A.O. Smith GCVL-40 200/210 User manual

1
Instruction Manual
PRINTEDINTHEU.S.A 0905 PART NO. 184165-003
KEEPTHISMANUALINTHEPOCKETONHEATERFORFUTUREREFERENCE
WHENEVERMAINTENANCEADJUSTMENTORSERVICEISREQUIRED.
NOTFORUSEINMANUFACTURED(MOBILE)HOMES
ALLTECHNICALANDWARRANTYQUESTIONS:SHOULDBEDIRECTEDTOTHELOCALDEALERFROMWHOMTHEWATERHEATERWAS
PURCHASED.IFYOUAREUNSUCCESSFUL,PLEASEWRITETOTHECOMPANYLISTEDONTHERATINGPLATEONTHEWATERHEATER.
RESIDENTIAL GAS WRESIDENTIAL GAS W
RESIDENTIAL GAS WRESIDENTIAL GAS W
RESIDENTIAL GAS WAA
AA
ATER HEATER HEA
TER HEATER HEA
TER HEATERSTERS
TERSTERS
TERS
• For Your Safety •
ANODORANTISADDEDTOTHEGASUSED
BYTHISWATERHEATER.
C3 Technology®Gas Water Heaters meet the new
ANSI Z21.10.1 standard that deals with the accidental or
unintended ignition of flammable vapors, such as those
emitted by gasoline.
GAMA certification applies to
all residential gas water
heaters with capacities of 20
to100 gallonswithinput rating
of 75,000 BTU/Hr. or less.
®

2
SAFE INSTSAFE INST
SAFE INSTSAFE INST
SAFE INSTALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION, USE AND SERVICE, USE AND SERVICE
, USE AND SERVICE, USE AND SERVICE
, USE AND SERVICE
Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very
important that the meaning of each safety message is understood by you and others who install, use or service this water heater.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and
how to avoid the risk of injury.
IMPORTANT DEFINITIONS
•Qualified Installer: Aqualified installermust have ability equivalent toa licensed tradesman inthe fields of plumbing,
air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas
Code as it relates to the installation of gas fired water heaters. The qualified installer must also be familiar with the
designfeaturesanduse of flammable vapor ignition resistant water heaters, and haveathoroughunderstandingof this
instructionmanual.
•ServiceAgency: Aservice agency also must have abilityequivalent to a licensed tradesman inthefields of plumbing,
air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas
Code as it relates to the installation of gas fired water heaters. The service agency must also have a thorough
understandingofthisinstruction manual, and be able toperformrepairsstrictlyinaccordancewith the service guidelines
providedbythe manufacturer.
•Gas Supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning
appliances within this application. The gas supplier typically has responsibility for the inspection and code approval of
gas piping up to and including the Natural Gas meter or Propane storage tank of a building. Many gas suppliers also
offerservice and inspection of appliances within the building.

3
GENERAL SAFETYGENERAL SAFETY
GENERAL SAFETYGENERAL SAFETY
GENERAL SAFETY

4
SAFEINSTALLATION,USEANDSERVICE...............................2
GENERALSAFETY ..................................................................3
TABLEOFCONTENTS..............................................................4
INTRODUCTION ........................................................................4
Preparing for the New Installation...................................4
TYPICALINSTALLATION ...................................................... 5-6
LOCATINGTHE NEWWATERHEATER .....................................7
Facts to ConsiderAbout Location ............................... 7-8
InsulationBlankets ...........................................................8
CombustionAir and Ventilation forAppliances
Located in Unconfined Spaces........................................8
CombustionAir and Ventilation forAppliances
Located in Confined Spaces ........................................ 8-9
INSTALLINGTHEWATERHEATER ......................................... 10
WaterPiping ..............................................................10-11
Temperature-Pressure Relief Valve............................... 11
Filling the Water Heater ..................................................12
Venting ..................................................................... 12-13
GasPiping ................................................................ 13-14
SedimentTraps ..............................................................14
LIGHTING&OPERATINGLABEL ............................................15
TEMPERATUREREGULATION ................................................16
FORYOURINFORMATION ............................................... 16-17
Start Up Conditions ........................................................16
Draft Hood Operation .....................................................16
Condensate .............................................................. 16-17
Smoke/Odor.................................................................... 17
ThermalExpansion ......................................................... 17
Strange Sounds..............................................................17
OPERATIONALCONDITIONS ..................................................18
SmellyWater ..................................................................17
“Air” in Hot Water Faucets............................................. 17
High Temperature Shut Off System ...............................17
PERIODICMAINTENANCE .......................................................18
Venting System Inspection ............................................18
Burner Inspection........................................................... 18
BurnerCleaning.............................................................. 18
Housekeeping .......................................................... 18-19
Anode Rod Inspection....................................................19
Temperature-Pressure Relief Valve Operation..............19
Draining ..........................................................................19
Drain Valve Washer Replacement ........................... 19-20
Service ...........................................................................20
LEAKAGECHECKPOINTS ...................................................... 20
REPAIRPARTS .......................................................................21
TROUBLESHOOTING ..............................................................22
NOTES ....................................................................................23
WARRANTY ..................................................................... Insert
Thank You for purchasing this water heater. Properly installed and
maintained,itshouldgiveyouyears of trouble free service.
AbbreviationsFoundInThis InstructionManual:
• CSA-CanadianStandardsAssociation
• ANSI-AmericanNationalStandardsInstitute
• NFPA-NationalFireProtectionAssociation
• ASME-AmericanSocietyof MechanicalEngineers
• GAMA-GasApplianceManufacturer’sAssociation
Thisgas-firedwaterheaterisdesigncertifiedby CSAINTERNATIONAL
underAmericanNationalStandard/CSAStandardforGasWaterHeaters
ANSIZ21.10.1 • CSA4.1(current edition).
PREPARINGFOR THEINSTALLATION
1. Read the“General Safety”section, page 3of thismanual first and
thenthe entire manualcarefully. Ifyou don’t follow thesafetyrules,
thewater heater will not operate properly. Itcouldcause DEATH,
SERIOUSBODILYINJURYAND/ORPROPERTYDAMAGE.
Thismanualcontainsinstructions fortheinstallation, operation,and
maintenanceofthegas-firedwaterheater. Italsocontainswarnings
throughout the manual that you must read and be aware of. All
warningsandall instructions are essential to the proper operation
ofthewaterheater andyoursafety. Since wecannotput everything
on the first few pages, READ THE ENTIRE MANUAL BEFORE
ATTEMPTINGTOINSTALLOROPERATETHEWATERHEATER.
2. Theinstallation must conform with these instructions and the local
code authority having jurisdiction. In the absence of local codes,
installations shall comply with the National Fuel Gas CodeANSI
Z223.1/NFPA54. This publication is available from the Canadian
StandardsAssociation, 8501 East Pleasant Valley Rd., Cleveland
Ohio 44131, or The National Fire Protection Association, 1
BatterymarchPark,Quincy,MA02269.
3. If after reading this manual you have any questions or do not
understandany portionofthe instructions,callthe localgasutility or
themanufacturer whose name appears on the rating plate.
4. Carefullyplan theplace whereyou aregoing toputthewaterheater.
Correct combustion,vent action,andvent pipe installationarevery
important in preventing death from possible carbon monoxide
poisoningandfires,seeFigures1and2.
Examinethelocationtoensurethewaterheatercomplieswiththe
“Locatingthe New Water Heater” sectioninthismanual.
5. ForCaliforniainstallationthiswaterheatermustbebraced,anchored,
or strapped to avoid falling or moving during an earthquake. See
instructionsfor correctinstallationprocedures. Instructions may be
obtainedfromCaliforniaOfficeof the StateArchitect,400PStreet,
Sacramento,CA95814.
6. Massachusetts Code requires this water heater to be installed in
accordancewithMassachusetts248-CMR2.00:StatePlumbingCode
and248-CMR5.00.
7. Complieswith SCAQMD rule#1121anddistrictshavingequivalent
NOxrequirements.
INTRODUCTIONINTRODUCTION
INTRODUCTIONINTRODUCTION
INTRODUCTION
TT
TT
TABLE OF CONTENTSABLE OF CONTENTS
ABLE OF CONTENTSABLE OF CONTENTS
ABLE OF CONTENTS

