Instruction Manual
RESIDENTIAL GAS WATER HEATERS
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
Everything you need to know is
contained in this fully illustrated
Installation Guide. For most of
you, this simple procedure
booklet is all that’s needed.
However, if necessary you can
get help from “HELPFUL HAL”.
He is there to help, with advice
and direction. Call our toll free
number and ask for “HELPFUL
HAL” It’s your hotline to fast help!
1-800-365-4054
• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
BYTHIS WATER HEATER.
ALLTECHNICALAND WARRANTY QUESTIONS: SHOULD BE DIRECTEDTOTHE LOCALDEALER FROM WHOM THE WATER HEATER WAS
PURCHASED.IFYOUAREUNSUCCESSFUL,PLEASEWRITETOTHECOMPANYLISTEDONTHERATINGPLATEONTHEWATERHEATER.
KEEPTHIS MANUALIN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
PRINTED IN THE U.S.A 1004
PART NO. 196296-001
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GENERAL SAFETY
3
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TABLE OF CONTENTS
SAFE INSTALLATION, USEAND SERVICE .............................. 2
FORYOUR INFORMATION ............................................... 22-24
Start Up Conditions ................................................... 22,23
Draft Hood Operation ............................................. 22
Condensation .................................................... 22,23
Smoke/Odor ............................................................ 23
Thermal Expansion ................................................. 23
Strange Sounds ...................................................... 23
OPERATIONALCONDITIONS .............................................23,24
Smelly Water .......................................................... 23
“Air” in Hot Water Faucets ................................ 23,24
High Temperature Shut Off System ....................... 24
PERIODICMAINTENANCE ................................................. 24-26
Venting System Inspection ............................................ 24
Burner Inspection ........................................................... 24
Burner Cleaning.............................................................. 25
Housekeeping ................................................................ 25
Anode Rod Inspection .................................................... 25
Temperature-Pressure Relief Valve Operation .............. 25
Draining .....................................................................25,26
Drain Valve Washer Replacement ................................. 26
Service ........................................................................... 26
LEAKAGECHECKPOINTS ...................................................... 27
TROUBLESHOOTINGGUIDELINES ......................................... 28
REPAIR PARTS LIST ............................................................... 29
GENERAL SAFETY .................................................................. 3
TABLE OF CONTENTS .............................................................. 4
INTRODUCTION ........................................................................ 4
Preparing for the New Installation ................................... 4
TYPICALINSTALLATION .......................................................5,6
REMOVINGTHE OLD WATER HEATER .................................... 7
MATERIALSAND BASICTOOLS NEEDED ............................... 8
LOCATINGTHE NEW WATER HEATER ............................... 9-12
Facts to Consider About Location ..............................9,10
Insulation Blankets .................................................... 10,11
Combustion Air and Ventilation for Appliances
Located in Unconfined Spaces ..................................... 11
Combustion Air and Ventilation for Appliances
Located in Confined Spaces .................................... 11,12
INSTALLING THE NEW WATER HEATER .......................... 13-19
Section A - Galvanized Piping .................................. 13,14
Section B - Copper (Sweat) Piping.......................... 14-15
Temperature-Pressure Relief Valve ..........................16,17
Filling the Water Heater .................................................. 17
Venting ...................................................................... 17,18
Gas Piping ................................................................. 18,19
Sediment Traps .............................................................. 19
LIGHTING&OPERATINGINSTRUCTIONS ..........................20,21
TEMPERATUREREGULATION ................................................ 22
WARRANTY ...................................................................... 30,31
INTRODUCTION
Thank You for purchasing this water heater. Properly installed
and maintained, it should give you years of trouble free service.
2. The installation 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 Code ANSI Z223.1/NFPA 54. This publication is
available from the CSA International, 8501 East Pleasant
Valley Rd., Cleveland, Ohio 44131, or The National Fire
Protection Association, 1 Batterymarch Park, Quincy, MA
02269.
Abbreviations Found In This Instruction Manual:
•
•
•
•
•
•
•
•
U.L. - Underwriters Laboratories Inc.
CSA - Canadian Standards Association
ANSI - American National Standards Institute
NFPA - National Fire Protection Association
ASME - American Society of Mechanical Engineers
GAMA - Gas Appliance Manufacturer’s Association
EPACT - Energy PolicyAct
3. If after reading this manual you have any questions or do not
understand any portion of the instructions, call the local gas
utility or the manufacturer whose name appears on the rating
plate.
CAN - Canada
4. Carefully plan the place where you are going to put the water
heater. Correct combustion, vent action, and vent pipe
installation are very important in preventing death from
possible carbon monoxide poisoning and fires, see Figures
9 through 14.
