A
YEAR BY A COMPETENT SERVICE PERSON.
USERS OF THIS APPLIANCE SHOULD BE AWARE THAT GAS
COMPONENTS WEAR OUT OVER A PERIOD OF TIME. THE
GAS CARRYING COMPONENTS OF THIS APPLIANCE SHOULD
BE INSPECTED FOR PROPER OPERATION PERIODICALLY BY
A QUALIFIED SERVICE TECHNICIAN.
PILOT AND MAIN BURNER
Check pilot and main burner every six months for proper flame
characteristics. This is done by removing door on heater, fig. 1.
The main burner should provide complete combustion of gas; ignite
rapidly; give reasonably quiet operation; cause no excessive flame
lifting from burner ports. Make sure that the flow of combustion
and ventilation air is not blocked.
If proper flame characteristics are not evident, check for accu-
mulation of lint or other foreign material that restricts or blocks the
air openings in the heater or burner.
WARNING
SOOT BUILD-UP INDICATES A PROBLEM THAT REQUIRES
CORRECTION BEFORE FURTHER USE. CONSULT WITH A
QUALIFIED SERVICE TECHNICIAN.
Should the main burner or burner air openings require cleaning,
turn the gas control knob to “OFF” position and allow the burner to
cool. Remove the burner and clean with a soft brush. Clean main
burner orifice with a suitable soft material.
HIGH TEMPERATURE LIMIT SWITCH
(Single-Use Type Energy Cut Off)
The thermostat has a factory-installed nonadjustable limit switch
that guards against excessive water temperatures.
In the event of high temperature switch operation, the pilot will
extinguish and cannot be relit until the entire gas control is replaced.
Such controls are labeled as being single-use types. Lower the
temperature adjustment dial setting on the new control. It is
important that a serviceman be called to determine the reason for
the limit operation and thus avoid repeated replacement of the control.
TEMPERATURE & PRESSURE RELIEF VALVE
At least once a year, the temperature and pressure relief valve, fig.
1. must be checked to ensure that it is in operating condition. Lift
the lever at the top of the valve several times until the valve seats
properly and operates freely.
If water does not flow, remove the valve and inspect for obstructions
or corrosion. Have a qualified servicer replace with a new valve of
the recommended size as necessary. Do not attempt to repair the
valve, as this could result in improper operation and a tank
explosion. In areas with poor water conditions, it may be necessary
to inspect the T&P valve more frequently.
CAUTION
THE WATER PASSING OUT OF THE VALVE DURING THIS
CHECKING OPERATION MAY BE EXTREMELY HOT. AVOID CON-
TACT AND DISCHARGE SAFELY TO PREVENT WATER DAMAGE.
DRAINING
If the heater is to be shut off and exposed to freezing temperatures,
it must be drained. Water, if left in the tank and allowed to freeze,
will damage the heater.
• Turn off the gas and cold water inlet valve to the heater, fig. 1.
• Open a nearby hot water faucet and the heater drain valve.
• BE CAREFUL TO GRASP THE DRAIN VALVE HANDLE SO
THAT THE HAND IS NOT EXPOSED TO HOT WATER. IF
DESIRED, A HOSE MAY BE CONNECTED TO THE DRAIN
VALVE TO CARRY THE WATER AWAY.
DANGER
The water CAN BE HOT.
• The drain valve must be left open during the shutdown period.
• To restart heater, refer to the FILLING instructions under
OPERATION.