5
TYPICAL INSTTYPICAL INST
TYPICAL INSTTYPICAL INST
TYPICAL INSTALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A Vent Pipe
B Drafthood
C Anode
D Hot Water Outlet
E Outlet
F Insulation
G Gas Supply
H Manual Gas Shut-off Valve
I Ground Joint Union
* INSTALLINACCORDANCE
WITH LOCAL CODES.
* DRIP LEG AS REQUIRED
BY LOCAL CODES.
FIGURE1.
J Drip Leg (Sediment Trap)
K Inner Door
L Outer door
M Union
N Inlet Water Shut-off Valve
O Cold Water Inlet
P Inlet Dip Tube
Q Temperature-Pressure Relief Valve
R Rating Plate
S Flue Baffle
T Thermostat
U Drain Valve
V Pilot and Main Burner
W Flue
X Drain Pan
Y Piezo Ignitor
Z Air Intake Screen
ZZ Thermostat Shield (optional)
* ALL PIPING MATERIALS TO BE
SUPPLIED BY CUSTOMERS.
TO VENT TERMINATION
ON ROOF
(T) THERMOSTAT
(V) PILOT & MAIN BURNER

6
TYPICAL INSTTYPICAL INST
TYPICAL INSTTYPICAL INST
TYPICAL INSTALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION
FIGURE2.
MIXING VALVE USAGE
Thisappliancehasbeen design certified as complying withAmerican
NationalStandard/CSAStandard for water heaters andis considered
suitablefor:
Water (Potable) Heating and Space Heating: All models are
consideredsuitableforwater(potable)heatingandspaceheating.
HOTTERWATERCANSCALD:
Water heaters are intended to produce hot water. Water heated to
a temperature which will satisfy space heating, clothes washing,
dishwashing, and other sanitizing needs canscaldand permanently
injure you upon contact. Some people are more likely to be
permanently injured by hot water than others. These include the
elderly, children, the infirm, or physically/mentally handicapped. If
anyone using hot water in your home fits into one of these groups
or if there is a local code or state law requiring a certain temperature
water at the hot water tap, then you must take special precautions.
In addition to using the lowest possible temperature setting that
satisfies your hot water needs, a means such as a *Mixing Valve,
shall be used at the hot water taps used by these people or at the
water heater. Mixing valves are available at plumbing supply or
hardware stores. Consult a Qualified Installer or ServiceAgency.
Follow mixing valve manufacturer’s instructions for installation of
the valves. Before changing the factory setting on the thermostat,
readthe “Temperature Regulation”sectioninthis manual, see Figures
14 and 15.

7
FACTSTOCONSIDERABOUT THE LOCATION
Carefullychoose anindoorlocation for thenewwater heater, because
the placement is a very important consideration for the safety of the
occupants in the building and for the most economical use of the
appliance. This water heater is not for use in manufactured
(mobile) homes or outdoor installation.
Whetherreplacing an old water heaterorputtingthe water heater in a
newlocation,thefollowing critical points must be observed:
1. Select a location indoors as close as practical to the gas vent or
chimneyto which the water heater vent isgoing tobe connected,
andas centralized with the water piping systemas possible.
2. Selectedlocation must provide adequate clearances for servicing
andproper operation of the water heater.
Installationofthe waterheatermustbeaccomplishedinsuchamanner
thatifthetankoranyconnectionsshouldleak,theflowwillnotcause
damagetothe structure. Forthis reason,itisnotadvisabletoinstallthe
waterheater in anatticor upper floor. Whensuch locations cannotbe
avoided,asuitabledrainpanshouldbeinstalledunderthewaterheater.
Drain pans are available at your local hardware store. Such a drain
panmusthaveaminimumlength andwidthofatleast2inches(51 mm)
greater that the water heater dimensions and must be piped to an
adequatedrain. Thepanmustnotrestrictcombustionairflow.
Waterheaterlife depends upon water quality, water pressure andthe
environmentinwhich the water heater is installed. Water heaters are
sometimesinstalled in locationswhereleakage may resultinproperty
damage,even with the use of adrain panpiped to a drain.However,
unanticipateddamage canbe reducedorprevented byaleak detector
or water shut-off device used in conjunction with a piped drain pan.
Thesedevices are available from someplumbingsupplywholesalers
andretailers,and detect and react to leakage in variousways:
• Sensorsmounted inthedrain panthattrigger analarmor turnoffthe
incomingwaterto the water heater when leakage is detected.
• Sensors mounted in the drain pan that turn off the water supply to
theentirehome when water is detected in the drain pan.
• Water supply shut-off devices that activate based on the water
pressure differential between the cold water and hot water pipes
connectedtothe water heater.
• Devicesthatwill turn off the gas supply toa gaswater heaterwhile
atthe same time shutting off itswatersupply.
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS
(VAPORS)ARELIKELYTOBEPRESENTORSTORED(GARAGES,
STORAGEAND UTILITYAREAS, ETC.):Flammableliquids(suchas
gasoline,solvents, propane(LPor butane, etc.)andother substances
(suchas adhesives, etc.) emitflammablevapors which can beignited
byagaswaterheater’spilotlightormainburner. Theresultingflashback
andfire cancausedeath or seriousburnsto anyone inthearea. Even
thoughthis waterheateris a flammablevaporsignition resistantwater
heater and is designed to reduce the chances of flammable vapors
LL
LL
LOCAOCA
OCAOCA
OCATING THE NEW WTING THE NEW W
TING THE NEW WTING THE NEW W
TING THE NEW WAA
AA
ATER HEATER HEA
TER HEATER HEA
TER HEATERTER
TERTER
TER
beingignited, gasoline andotherflammable substances shouldnever
bestored or used in the samevicinity orarea containingagas water
heateror other open flame or sparkproducingappliance.
Also, the water heater must be located and/or protected so it is not
subjectto physical damage by amovingvehicle.
Thiswaterheater mustnot beinstalled directlyon carpeting. Carpeting
must be protected by metal or wood panel beneath the appliance
extendingbeyond the full width and depth of the appliance by at least
3inches (76.2mm)in anydirection,or iftheappliance isinstalledin an
alcoveor closet,theentire floor mustbecovered bythepanel. Failure
toheed this warning may result ina firehazard.
Minimum clearances between the water heater and combustible
constructionare 0 inch atthesidesand rear,4inches (102 mm) atthe
front,and6inches (153 mm) from the vent pipe. Clearance from the
top of the jacket is 12 inches (305 mm) on most models. Note that a
lesserdimension may be allowed on some models,referto the label
attached adjacent to the gas control valve on the water heater, see
Figure3.