This gas-fired water heater is design certified by Underwriters
Laboritories, Inc. under American National Standard/CSA
Standard for Gas Water Heaters ANSI Z21.10.3 - CSA 4.3 (current
edition).
Examine the location to ensure the water heater complies
with the Locating the New Water Heater section in this
manual.
PREPARING FOR THE NEW INSTALLATION
1. Read the “General Safety” section, page 3 of this manual
first and then the entire manual carefully. If you don’t follow
the safety rules, the water heater will not operate properly. It
could cause DEATH, SERIOUS BODILY INJURY AND/OR
PROPERTY DAMAGE.
5. For California installation this water heater must be braced,
anchored, or strapped to avoid falling or moving during an
earthquake. See instructions for correct installation
procedures. Instructions may be obtained from California
Office of the State Architect, 400 P Street, Sacramento, CA
95814.
This manual contains instructions for the installation,
operation, and maintenance of the gas-fired water heater. It
also contains warnings throughout the manual that you must
read and be aware of. All warnings and all instructions are
essential to the proper operation of the water heater and
your safety. Since we cannot put everything on the first few
pages, READ THE ENTIRE MANUALBEFOREATTEMPTING
TO INSTALLOR OPERATE THE WATER HEATER.
6. Massachusetts Code requires this water heater to be
installed in accordance with Massachusetts 248-CMR 2.00:
State Plumbing Code and 248-CMR 5.00.
7. Complies with SCAQMD rule #1146.2 and districts having
equivalent NOx requirements.
4
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TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A
B
C
D
E
F
VENT PIPE
DRAFT HOOD
ANODE
HOT WATER OUTLET
OUTLET
INSULATION
GAS SUPPLY
MANUAL GAS SHUT-OFF VALVE
I
J
GROUND JOINT UNION
DRIP LEG (SEDIMENT TRAP)
INNER DOOR
OUTER DOOR
UNION
INLET WATER SHUT-OFF VALVE
COLD WATER INLET
INLET DIP TUBE
Q
TEMPERATURE-PRESSURE
RELIEF VALVE
RATING PLATE
FLUE BAFFLE(S)
THERMOSTAT
DRAIN VALVE
PILOT AND MAIN BURNER
FLUE
K
L
M
N
O
P
R
S
T
U
V
W
X
G
H
DRAIN PAN
* INSTALL IN ACCORDANCE WITH
LOCAL CODES.
* DRIP LE
LOCAL CO
(T) THERMOSTAT
* ALL PIPIN
SUPPLIED
(V) PILOT & MAIN BURNER - NATURAL GAS
(V) PILOT & MAIN BURNER - PROPANE GAS
MAIN
BURNER
THERMOCOUPLE
PILOT
BURNER
** CLOSED WATER SYSTEMSARE THOSE
WITH BACK FLOW PREVENTION DEVICES
INSTALLED IN THE INLETWATER SERVICE LINE.
FIGURE 1.
5
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TYPICAL INSTALLATION
MIXING VALVE USAGE
FIGURE2.
HOTTER WATER CAN SCALD:
This appliance has been design certified as complying with
ANSI Z21.10.3 latest edition, for water heaters and is considered
suitable for:
Water heaters are intended to produce hot water. Water heated
to a temperature which will satisfy space heating, clothes
washing, dish washing, and other sanitizing needs can scald
and 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 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 Service Agency. Follow mixing valve
manufacturer’s instructions for installation of the valves. Before
changing the factory setting on the thermostat, read the
“Temperature Regulation” section in this manual, see Figures
31 and 32 on page 22.
Water (Potable) Heating: All models are considered suitable
for water (potable) heating only.
6
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REMOVING THE OLD WATER HEATER
4. Attach a hose to the water heater
drain valve and put the other end in
a floor drain or outdoors. Open the
water heater drain valve. Open a
nearby hot water faucet which will
relieve pressure in the water
heater and speed draining. The
water passing out of the drain valve
may be extremely hot. To avoid
being scalded, make sure all
connections are tight and that the
water flow is directed away from
any person, see Figures 3 and 6.
FIGURE 6.
5. Disconnect the vent pipe from the draft hood where they
connect to the water heater. In most installations the vent
pipe can be lifted off after any screw or other attached devices
are removed. Dispose of the draft hood. The new water
heater has the draft hood which must be used for proper
operation.
6. If you have copper piping to the water heater, the two copper
water pipes can be cut with a hacksaw approximately four
inches away from where they connect to the water heater.