8
FIGURE3.
Agaswaterheatercannotoperate properlywithout thecorrect amount
ofairforcombustion. Do notinstallinaconfined areasuchasacloset,
unless you provide air as shown in the “Locating The New Water
Heater”section. Never obstruct the flow of ventilation air. Ifyou have
anydoubtsor questionsatall, callyour gassupplier. Failure toprovide
the proper amount of combustion air can result in a fire or explosion
andcause death, serious bodily injury, orpropertydamage.
FIGURE4.
Ifthiswater heaterwill beusedinbeautyshops,barbershops,cleaning
establishments,or self-servicelaundrieswith dry cleaningequipment,
it is imperative that the water heater or water heaters be installed so
thatcombustion and ventilationairbe taken fromoutsidetheseareas.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorinebased chemicals,refrigerants,etc.) in additiontobeing highly
flammableinmany cases, will also change to corrosivehydrochloric
acid when exposed to the combustion products of the water heater.
Theresultscanbe hazardous, and also cause product failure.
INSULATIONBLANKETS
Insulationblankets are available tothegeneralpublic for external use
ongas water heaters but are not necessarywiththeseproducts. The
purpose of an insulation blanket is to reduce the standby heat loss
encountered with storage tank heaters. Your water heater meets or
exceedstheNationalAppliance Energy ConversationAct standards
withrespectto insulation and standby loss requirements, makingan
insulationblanket unnecessary.
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions (For identification of components
mentioned below, see Figure 1). Failure to follow these instructions
can restrict the air flow required for proper combustion, potentially
resultingin fire, asphyxiation, serious personal injury or death.
•Do not apply insulation to the top of the water heater, as this will
interfere with safe operation of the draft hood.
•Do not cover the outer door, thermostat or temperature & pressure
reliefvalve.
•Do not allow insulation to come within 2" (50.8 mm) of the floor to
preventblockageofcombustion air flow to the burner.
•Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
•Doobtain newwarningandinstruction labels fromthemanufacturer
forplacement on the blanket directly over theexistinglabels.
•Do inspect the insulation blanket frequently to make certain it
doesnotsag,thereby obstructing combustion air flow.
COMBUSTIONAIR AND VENTILATION FOR
APPLIANCESLOCATEDIN UNCONFINEDSPACES
UNCONFINED SPACE is space whose volume is not less than
50cubic feet per 1,000 Btuperhour(4.8cm per kW) of the aggregate
input rating of all appliances installed in that space. Rooms
communicating directly with the space in which the appliances are
installed,through openingsnotfurnished with doors,areconsidered a
partof the unconfined space.
Inunconfinedspacesinbuildings,infiltrationmaybeadequatetoprovide
airforcombustion,ventilationanddilutionoffluegases. However, in
buildingsof tight construction (forexample,weatherstripping, heavily
insulated,caulked, vapor barrier, etc.),additionalair may need to be
providedusingthemethodsdescribedin“CombustionAirandVentilation
forAppliancesLocatedinConfinedSpaces.”
COMBUSTIONAIR AND VENTILATION FOR
APPLIANCESLOCATED INCONFINED SPACES
CONFINEDSPACEisaspacewhosevolumeislessthan 50cubicfeet
per1,000Btuper hour(4.8cmperkW) of theaggregateinputratingof
allappliances installed inthatspace.
A. ALLAIRFROM INSIDEBUILDINGS:(SeeFigure4and5)
Theconfined space shall beprovided with two permanent openings
communicatingdirectly withanadditional room(s) ofsufficientvolume
so that the combined volume of all spaces meets the criteria for an

9
unconfinedspace. Thetotalinputofallgasutilizationequipmentinstalled
inthecombinedspaceshallbeconsideredinmakingthisdetermination.
Eachopening shall have a minimum free area ofonesquareinchper
1,000 Btu per hour (22 cm2/kW) of the total input rating of all gas
utilizationequipmentintheconfinedspace,butnotlessthan100square
inches (645 cm2). One opening shall commence within 12 inches
(30cm)ofthetopandonecommencing within12 inches(30 cm)of the
bottomof the enclosures.
FIGURE5.
B.ALL AIRFROM OUTDOORS: (See Figures6,7and8)
Theconfinedspaceshall be provided with two permanent openings,
one commencing within 12 inches (30 cm) of the top and one
commencingwithin12inches(30cm)fromthebottomoftheenclosure.
Theopeningsshallcommunicatedirectly,orbyducts,withtheoutdoors
orspaces (crawl or attic) that freelycommunicate withtheoutdoors.
1. When directly communicating with the outdoors, each opening shall
have a minimum free area of 1 square inch per 4,000 Btu per hour
(5.5 cm2/kW)oftotalinputratingofallequipmentintheenclosure, see
Figure6.
FIGURE6.
2. Whencommunicatingwiththeoutdoorsthroughverticalducts, each
openingshall haveaminimum freeareaof 1squareinch per4,000
Btuperhour(5.5cm2/kW)of totalinputratingofallequipmentinthe
enclosure,see Figure 7.
3. Whencommunicating with the outdoors through horizontal ducts,
eachopening shall have aminimumfreearea of 1 square inchper
2,000Btuper hour(11cm2/kW))of totalinputratingofallequipment
inthe enclosure, see Figure 8.
FIGURE7.
4. When ducts are used, they shall be of the same cross-sectional
areaas the free area of the openingsto whichthey connect. The
minimumshort side dimensionofrectangularair ducts shallnotbe
lessthan 3 inches (76.2 mm), see Figure 8.
FIGURE8.
5. Louversand Grilles:Incalculating freearea,consideration shallbe
givento the blocking effect oflouvers,grillesorscreens protecting
openings. Screens used shall not be smaller than 1/4 inch
(6.4mm) mesh. If the free area throughadesignoflouver or grille
isknown, itshouldbe used incalculatingthe sizeopeningrequired
toprovide the freeareaspecified. If the designandfree area isnot
known,it may beassumedthat wood louverswillbe 20-25 percent
freearea andmetallouvers and grilleswillhave 60-75percentfree
area. Louvers and grilles shall be fixed in the open position or
interlockedwiththeequipmentsothattheyareopenedautomatically
duringequipmentoperation.
6. SpecialConditionsCreatedbyMechanicalExhaustingorFireplaces:
operation of exhaust fans, ventilation systems, clothes dryers or
fireplacesmaycreateconditionsrequiringspecialattentionto avoid
unsatisfactoryoperation of installedgasutilizationequipment.

10
WATER PIPING
HOTTER WATER CAN SCALD:
Water heaters are intended to produce hot water. Water heated to a
temperature which will satisfy space heating, clothes washing, dish
washing,cleaningandothersanitizingneedscanscaldandpermanently
injureyouuponcontact. Somepeoplearemorelikely tobepermanently
injured by hot water than others. These include the elderly, children,
the infirm, or physically/mentally handicapped. If anyone using hot
water in your home fits into one of these groups or if there is a local
code or state law requiring a certain temperature water at the hot
watertap, then you must takespecialprecautions. Inadditionto using
the lowest possible temperature setting that satisfies your hot water
needs, a means such as a *mixing valve, shall be used at the hot
watertapsused bythese people or at thewater heater, see Figure2.
Valves for reducing point of use temperature by mixing cold and hot
water are also available. Consult a Qualified Installer or Service
Agency. Follow manufacturer’s instructions for installation of the
valves. Before changing the factory setting on the thermostat, read
the“Temperature Regulation” section in thismanual.
This water heater shall not be connected to any heating systems or
component(s)used with a non-potable water heating appliance.
All piping components connected to this unit for space heating
applicationsshallbe suitableforusewith potablewater.
Toxic chemicals, such as those used for boiler treatment shall not be
introducedinto this system.
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 Figure 2 for suggested piping
arrangement.
Water supply systems may, because of such events as high line
pressure,frequent cut-offs,theeffects ofwaterhammer among others,
haveinstalleddevicessuch aspressurereducing valves,checkvalves,
back flow preventers, etc. to control these types of problems. When
thesedevicesarenotequipped with an internal by-pass, and no other
measuresare taken, the devicescausethe water system to beclosed.
INSTINST
INSTINST
INSTALLING THE NEW WALLING THE NEW W
ALLING THE NEW WALLING THE NEW W
ALLING THE NEW WAA
AA
ATER HEATER HEA
TER HEATER HEA
TER HEATERTER
TERTER
TER
Aswater is heated,itexpands (thermal expansion)andclosedsystems
do not allow for the expansion of heated water.
The water within the water heater tank expands as it is heated and
increasesthe pressure of the water system. If the relieving point of the
waterheater’stemperature-pressure relief valve is reached, the valve
will relieve the excess pressure. The temperature-pressure relief
valve is not intended for the constant relief of thermal
expansion. Thisisan unacceptable condition and must be corrected.
Itisrecommended thatany devicesinstalled whichcould createa closed
system have a by-pass and/or the system have an expansion tank to
relieve the pressure built by thermal expansion in the water system.
Expansion tanks are available for ordering through a local plumbing
contractor. Contactthelocal water supplier and/oraservice agency for
assistancein controlling these situations.
NOTE: To protect against untimely corrosion of hot and cold
water fittings, it is strongly recommended that di-electric unions
or couplings be installed on this water heater when connected
to copper pipe.
FIGURE9.

11
Figure 9 shows the typical attachment of the water piping to the water
heater. The water heater is equipped with 3/4 inch NPT water
connections.
NOTE: If using copper tubing, solder tubing to an adapter before
attaching the adapter to the cold water inlet connection. Do not
solder the cold water supply line directly to the cold water inlet.
It will harm the dip tube and damage the tank.
T & P Valve and Pipe Insulation
Removeinsulation for T & Pvalveandpipe connections from carton.
FIGURE9A.
Fit pipe insulation over the incoming cold water line and the hot water
line.Make sure that the insulationisagainstthe top cover of the heater.
FitT & P valveinsulationovervalve. Make sure thattheinsulationdoes
not interfere with the lever of the T & P valve.
Secureall insulationusingtape.
TEMPERATURE-PRESSURERELIEF VALVE
This heater is provided with a properly certified combination
temperature-pressurereliefvalvebythe manufacturer.
Thevalveis certified by a nationally recognized testing laboratorythat
maintains periodic inspection of production of listed equipment of
materialsas meeting the requirements for Relief ValvesandAutomatic
GasShut-offDevicesforHotWaterSupplySystems,ANSIZ21.22 •CSA
4.4,and the coderequirementsofASME.
Ifreplaced, thevalvemust meettherequirements oflocalcodes, butnot
lessthan a combination temperature and pressure relief valve certified
asindicated in the above paragraph.
Thevalve must be marked with a maximumsetpressurenottoexceed
the marked hydrostatic working pressure of the water heater
(150 psi = 1,035 kPa) and a discharge capacity notlessthanthewater
heaterinput rate as shown on the model rating plate.
For safe operation of the water heater, the relief valve must not be
removedfrom itsdesignatedopeningnor plugged.
Thetemperature-pressure relief valvemustbe installed directlyintothe
fitting of the water heater designed for the relief valve. Position the
valvedownwardandprovidetubingsothatanydischargewill exit only
within6 inches (153 mm)above,orat any distance below thestructural
floor. Be certainthat nocontactismade withanylive electricalpart. The
discharge opening must not be blocked or reduced in size under any
circumstances. Excessivelength, over 30 feet(9.14m), or use ofmore
than four elbows can cause restriction and reduce the discharge
capacityofthe valve, see Figure 10.
No valve or other obstruction is to be placed between the relief valve
andthe tank. Do notconnecttubing directly todischargedrainunless a
6 inch air gap is provided. To prevent bodily injury, hazard to life, or
propertydamage, the reliefvalvemust be allowed todischargewater in
quantities should circumstances demand. If the discharge pipe is not
connectedto a drainorother suitable means, thewaterflow may cause
propertydamage.
TheDischargePipe:
•Shall not be smallerinsize than the outlet pipesize of the valve, or
haveanyreducingcouplingsor other restrictions.
•Shall notbeplugged or blocked.
•Shall be of material listed for hot water distribution.
•Shall be installed so as to allow complete drainage of both the
temperature-pressurerelief valve, and the discharge pipe.
•Shall terminateatan adequatedrain.
•Shall not have any valve between therelief valve andtank.
Thetemperature-pressurereliefvalvemustbemanuallyoperatedatleast
onceayear. Caution shouldbetakentoensure that(1)nooneis infront
oforaroundtheoutletofthetemperature-pressurereliefvalvedischarge
line, and (2) the water manually discharged will not cause any bodily
injuryor property damage because the water may be extremely hot.
If after manually operating the valve, it fails to completely reset and
continuesto release water, immediately close thecoldwater inlet to the
water heater, follow the draining instructions, and replace the
temperature-pressurerelief valve with a newone.