This will avoid cutting off pipes too short. Additional cuts can
be made later if necessary. Disconnect the temperature-
pressure relief valve drain line. When the water heater is
drained, disconnect the hose from the drain valve. Close the
drain valve. The water heater is now completely disconnected
and ready to be removed, see Figure 7.
FIGURE 3.
1. Turn “OFF” the gas supply to the
water heater.
If the main gas line shut-off valve
serving all gas appliances is
used, also shut “OFF” the gas at
each appliance. Leave all gas
appliances shut “OFF” until the
water heater installation is
completed, see Figures 3 and 4.
FIGURE 4.
FIGURE 7.
If you have galvanized pipe to the water heater, loosen the two
galvanized pipes with a pipe wrench at the union in each line.
Also disconnect the piping remaining to the water heater.
These pieces should be saved since they may be needed
when reconnecting the new water heater. Disconnect the
temperature-pressure relief valve drain line. When the water
heater is drained, disconnect the hose from the drain valve.
Close the drain valve. The water heater is now completely
disconnected and ready to be removed. Mineral buildup or
sediment may have accumulated in the old water heater. This
causes the water heater to be much heavier than normal and
this residue, if spilled out, could cause staining, see
Figure 8.
2. Turn “OFF” the water supply to the
water heater at the water shut off
valve or water meter. Some
installations require that the water
be turned off to the entire house,
see Figures 3 and 5.
FIGURE 5.
3. Check again to make sure the gas supply is “OFF” to the
water heater. Then disconnect the gas supply connection
from the gas control valve.
FIGURE 8.
7
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MATERIALS AND BASIC TOOLS NEEDED
DECIDING ON THE TYPE OF INSTALLATION
Section B
Copper (Sweat) Piping
There are typically two different types of installations. The
installation section of this manual has been broken into these
two methods:
The original piping is copper sweat and you are going to
reconnect with sweat joints.
Look at your old water heater installation to determine which
type of installation you have. After finding out what type of
installation you have, look at the options:
Section A
Galvanized Piping
The original piping is galvanized pipe.
Individual Parts
LENGTH OF HARD COPPER PIPING
(SIZE OF COPPER PIPE AND SWEAT FITTINGS MUST
BE THE SAME SIZE AS THE ORIGINAL PIPING.)
FLEXIBLE GAS
CONNECTOR
PART NO. 9000068
2 FEMALE AND 1 MALE
THREADED TO SWEAT
CONNECTORS
2 - SWEAT
COUPLINGS
CHECK YOUR TOOLS
FLEXIBLE GAS
CONNECTOR
PART NO. 9000068
CHECK YOUR TOOLS
PIPE WRENCHES
DRILL
MAAP GAS
TORCH
SOLDER FLUX
HACKSAW
PIPE WRENCHES
DRILL
ROLL
PIPE DOPE STICK
(USE ONLY ON WATER (FOR WATER AND GAS
CONNECTIONS)
CONNECTIONS)
SLOT-HEAD SCREWDRIVER
SLOT-HEAD SCREWDRIVER
PHILLIPS HEAD SCREWDRIVER
PIPE
DOPE STICK
PHILLIPS HEAD SCREWDRIVER
ROLL 95-5 OR
EQUIVALENT
SOFT SOLDER
TUBING CUTTER
3/4” WIRE BRUSH
1/2” WIRE BRUSH
ROLL OF
EMERY CLOTH
ROLL OF TEFLON TAPE
(USE ONLY ON WATER
CONNECTIONS)
ROLL OF
EMERY CLOTH
GARDEN
HOSE
GARDEN
HOSE
8
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LOCATING THE NEW WATER HEATER
•
Water supply shut-off devices that activate based on the
water pressure differential between the cold water and hot
water pipes connected to the water heater.
FACTS TO CONSIDERABOUT THE LOCATION
Carefully choose an indoor location for the new water 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.
•
Devices that will turn off the gas supply to a gas water heater
while at the same time shutting off its water supply.
Whether replacing an old water heater or putting the water
heater in a new location, the following critical points must be
observed:
1. Select a location indoors as close as practical to the gas
vent or chimney to which the water heater vent is going to be
connected, and as centralized with the water piping system
as possible.
2. Selected location must provide adequate clearances for
servicing and proper operation of the water heater.
Installation of the water heater must be accomplished in such
a manner that if the tank or any connections should leak, the
flow will not cause damage to the structure. For this reason, it
is not advisable to install the water heater in an attic or upper
floor. When such locations cannot be avoided, a suitable drain
pan should be installed under the water heater. Drain pans
are available at your local hardware store. Such a drain pan
must have a minimum length and width of at least 2” (51 mm)
greater than the water heater dimensions and must be piped
to an adequate drain. The pan must not restrict combustion air
flow.