12
FIGURE10.
FILLINGTHE WATER HEATER
Neverusethiswaterheaterunlessitis completelyfullofwater.To prevent
damagetothetank,thetank must be filled with water.Watermustflow
fromthe hot water faucet before turning “ON” gastothewaterheater.
To fill the water heater with water:
1. Close the water heater drain valve by turning the handle to the right
(clockwise). Thedrainvalveisonthelowerfrontofthe water heater.
2. Open the cold water supply valve to the water heater.
NOTE: The cold water supply valve must be left open when
the water heater is in use.
3. Toinsure completefillingof thetank,allowair to exitby opening the
nearest hot water faucet. Allow water to run until a constant flow
isobtained. Thiswilllet air out of the water heater and thepiping.
4. Checkallwaterpipingandconnectionsforleaks. Repairasneeded.
VENTING
VENTDAMPERS-Anyventdamper,whetheritisoperatedthermallyor
otherwise must be removed if its use inhibits proper drafting of the
water heater.
Thermally Operated Vent Dampers: Gas-fired water heaters having
thermalefficiencyinexcessof80%mayproducearelativelylowflue
gas temperature. Such temperatures may not be high enough to
properly open thermally operated vent dampers. This would cause
spillageof thefluegasesand may causecarbonmonoxide poisoning.
Vent dampers must bear evidence of certification as complying with
the current edition of the American National Standard ANSI Z21.68
(ANSIZ21.66&67,respectively,cover electricallyand mechanically
actuatedventdampers). Beforeinstallationofanyventdamper,consult
thelocalgasutilityforfurtherinformation.
Forreplacement heaterinstallationswhere usingpre-existingventing,
ventingmustbeinspectedforobstructionsandifdeteriorationispresent
ventingmust be replaced.
To insure proper venting of this gas-fired water heater, the correct
ventpipediametermust beutilized. Anyadditions ordeletions ofother
gasappliancesonacommonventwiththiswaterheatermayadversely
affect the operation of the water heater. Consult your gas supplier if
anysuchchangesareplanned.
Forproper venting in certain installations, a larger diameter vent pipe
maybenecessary. Consultyourgassuppliertoaid youindetermining
the proper venting for your water heater from the vent tables in the
currenteditionofthe NationalFuel GasCodeANSI Z223.1/NFPA 54.
Periodically check the venting system for signs of obstruction or
deteriorationand replace if needed.
Thecombustion and ventilation air flow must notbeobstructed.
The water heater with draft hood installed must be connected to a
chimneyor listed vent pipe system, which terminates totheoutdoors.
Neveroperate the waterheaterunless it isventedtothe outdoors and
hasadequateairsupplytoavoid risksof improperoperation,explosion
orasphyxiation.
For proper drafthood attachment, the drafthood legs may be angled
slightlyinward.
Obstructedordeterioratedvent systems may present serious health
riskor asphyxiation.
Thevent pipefromthe waterheatermust benoless than thediameter
ofthe draft hood outlet on the water heater and must slope upward at
least1/4 inch per linear foot (21 mmpermeter),seeFigure11.
All vent gases must be completely vented to the outdoors of the
structure(dwelling). Installonlythedrafthoodprovidedwiththenew
waterheater and no other drafthood.
Vent pipes must be securedateach joint with sheet metal screws.
FIGURE11.

13
There must be a minimum of 6 inches (153 mm) clearance between
singlewallvent pipe and any combustible material. Fill and seal any
clearancebetweensinglewall ventpipeand combustiblematerial with
mortar mix, cement, or other noncombustible substance. For other
than single wall, follow vent pipe manufacturer’s clearance
specifications. Toinsureatight fit of the vent pipe in a brick chimney,
sealaround the vent pipe with mortar mixcement.
Failuretohaverequiredclearancesbetweenventpipingandcombustible
materialwillresultina fire hazard.
Besureventpipeisproperlyconnectedtopreventescapeofdangerous
fluegases which could cause deadly asphyxiation.
Chemicalvapor corrosion of the flue and vent system may occur if air
for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants,swimming pool chemicals, calcium and sodiumchloride,
waxes,bleach and process chemicals are typical compoundswhich
arepotentially corrosive.
GAS PIPING
Makesure thegassupplied isthesame typelistedon themodelrating
plate. Theinletgaspressuremustnotexceed14inch watercolumn
(2.6kPa) for natural and propanegas (L.P.). The minimum inlet gas
pressure shown on the rating plate is that which will permit firing at
ratedinput.
Ifthe gas controlvalveis subjected topressuresexceeding1/2 pound
persquareinch (3.5 kPa), the damage to the gas controlvalve could
resultinafireorexplosionfromleakinggas.
If the main gas line Shut-off serving all gas appliances is used, also
turn “off” the gas at each appliance. Leave all gas appliances shut
“off”untilthewaterheaterinstallationiscomplete.
Agas line of sufficient size must be run to the water heater. Consult
thecurrenteditionofNationalFuelGasCodeANSIZ223.1/NFPA54and
yourgassupplierconcerningpipesize.
Theremustbe:
• A readily accessible manual shut off valve in the gas supply line
servingthe water heater, and
• A drip leg (sediment trap) ahead of the gas control valve to help
preventdirtandforeignmaterialsfrom enteringthe gascontrolvalve.
• Aflexible gas connectororaground joint unionbetweenthe shut off
valveandcontrolvalvetopermitservicing of the unit.
Besure to check all the gaspiping forleaks beforelightingthe water
heater. Use a soapywatersolution, not amatchor open flame. Rinse
off soapy solution and wipe dry.
Waterheaters coveredinthis manual havebeentested andapproved
forinstallationatelevations upto7,700 feet(2,347 m)abovesea level.
Forinstallationabove7,700feet(2,347m),thewaterheater’sBtuinput
shouldbe reduced at the rate of4percentfor each 1,000 feet (305 m)
above sea level which requires replacement of the burner orifice in
accordancewiththeNationalFuelGasCodeANSI Z223.1/NFPA54.
Contactyourlocalgassupplierforfurtherinformation.
Failure to replace the standard orifice with the proper high altitude
orificewheninstalled at elevations above 7,700 feet (2,347m) could
resultin improperandinefficient operation oftheappliance, producing
carbonmonoxidegasinexcessof the safe limits. This could result in
seriousinjury ordeath.Contact your localgassupplier for anyspecific
changesthatmay be required in your area.

14
Usepipejoint compoundor teflontapemarkedasbeingresistanttothe
actionof petroleum [Propane(L.P.)] gases.
Theapplianceanditsgasconnectionmustbeleaktestedbeforeplacing
theappliance inoperation.
TheapplianceanditsindividualShut-offvalveshallbedisconnected
fromthe gas supply piping system during any pressure testing of that
system at test pressures in excess of 1/2 pound per square inch
SEDIMENTTRAPS
FIGURE12. GASPIPINGWITH
FLEXIBLECONNECTOR. FIGURE13. GASPIPINGWITH ALL
BLACKIRONPIPE TO GAS CONTROL.
(3.5 kPa). It shall be isolated from the gas supply piping system by
closingitsindividualmanual Shut-offvalveduring anypressure testing
ofthe gas supply pipingsystemattest pressures equal to orlessthan
1/2pound per square inch (3.5 kPa).
Connectingthe gas piping to the gascontrolvalveofthe water heater
canbe accomplished by either of thetwomethods shown in Figures
12and 13.
A sediment trap shall be installed as close to the inlet of the water
heateraspractical atthetimeofwaterheaterinstallation.Thesediment
trapshallbeeither ateefittingwitha cappednippleinthebottom outlet
orother devicerecognizedas an effectivesedimenttrap. Ifateefitting
isused, it shallbeinstalledin conformance withoneof the methods of
installationshown in Figures 12 and 13.
Contaminantsinthe gaslinesmaycauseimproperoperationofthegas
controlvalve that may result in fire or explosion. Before attaching the
gasline be surethatall gas pipeiscleanon the inside. Totrap any dirt
orforeignmaterialin thegas supplyline,adripleg (sometimescalled a
sedimenttrap)must beincorporated inthe piping. Thedrip legmust be
readilyaccessible. Install inaccordancewith the“GasPiping” section.
Refer to the current edition of the National Fuel Gas Code,
ANSIZ223.1/NFPA54.

15
FORYOURSAFETYREAD BEFORELIGHTING
WARNING: If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal injury or loss of life.
• 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.Iftheknob will notpushinor turn
by hand, don’t try to repair it, call a qualified service
technician.Forceor attemptedrepairmay resultina fire
orexplosion.
D. Do not use this appliance if any part has been under
water.Immediatelycontacta qualifiedinstalleror service
agencytoreplace aflooded waterheater.Donotattempt
torepair theunit!It mustbereplaced!
LIGHTINGINSTRUCTIONS
1. Setthermostattothelowestsetting(PILOTLIGHTING).
TOTURN OFFGASTO APPLIANCE
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATERAND AIR PURGED FROMALL LINES.
1. STOP! Readthesafetyinformation
aboveon this label.
2. Setthe thermostat to lowest setting (PILOT LIGHTING).
Turnthermostatdial fully clockwise until it stops.
3. Pushthegascontrolknobdownslightlyandturnclockwise
to“OFF”,seeFigure “A”..
NOTE:Knob CANNOT beturnedfrom“PILOT” to “OFF”
unlessit is pushed down slightly. Do notforce.
4. Remove the outer burner door located below the gas
control.
5. Wait five (5) minutes to clear out any gas. If you then
smellgas, STOP! Follow“B”inthesafety information
aboveon thislabel.Ifyoudon’tsmellgas,gotonextstep.
6. Thisunit isequipped witha pushbuttonpilotignitor,which
is used to light the pilot. Locate the ignitor on the gas
control.
7. Turngas control knob counterclockwise to“PILOT”,
seeFigure “B”.
8. Thepilotislocated onthe rightside ofthe burner. Itcan be
located by looking through the glass view port while
pressingthe piezoignitorbutton severaltimes.Look fora
sparkat the pilot location,seeFigure“D”.
9. Once the pilot has been found, push the gas knob all the
waydown. Immediatelypress thepilotignitorbuttonrapidly
(4) to (5) times. If the pilot will not light, repeat step (3)
through(9).
10. Continue to hold the gas control knob down forabout one
(1)minute afterthepilot is lit.Releasethe gas controlknob
andit will popbackup. Pilot shouldremainlit. If itgoesout,
repeatstep (3) through(9).Itmay take several minutesfor
airtoclearthelinesbeforethepilotwill light.
• If knob does not pop up when released, stop and
immediatelycall your servicetechnicianor gas supplier.
• Ifthepilotwillnotstaylitafterseveraltries,turnthe gas
controlknobclockwise to “OFF”andcallyourservice
technicianorgassupplier,seeFigure “A”.
11. Oncethepilot flameis establishedreplacetheouterburner
door.
12. At arms length away, turn gas control knob
counterclockwise to“ON”,seeFigure“C”.
13. Setthermostat todesiredsetting.
DANGER: Hotter water increases the risk of
scald injury. Consult the instruction manual
before changing temperature.
A. Thisappliance has a pilot which is lit by apiezo-electric
sparkgas ignition system.Donot open theinnerdoor of
theappliance and try to lightthe pilot by hand.
B. BEFORELIGHTING smellallaroundtheappliancearea
forgas. Be sure tosmellnextto the floor becausesome
gasis heavier than air and will settleon thefloor.
WHATTODOIFYOUSMELLGAS:
• Donot try to light any appliance.
• Donottouch anyelectric switch;do notuse anyphone
inyour building.
• Immediatelycallyour gas supplier from a neighbor’s
phone.Follow the gas supplier’s instructions.
2. Push gascontrol knobdown slightly andturn clockwise
to “OFF”, see Figure “A”. Do not force.
FIGURE“D”GAS CONTROL TOPKNOB

16
FOR YFOR Y
FOR YFOR Y
FOR YOUR INFORMAOUR INFORMA
OUR INFORMAOUR INFORMA
OUR INFORMATIONTION
TIONTION
TION
START UPCONDITIONS
DRAFTHOODOPERATION
Checkdrafthoodoperationbyperformingaworstcasedepressurization
of the building. With all doors and windows closed, and with all air
handlingequipmentandexhaustfansoperatingsuchasfurnaces,clothes
dryers,rangehoodsandbathroomfans,a match flame should still be
drawnintothedraft hoodof thewaterheater withits burnerfiring. Ifthe
flame is not drawn toward the draft hood, shut off water heater and
makenecessary air supplychangesto correct.
CONDENSATE
Wheneverthe water heater isfilledwithcold water,somecondensate
NOTE: A water temperature range of 120°F-140°F (49°C-60°C) is
recommendedby most dishwasher manufacturers.
Thethermostatof this water heater has been factory set atits lowest
position(PILOTLIGHTING). It is adjustable and must be reset tothe
desiredtemperaturesettingtoreducethe riskof scaldinjury. Themark
() indicative of approximately 120°F (49°C) is preferred starting
point. SomeStateshave a requirement for a lower setting.
Turn the water temperature dial clockwise ( ) to decrease the
temperature,or counterclockwise ( ) to increase thetemperature.
Shouldoverheating occur or the gas supply failtoshutoff,turn off the
manualgas control valve totheappliance.
FIGURE14.
FIGURE15.
Due to the nature of the typical gas water heater, the water
temperature in certain situations may vary up to 30F° (16.7 C°)
higher or lower at the point of use such as, bathtubs, showers,
sink, etc.
HOTTERWATERCANSCALD:Waterheatersareintendedtoproduce
hot water. Water heated to a temperature which will satisfy space
heating, clothes washing, dish washing, and other sanitizing needs
canscald andpermanentlyinjure youuponcontact. Some people are
morelikely to bepermanentlyinjured by hotwaterthanothers. These
include the elderly, children, the infirm, or physically/mentally
handicapped. Ifanyoneusing hot water in your home fitsinto oneof
thesegroupsorifthereis a local code or state law requiring a certain
temperature water at the hot water tap, then you must take special
precautions. In addition to using the lowest possible temperature
settingthatsatisfiesyourhot water needs, a means such as a mixing
valve,shall be used at thehot water taps used bythese people or at
the water heater. Mixing valves are available at plumbing supply or
hardware stores, see Figure 2. Follow manufacturer’s instructions
for installation of the valves. Before changing the factory setting on
the thermostat, read the “Temperature Regulation” section in this
manual,seeFigures14and15.
Neverallow small children to use a hot watertap,ortodrawtheir own
bathwater. Neverleavea child or handicappedpersonunattendedin
a bathtub or shower.
TEMPERATEMPERA
TEMPERATEMPERA
TEMPERATURE REGULATURE REGULA
TURE REGULATURE REGULA
TURE REGULATIONTION
TIONTION
TION
willformwhiletheburnerison. Awaterheatermayappeartobeleaking
whenin fact the wateris condensation. This usually happens when:
a. A new water heater is filled with cold water for the first time.
b. Burning gas produces water vapor in water heaters, particularly
highefficiencymodels wherefluetemperatures are lower.
c. Large amounts of hot water are used in a short time and the refill
water in the tank is very cold.
Moisturefromtheproductsofcombustion condenseon thecoolertank
surfaces and form drops of water which may fall onto the burner or
other hot surfaces to produce a “sizzling” or “frying” noise.
Excessive condensation can cause pilot outage due to water running
downthefluetube ontothe mainburnerandputtingout thepilot.