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS
(VAPORS) ARE LIKELY TO BE PRESENT OR STORED
(GARAGES, STORAGE AND UTILITY AREAS, ETC.):
Flammable liquids (such as gasoline, solvents, propane [LP
or butane, etc.] and other substances such as adhesives, etc.)
emit flammable vapors which can be ignited by a gas water
heater’s pilot light or main burner. The resulting flashback and
fire can cause death or serious burns to anyone in the area, as
well as property damage. If installation in such areas is your
only option, then the installation must be accomplished in a
way that the pilot flame and main burner flame are elevated
from the floor at least 18 inches. While this may reduce the
chances of flammable vapors, from a floor spill being ignited,
gasoline and other flammable substances should never be
stored or used in the same room or area containing a gas
water heater or other open flame or spark producing appliance.
NOTE: Flammable vapors may be drawn by air currents from
other areas of the structure to the appliance.
Water heater life depends upon water quality, water pressure
and the environment in which the water heater is installed.
Water heaters are sometimes installed in locations where
leakage may result in property damage, even with the use of a
drain pan piped to a drain. However, unanticipated damage
can be reduced or prevented by a leak detector or water shut-
off device used in conjunction with a piped drain pan. These
devices are available from some plumbing supply wholesalers
and retailers, and detect and react to leakage in various ways:
•
Sensors mounted in the drain pan that trigger an alarm or
turn off the incoming water to the water heater when leakage
is detected.
•
Sensors mounted in the drain pan that turn off the water
supply to the entire home when water is detected in the
drain pan.
Also, the water heater must be located and/or protected so it is
not subject to physical damage by a moving vehicle.
9
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This water heater must not be installed directly on carpeting.
Carpeting must be protected by metal or wood panel beneath
the appliance extending beyond the full width and depth of the
appliance by at least 3” (76.2 mm) in any direction, or if the
appliance is installed in an alcove or closet, the entire floor
must be covered by the panel. Failure to heed this warning
may result in a fire hazard.
FIGURE 10.
If this water heater will be used in beauty shops, barber shops,
cleaning establishments, or self-service laundries with dry
cleaning equipment, it is imperative that the water heater or
water heaters be installed so that combustion and ventilation
air be taken from outside these areas.
Minimum clearances between the water heater and
combustible construction are 0 inch at the sides and rear,
4” (102 mm) at the front, and 6” (153 mm) from the vent pipe.
Clearance from the top of the jacket is 12” (305 mm) on most
models. Note that a lesser dimension may be allowed on
some models, refer to the label attached adjacent to the gas
control valve on the water heater, see Figure 9.
Propellants of aerosol sprays and volatile compounds,
(cleaners, chlorine based chemicals, refrigerants, etc.) in
addition to being highly flammable in many cases, will also
change to corrosive hydrochloric acid when exposed to the
combustion products of the water heater. The results can be
hazardous, and also cause product failure.
INSULATION BLANKETS
FIGURE9.
A gas water heater cannot operate properly without the correct
amount of air for combustion. Do not install in a confined area
such as a closet, unless you provide air as shown in the
Locating The New Water Heater section. Never obstruct the
flow of ventilation air. If you have any doubts or questions at all,
call your gas supplier. Failure to provide the proper amount of
combustion air can result in a fire or explosion and cause
death, serious bodily injury, or property damage.
10
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Insulation blankets are available to the general public for
external use on gas water heaters but are not necessary with
Reliance products. The purpose of an insulation blanket is to
reduce the standby heat loss encountered with storage tank
heaters. Your Reliance water heater meets or exceeds the
EPACT standards with respect to insulation and standby loss
requirements, making an insulation blanket unnecessary.
per 1,000 Btu per hour (22cm2/kW) of the total input rating of all
gas utilization equipment in the confined space, but not less
than 100 square inches (645cm2). One opening shall
commence within 12” (30 cm) of the top and one commencing
within 12” (30 cm) of the bottom of the enclosures.
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 resulting in 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 relief valve.
Do not allow insulation to come within 2" of the floor to
prevent blockage of combustion 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.
FIGURE 11.
B. ALL AIR FROM OUTDOORS: (See Figures 12, 13 and 14)
Do obtain new warning and instruction labels from Reliance
for placement on the blanket directly over the existing labels.
The confined space shall be provided with two permanent
openings, one commencing within 12” (30 cm) of the top and
one commencing within 12” (30 cm) from the bottom of the
enclosure. The openings shall communicate directly, or by
ducts, with the outdoors or spaces (crawl or attic) that freely
communicate with the outdoors.