17
Becauseof thesuddennessand amountofwater,condensation water
maybediagnosedasa“tankleak”. Afterthewaterinthetankwarms up
(about1-2hours),theconditionshoulddisappear.
Donotassumethe waterheater isleakinguntiltherehas beenenough
timefor the water in the tank to warm up.
Anundersized waterheaterwill cause morecondensation. Thewater
heatermustbesizedproperlytomeetthefamily’sdemandsforhotwater
includingdishwashers, washing machinesandshower heads.
Excessive condensation may be noticed during the winter and early
springmonths whenincomingwater temperaturesareat their lowest.
Goodventingisessentialforagasfiredwaterheatertooperateproperly
as well as to carry away products of combustion and water vapor.
SMOKE/ODOR
It is not uncommon to experience a small amount of smoke and odor
duringtheinitialstart-up. Thisisduetoburningoffofoilfrommetalparts,
andwill disappear in a shortwhile.
THERMALEXPANSION
Water supply systems may, because of such events as high line
pressure, frequent cut-offs, the effects of water hammer among
others,haveinstalled devicessuch aspressurereducingvalves,check
valves,backflowpreventers,etc.to control these types of problems.
Whenthesedevicesare notequippedwith aninternalby-pass,andno
othermeasuresaretaken, the devices cause the water system to be
closed. Aswaterisheated, itexpands (thermalexpansion)and closed
systems do not allow for the expansion of heated water.
The water within the water heater tank expands as it is heated and
increases the pressure of the water system. If the relieving point of
the water heater’s temperature-pressure relief valve is reached, the
valve will relieve the excess pressure. The temperature-pressure
relief valve is not intended for the constant relief of thermal
expansion. Thisis anunacceptable conditionandmust becorrected.
It is recommended that any devices installed which could create a
closedsystemhaveaby-passand/orthesystem have an expansion
tankor device torelievethe pressure builtbythermal expansion inthe
water system. Expansion tanks are available for ordering through a
localplumbingcontractor. Contact the localwater heatersupplier or
serviceagencyforassistance in controlling these situations.
STRANGESOUNDS
Possiblenoises duetoexpansion andcontractionof somemetalparts
duringperiods of heat-upandcool-down do notnecessarilyrepresent
harmfulor dangerous conditions.
Condensationcausessizzlingandpoppingwithintheburnerareaduring
heatingand cooling periods andshould be considered normal. See
“Condensation”in this section.
OPERATIONALCONDITIONS
SMELLYWATER
In each water heater there is installed at least one anode rod (see
parts sections) for corrosion protection of the tank. Certain water
conditionswill cause a reaction between this rodand thewater. The
most common complaint associated with the anode rod is one of a
“rottenegg smell”inthehot water. Thisodor is derivedfromhydrogen
sulfide gas dissolved in the water. The smell is the result of four
factors which must all be present for the odor to develop:
a. Aconcentration of sulfate in the supply water.
b. Little orno dissolvedoxygen inthe water.
c. Asulfate reducingbacteria whichhasaccumulatedwithinthewater
heater(this harmless bacteria is nontoxic to humans).
d. An excess of active hydrogen in the tank. This is caused by the
corrosionprotectiveactionoftheanode.
Smelly water may be eliminated or reduced in some water heater
modelsby replacing theanode(s)with one oflessactivematerial, and
thenchlorinating thewaterheater tankandall hotwaterlines. Contact
thelocalwaterheater supplieror serviceagencyfor furtherinformation
concerninganAnodeReplacement Kitandthischlorinationtreatment.
Ifthesmellywaterpersistsaftertheanodereplacementandchlorination
treatment, we can only suggest that chlorination or aeration of the
watersupply be considered to eliminate the water problem.
Do not remove the anode leaving the tank unprotected. By
doing so, all warranty on the water heater tank is voided.
“AIR”IN HOTWATERFAUCETS
HYDROGEN GAS: Hydrogen gas can be produced in a hot water
systemthat has not beenusedfora long period oftime(generallytwo
weeksormore). Hydrogengas isextremelyflammable andexplosive.
To prevent the possibility of injury under these conditions, we
recommend the hot water faucet, located farthest away, be opened
for several minutes before any electrical appliances which are
connectedto the hot watersystemareused (such as a dishwasheror
washingmachine). Ifhydrogengasispresent,therewillprobablybe
an unusual sound similar to air escaping through the pipe as the hot
waterfaucetisopened. There mustbe nosmokingoropenflame near
thefaucetat the time it is open.
HIGHWATERTEMPERATURESHUTOFFSYSTEM
Thiswater heater is equipped with an automaticgasShut-offsystem.
Thissystem works when high water temperaturesare present. Turn
“OFF”the entiregassupply tothewater heater. Thehigh temperature
Shut-off is built into the gas control valve. It is non-resettable. If the
high temperature Shut-off activates, the gas control valve must be
replaced.Contactyourgassupplierorservice agency.

18
VENTINGSYSTEM INSPECTION
Atleast once ayearavisual inspection should bemadeof the venting
system. You should look for:
1. Obstructionswhich couldcause improperventing. The combustion
andventilationairflowmustnotbeobstructed.
2. Damage or deterioration which could cause improper venting or
leakageof combustion products.
3. Rusted flakesaround topofwater heater.
Be sure the vent piping is properly connected to prevent escape of
dangerousfluegasses which could cause deadly asphyxiation.
Obstructionsanddeterioratedventsystemsmaypresentserioushealth
riskor asphyxiation.
Chemicalvapor corrosion of the flue and vent system may occur if air
forcombustioncontainscertainchemicalvapors.Spraycanpropellants,
cleaning solvents, refrigerator and air conditioner refrigerants,
swimmingpoolchemicals,calciumandsodium chloride,waxes,bleach
and process chemicals are typical compounds which are potentially
corrosive.
Ifafterinspectionoftheventsystemyou foundsooting ordeterioration,
somethingiswrong. Callthelocalgas utilityto correctthe problemand
cleanor replace theflueandventing before resumingoperationofthe
water heater.
BURNERINSPECTION
Flooddamagetoawaterheatermaynotbereadilyvisibleorimmediately
detectable.However, over a period of time a flooded water heater will
create dangerous conditions which can cause DEATH, SERIOUS
BODILYINJURY,ORPROPERTYDAMAGE.Contactaqualifiedinstaller
orservice agency toreplaceaflooded water heater.Do not attempt to
repairthe unit!It must bereplaced!
At least once a year a visual inspection should be made of the main
burnerand pilot burner,see Figure 16.
PERIODIC MAINTENANCEPERIODIC MAINTENANCE
PERIODIC MAINTENANCEPERIODIC MAINTENANCE
PERIODIC MAINTENANCE
Youshouldcheck forsooting.Soot is notnormaland willimpairproper
combustion.
Sootbuild-upindicatesaproblemthat requirescorrectionbeforefurther
use. Turn “OFF” gas to water heater and leave off until repairs are
made,because failure to correctthecauseof the sooting canresultin
afirecausingdeath,seriousinjury,or property damage.
FIGURE16.
BURNERCLEANING
In the event your burner needs cleaning, follow these instructions:
Ifinspection oftheburner shows thatcleaningis required,turnthe gas
controlknob clockwise( ) tothe“OFF” position,depressing slightly.
NOTE:The knob cannotbe turned from“PILOT” to “OFF” unless
knob is depressed slightly. DO NOT FORCE.
Theburnerneedstoberemoved forcleaning. Call aserviceagencyto
removeandcleanthe burnerandcorrect theproblemthat requiredthe
burnerto be cleaned.
HOUSEKEEPING
Vacuum aroundbaseof waterheaterfor dust,dirt,and lintona regular
basis.
AT LEAST ONCE EVERAT LEAST ONCE EVER
AT LEAST ONCE EVERAT LEAST ONCE EVER
AT LEAST ONCE EVERY SIX MONTHSY SIX MONTHS
Y SIX MONTHSY SIX MONTHS
Y SIX MONTHS AA
AA
A VISUVISU
VISUVISU
VISUALAL
ALAL
AL
INSPECTION SHOULD BE MADE OF THE AIRINSPECTION SHOULD BE MADE OF THE AIR
INSPECTION SHOULD BE MADE OF THE AIRINSPECTION SHOULD BE MADE OF THE AIR
INSPECTION SHOULD BE MADE OF THE AIR
INTINT
INTINT
INTAKE SCREENAKE SCREEN
AKE SCREENAKE SCREEN
AKE SCREEN..
..
.CLEAN IF LINTCLEAN IF LINT
CLEAN IF LINTCLEAN IF LINT
CLEAN IF LINT AA
AA
ACCUMULACCUMULA
CCUMULACCUMULA
CCUMULATIONSTIONS
TIONSTIONS
TIONS
ARE NOARE NO
ARE NOARE NO
ARE NOTICEDTICED
TICEDTICED
TICED..
..
.

19
INSTALLEDINSUITABLEAREA:To insure sufficientventilationand
combustionair supply, proper clearances from the water heater must
be maintained. See “Locating the New Water Heater” section.
Combustiblematerialssuchasclothing,cleaningmaterials,orflammable
liquids,etc. mustnotbe placed againstoradjacent to thewaterheater
which can cause a fire.
ANODEROD INSPECTION
The anode rod is used to protect the tank from corrosion. Most hot
water tanks are equipped with an anode rod. The submerged rod
sacrifices itself to protect the tank. Instead of corroding the tank,
water ions attack and eat away the anode rod. This does not affect
thewater’stasteorcolor. Therod mustbemaintainedto keepthetank
inoperatingcondition.
Anode deterioration depends on water conductivity, not necessarily
water condition.Acorroded or pitted anode rod indicates high water
conductivityand should be checked and/or replaced more often than
an anode rod that appears to be intact. Replacement of a depleted
anoderodcanextendthelife of your water heater.Inspection should
beconducted by a qualified technician, andata minimum should be
checkedannuallyafter the warranty period.
TEMPERATURE-PRESSURE
RELIEFVALVE OPERATION
Thetemperature-pressurereliefvalvemustbe manually operated at
leastoncea year.
FIGURE 17.
Whencheckingthetemperature-pressure reliefvalveoperation, make
surethat(1) noone isin frontof oraround theoutlet ofthetemperature-
pressurerelief valve discharge line, and (2) thatthewater discharge
will not cause any property damage, as the water may be extremely
hot,see Figure 17.
If after manually operating the valve, it fails to completely reset and
continuesto release water,immediately close the cold water inletto
the water heater, follow the draining instructions, and replace the
temperature-pressurerelief valve with a newone.
If the temperature-pressure relief valve on the appliance weeps or
discharges periodically, this may be due to thermal expansion. You
may have a check valve installed in the water line or a water meter
with a check valve. Consult your local water supplier or service
agencyfor further information. Donotplug the temperature-pressure
reliefvalve.
DRAINING
Thewater heatershould bedrainedif beingshutdown duringfreezing
temperatures. Alsoperiodicdraining and cleaning of sediment from
thetank may be necessary.
1. Turnthe gas control knobtothe“OFF” position.
2. CLOSEthe cold water inlet valveto the water heater.
3. OPEN anearby hotwater faucetand leaveopen to allowfor
draining.
4. Connect a hose to the drain valve and terminate to an adequate
drain.
5. OPENthe water heater drain valve to allow for tank draining.
NOTE: If the water heater is going to be shut down and
drained for an extended period, the drain valve should be
left open with hose connected allowing water to terminate
to an adequate drain.
6. CLOSEthedrainvalve.
7. Followinstructions in the “FillingTheWater Heater” section.
8. Follow thelighting instructionsonthe label or see page 14under
“LightingInstructions”torestartthe waterheater.
DRAINVALVEWASHER REPLACEMENT
(SeeFigure 18)
1. Turn“OFF” gas supply to water heater.
2. Follow“Draining” instructions.
3. Turning counterclockwise ( ), remove the hex cap below the
screw handle.
4. Remove thewasher andput the newone inplace.
5. Screwthe handle and cap assembly back intothedrainvalveand
retightenusingawrench.DONOTOVERTIGHTEN.
6. Followinstructions in the “FillingTheWater Heater” section.
7. Checkfor leaks.

20
LEAKAGE CHECKPOINTSLEAKAGE CHECKPOINTS
LEAKAGE CHECKPOINTSLEAKAGE CHECKPOINTS
LEAKAGE CHECKPOINTS
Readthismanualfirst. Thenbeforechecking the water heater make
sure the gas supply has been turned “OFF”, and never turn the gas
“ON”beforethe tankis completely full of water.
Neveruse thiswaterheater unless itiscompletely filled withwater. To
preventdamage to the tank,thetankmustbefilledwithwater. Water
must flow from the hot water faucet before turning “ON” gas to the
water heater.
A. Wateratthedrafthood is water vaporwhichhascondensed out of
thecombustion products. This is caused byaproblemin the vent.
Contactthegasutility.
B. *Condensation may be seen on pipes in humid weather or pipe
connectionsmay beleaking.
C. *Theanode rodfittingmay be leaking.
D. Small amounts of water from temperature-pressure relief valve
may be due to thermal expansion or high water pressure in your
area.
E. *Thetemperature-pressure relief valve may be leaking at thetank
fitting.
F. Water from a drain valve may be due to the valve being slightly
opened.
G. *Thedrain valve maybeleaking at thetankfitting.
H. Combustionproducts contain watervaporwhich can condenseon
the cooler surfaces of the tank. Droplets form and drip onto the
burner or run on the floor. This is common at the time of start-up
afterinstallationandwhenincoming water is cold.
I. Water in the water heater bottom or on the floor may be from
condensation,looseconnections,orthereliefvalve. DONOTreplace
thewater heater until afullinspectionof all possible water sources
ismadeand necessary corrective steps taken.
Leakagefromotherappliances,waterlines,orgroundseepageshould
alsobe checked.
* To check where threaded portion enters tank, insert cotton swab
betweenjacketopening andfitting. If cottonis wet,follow “Draining”
instructionsinthe“Periodic Maintenance”sectionandthenremove
fitting. Put pipe dope or teflon tape on the threads and replace.
Thenfollow “Filling the Water Heater”instructionsinthe “Installing
theNew Water Heater” section.
8. Followthe lightinginstructions inthe“Lighting” sectiontorestartthe
water heater.
FIGURE 18.
SERVICE
Ifaconditionpersists or you are uncertain about the operation of the
water heater contact a service agency.
Use this guide to check a “Leaking” water heater. Many suspected
“Leakers”are not leaking tanks. Often thesourceofthewater can be
foundand corrected.
If you are not thoroughly familiar with gas codes, your water heater,
andsafety practices, contact your gassupplierorqualifiedinstaller to
checkthe water heater.