Do inspect the insulation blanket frequently to make certain
it does not sag, thereby obstructing combustion air flow.
COMBUSTION AIR AND VENTILATION FOR
APPLIANCES LOCATED IN UNCONFINED SPACES
UNCONFINED SPACE is space whose volume is not less than
50 cubic feet per 1,000 Btu per hour (4.8 m3 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 openings not furnished with
doors, are considered a part of the unconfined space.
In unconfined spaces in buildings, infiltration may be adequate
to provide air for combustion, ventilation and dilution of flue
gases. However, in buildings of tight construction (for example,
weather stripping, heavily insulated, caulked, vapor barrier, etc.),
additional air may need to be provided using the methods
described in “Combustion Air and Ventilation for Appliances
Located in Confined Spaces.”
COMBUSTION AIR AND VENTILATION FOR
APPLIANCES LOCATED IN CONFINED SPACES
CONFINED SPACE is a space whose volume is less than 50
cubic feet per 1,000 Btu per hour (4.8 m3 per kW) of the
aggregate input rating of all appliances installed in that space.
FIGURE 12.
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) of total input rating of all
equipment in the enclosure, see Figure 12.
A. ALL AIR FROM INSIDE BUILDINGS:
(See Figures 10 and 11)
The confined space shall be provided with two permanent
openings communicating directly with an additional room(s)
of sufficient volume so that the combined volume of all spaces
meets the criteria for an unconfined space. The total input of
all gas utilization equipment installed in the combined space
shall be considered in making this determination. Each
opening shall have a minimum free area of one square inch
2. When communicating with the outdoors through vertical
ducts, each opening must have a minimum free area of 1
square inch per 4,000 Btu per hour (5.5 cm2/kW) of total
input rating of all equipment in the enclosure, see
Figure 13.
11
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a design of louver or grille is known, it should be used in
calculating the size opening required to provide the free
area specified. If the design and free area is not known, it
may be assumed that wood louvers will be 20-25 percent
free area and metal louvers and grilles will have 60-75
percent free area. Louvers and grilles shall be fixed in the
open position or interlocked with the equipment so that they
are opened automatically during equipment operation.
FIGURE 13.
3. When communicating with the outdoors through horizontal
ducts, each opening shall have a minimum free area of 1
square inch per 2,000 Btu per hour (11 cm2/kW) of total input
rating of all equipment in the enclosure, see Figure 14.
4. When ducts are used, they shall be of the same cross-
sectional area as the free area of the openings to which
they connect. The minimum short side dimension of
rectangular air ducts shall not be less than 3” (76.2 mm),
see Figure 14.
FIGURE 14.
6. Special Conditions Created by Mechanical Exhausting or
Fireplaces: operation of exhaust fans, ventilation systems,
clothes dryers or fireplaces may create conditions requiring
special attention to avoid unsatisfactory operation of installed
gas utilization equipment.
5. Louvers and Grilles: In calculating free area, consideration
shall be given to the blocking effect of louvers, grilles or
screens protecting openings. Screens used shall not be
smaller than 1/4 inch (6.4 mm) mesh. If the free area through
12
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INSTALLING THE NEW WATER HEATER
FIGURE 16A.
3. Place the vent pipe over the draft hood. With the vent pipe
in position, drill a small hole through both the vent pipe
and draft hood. Secure them together with a sheet metal
screw.
4. Wrap the 1” NPT threaded nipples (75 gallon models) or
1.25” NPT threaded nipples (100 gallon models) with teflon
tape or pipe joint compound, see Figure 17. Connect the
existing piping to the water heater.
FIGURE 15.
SECTIONA - GALVANIZED PIPING
(See Figure 15)
1. Position the water heater so that the existing piping will
require the shortest distance between connections. Make
sure that you are able to reach the drain valve and all
connections when the water heater is in place. This will
make it easy to service the water heater. The water heater
must be level before you begin the piping.
FIGURE 17.
If a water heater is installed in a closed water supply system,
such as one having a back-flow preventer, check valve,
water meter with check valve, etc. . . in the cold water
supply, means shall be provided to control thermal
expansion. Contact a qualified installer or service agency
on how to control this situation.
5. See the Temperature-Pressure Relief Valve section for
instructions on installing the discharge pipe.
6. Connect the flexible gas connector to the incoming gas
line using the end with the 1/2” female fitting, a 1/2”
threaded nipple is available if needed. The 1/2” male fitting
on the other end is to be connected to the gas thermostat.
Make sure that the gas type you have is the same as the
gas type indicated on the rating plate. Make sure that all
connections are tight. All threaded fittings must have teflon
tape or pipe dope (which is resistant to the action of liquefied
petroleum (L.P. Gas) applied, see Figure 15.
2. Place the draft hood in the receiving holes where it
connects to the water heater. The legs should snap in to
give a tight fit.
Secure the legs of the draft hood with the supplied draft
hood brackets, see Figures 16 and 16A.
7. With the thermostat knob in the “OFF” position, turn the
gas on. Check for leaks with a soapy solution. If leaks are
found, turn the gas off immediately and correct. Do not
test for gas leaks with a match or flame. Read Lighting
instructions on page 20 for natural gas models and page
21 for propane gas models. Do not light the water heater
until it is completely filled with water.
FIGURE 18.
FIGURE 16.
13
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8. After checking that all connections are tight and the drain
valve near the bottom of the water heater is closed, go to
“Filling the Water Heater”.
FIGURE 20.
SECTION B
COPPER (SWEAT) PIPING
(See Figure 19)
FIGURE 20A.
3. Place the vent pipe over the draft hood. With the vent pipe
in position, drill a small hole through both the vent pipe
and draft hood. Secure them together with a sheet metal
screw.
4. Put two or three turns of teflon tape or pipe joint compound
around the exposed end of the 1” NPT threaded nipples
for 75 gallon models or 1.25” NPT threaded nipples for
100 gallon models, see Figure 21.
FIGURE 19.
1. Position the water heater so that the existing piping will
require the shortest distance between connections. Make
sure that you are able to reach the drain valve and all
connections when the water heater is in place. This will
make it easy to service the water heater. The water heater
must be level before you begin the piping.
FIGURE 21.
5. Cutting custom lengths of copper pipe will be needed in
this procedure. The pipe cutter is simple to use, screw
the adjustment knob until the opening of the jaws will
allow the cutters to be placed around the pipe. Then close
the adjustment until the cutting blade is just tight against
the pipe. Do not over tighten. Make one or two revolutions
of the cutter around the pipe. Tighten the adjustment knob
slightly, and revolve the cutters around the pipe once again.
Continue this procedure until the pipe is completely cut in
two.
If a water heater is installed in a closed water supply
system, such as one having a back-flow preventer, check
valve, water meter with check valve, etc. . . in the cold water
supply, means shall be provided to control thermal
expansion. Contact the water supplier or plumbing
contractor on how to control this situation.
2. Place the draft hood in the receiving holes where it
connects to the water heater. The legs should snap in to
give a tight fit.
6. Cleaning and brushing the piping and fittings is one of
the most important aspects of sweat connections. Clean
the ends of each piece of copper pipe with emery cloth as
Secure the legs of the draft hood with the supplied draft
hood brackets, see Figures 20 AND 20A.
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shown. Clean the inside of each sweat fitting with the wire
brush as shown. Make sure you do not touch the cleaned
areas, see Figure 22.
Flux the ends of the length of pipe cut for the T & P line and
the inside of the 3/4” male threaded to sweat connector.
Then solder this assembly together. Do not screw the
connector into the Temperature-Pressure Relief Valve
before the assembly is soldered together, see Figure 25.
13. Using your pipe wrench, screw the assembly into the
Temperature-Pressure Relief valve, see Figure 25.
FIGURE 22.
7. Using the diagram map out the installation. Screw
fittings onto the nipples, hand tight. Then measure and
cut the copper tubing. Please note that special adapters
may be needed to match existing piping.
Remove the fittings, then go to the next step, see
Figure 23.
FIGURE 25.
14. Connect the flexible gas connector to the incoming gas
line using the end with the 1/2” female fitting, a 1/2”
threaded nipple is available if needed. The 1/2” male
fitting on the other end is to be connected to the gas
thermostat, make sure that the type gas you have is the
same as the gas type indicated on the rating plate. Make
sure that all connections are tight. All threaded fittings
must have teflon tape or pipe dope (which is resistant to
the action of liquefied petroleum [L.P.] gas).
FIGURE 23.
15. With the thermostat knob in the “OFF” position, turn the
gas on. Check for leaks with a soapy solution. If leaks are
found, turn the gas off immediately and correct. Do not
test gas leaks with a match or flame. Read lighting
instructions on page 20 for natural gas models and
page 21 for propane gas models. Do not light the water
heater until it is completely filled with water, see
Figure 26.
8. The female threaded to sweat connectors and two pieces
of copper pipe to connect the water heater to the house
plumbing should be cleaned, fluxed and assembled. Do
not screw the connectors into the nipples in the tank
before soldering.
Solder pipe/connector assembly as shown. When solder
flows into and completely around the joint, you should
remove the solder and the heat immediately, see
Figure 24.
FIGURE 26.
16. After checking that all connections are tight and the drain
valve near the bottom of the water heater is closed, go to
“Filling the Water Heater”.
FIGURE 24.
9. Using your pipe wrench, secure the pipe/connector
assemblies onto the nipples.
10. Flux the ends of piping and inside the couplings.
11. Put the pipes and coupling together and solder as show
Solder the top first, and then quickly solder the bottom.
12. See the Temperature-Pressure Relief Valve section and
the text in Steps 12 and 13 for instructions on installing
the discharge piping.
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TEMPERATURE-PRESSURE RELIEF VALVE
This heater is provided with a properly certified combination
temperature - pressure relief valve by the manufacturer.
FIGURE 27.
The valve is certified by a nationally recognized testing
laboratory that maintains periodic inspection of production of
listed equipment of materials as meeting the requirements for
Relief Valves for Hot Water Supply Systems, ANSI Z21.22•CSA
4.4 and the code requirements of ASME.
If replaced, the valve must meet the requirements of local
codes, but not less than a combination temperature and
pressure relief valve certified as indicated in the above
paragraph.
The Discharge Pipe:
The valve must be marked with a maximum set pressure not to
exceed the marked maximum working pressure of the water
heater (150 psi = 1,035 kPa) and a discharge capacity not less
than the water heater input rate as shown on the model rating
plate.
•
Shall not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restrictions.
•
•
•
Shall not be plugged or blocked.
Shall be of material listed for hot water distribution.
For safe operation of the water heater, the relief valve must not
be removed from its designated opening nor plugged.
Shall be installed so as to allow complete drainage of both
the temperature-pressure relief valve, and the discharge
pipe.
The temperature-pressure relief valve must be installed directly
into the fitting of the water heater designed for the relief valve.
Position the valve downward and provide tubing so that any
discharge will exit only within 6” (153 mm) above, or at any
distance below the structural floor. Be certain that no contact is
made with any live electrical part. The discharge opening must
not be blocked or reduced in size under any circumstances.
Excessive length, over 30’ (9.14 m), or use of more than four
elbows can cause restriction and reduce the discharge capacity
of the valve, see Figure 27.
•
•
Shall terminate at an adequate drain.
Shall not have any valve between the relief valve and tank.
No valve or other obstruction is to be placed between the relief
valve and the tank. Do not connect tubing directly to discharge
drain unless a 6 inch air gap is provided. To prevent bodily
injury, hazard to life, or property damage, the relief valve must
be allowed to discharge water in quantities should
circumstances demand. If the discharge pipe is not connected
to a drain or other suitable means, the water flow may cause
property damage.
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The temperature-pressure relief valve must be manually
operated at least once a year. Caution should be taken to
ensure that (1) no one is in front of or around the outlet of the
temperature-pressure relief valve discharge line, and (2) the
water manually discharged will not cause any bodily injury or
property damage because the water may be extremely hot.
actuated vent dampers). Before installation of any vent damper,
consult the local gas utility for further information.
If after manually operating the valve, it fails to completely reset
and continues to release water, immediately close the cold
water inlet to the water heater, follow the draining instructions,
and replace the temperature-pressure relief valve with a new
one.
FILLING THE WATER HEATER
Never use this water heater unless it is completely full of water.
To prevent damage to the tank, the tank must be filled with
water. Water must flow from the hot water faucet before turning
“ON” gas to the water heater.
To insure proper venting of this gas-fired water heater, the
correct vent pipe diameter must be utilized. Any additions or
deletions of other gas appliances on a common vent with this
water heater may adversely affect the operation of the water
heater. Consult your gas supplier if any such changes are
planned.
To fill the water heater with water:
1. Close the water heater drain valve by turning the handle to
the right (clockwise). The drain valve is on the lower front of
the water heater.
For proper venting in certain installations, a larger diameter
vent pipe may be necessary. Consult your gas supplier to aid
you in determining the proper venting for your water heater
from the vent tables in the current edition of the National Fuel
Gas Code ANSI Z223.1/NFPA 54.
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.
Periodically check the venting system for signs of obstruction
or deterioration and replace if needed.
3. To insure complete filling of the tank, allow air to exit by
opening the nearest hot water faucet. Allow water to run
until a constant flow is obtained. This will let air out of the
water heater and the piping.
The combustion and ventilation air flow must not be obstructed.
The water heater with draft hood installed must be connected
to a chimney or listed vent pipe system, which terminates to
the outdoors. Never operate the water heater unless it is vented
to the outdoors and has adequate air supply to avoid risks of
improper operation, explosion or asphyxiation.
4. Check all water piping and connections for leaks. Repair as
needed.
VENTING
For proper draft hood attachment, the draft hood legs may be
angled slightly inward.
VENT DAMPERS - Any vent damper, whether it is operated
thermally or otherwise must be removed if its use inhibits proper
drafting of the water heater.
Obstructed or deteriorated vent systems may present serious
health risk or asphyxiation.
The vent pipe from the water heater must be no less than the
diameter of the draft hood outlet on the water heater and must
slope upward at least 1/4 inch per linear foot (21 mm per meter),
see Figure 28.
Thermally Operated Vent Dampers: This gas-fired water
heater has a thermal efficiency at or above 80% which may
produce a relatively low flue gas temperature. Such
temperatures may not be high enough to properly open
thermally operated vent dampers. This would cause spillage
of the flue gases and may cause carbon monoxide poisoning.
All vent gases must be completely vented to the outdoors of the
structure (dwelling). Install only the draft hood provided with
the new water heater and no other draft hood.
Vent dampers must bear evidence of certification as complying
with the current edition of the American National Standard
ANSI Z21.66 / CGA 6.14 (covering electrically and mechanically
Vent pipes must be secured at each joint with sheet metal
screws.
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FIGURE 28.
There must be a minimum of 6” (153 mm) clearance between
single wall vent pipe and any combustible material. Fill and
seal any clearance between single wall vent pipe and
combustible material with mortar mix, cement, or other
noncombustible substance. For other than single wall, follow
vent pipe manufacturer’s clearance specifications. To insure
a tight fit of the vent pipe in a brick chimney, seal around the
vent pipe with mortar mix cement.
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 until the water heater installation is
complete.
Failure to have required clearances between vent piping and
combustible material will result in a fire hazard.
A gas line of sufficient size must be run to the water heater.
Consult the current edition of the National Fuel Gas Code
ANSI Z223.1/NFPA 54 and your gas supplier concerning pipe
size.
Be sure vent pipe is properly connected to prevent escape of
dangerous flue gases which could cause deadly asphyxiation.
There must be:
•
•
A readily accessible manual shut off valve in the gas supply
line serving the water heater, and
A drip leg (sediment trap) ahead of the gas control valve to
help prevent dirt and foreign materials from entering the
gas control valve.
•
A flexible gas connector or a ground joint union between the
shut off valve and control valve to permit servicing of the unit.
Be sure to check all the gas piping for leaks before lighting the
water heater. Use a soapy water solution, not a match or open
flame. Rinse off soapy solution and wipe dry.
The minimum inlet gas pressure shown on the rating plate is
that which will permit firing at the rated input.
Chemical vapor 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 sodium chloride, waxes, bleach and process chemicals
are typical compounds which are potentially corrosive.
GAS PIPING
Make sure the gas supplied is the same type listed on the
model rating plate. The inlet gas pressure must not exceed
14 inch water column (2.6 kPa) for natural and propane (L.P.)
gas. If the gas control valve is subjected to pressures exceeding
1/2 pound per square inch (3.5 kPa), the damage to the gas
control valve could result in a fire or explosion from leaking
gas.
Standard Models are for installation up to 2,000 feet (610 m)
above sea level.
High Altitude models are for installation from 2,000 feet
(610 m) to 4,500 feet (1,370 m) above sea level.
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piping system at test pressures equal to or less than 1/2 pound
per square inch (3.5kPa).
If a standard model is installed above 2,000 feet (610 m) or
high altitude model is installed above 4,500 feet (1,370 m), the
input rating should be reduced at the rate of 4 percent for each
1000 feet (305 m) above sea level which requires replacement
of the burner orifice in accordance with National Fuel Gas Code
ANSI Z223.1/NFPA 54 or Contact your local gas supplier
for further information.
Connecting the gas piping to the gas control valve of the water
heater can be accomplished by either of the two methods
shown in Figures 29 and 30.
SEDIMENT TRAPS
Failure to replace the standard orifice with a high altitude orifice
when installed at elevations above 2,000 feet (610 m) or above
4,500 feet (1,370 m) for high altitude model could result in
improper and inefficient operation of the appliance, producing
carbon monoxide gas in excess of safe limits, which could
result in serious injury or death. Contact your local gas supplier
for any specific changes which may be required in your area.
A sediment trap shall be installed as close to the gas valve
inlet of the water heater as practical at the time of water heater
installation. The sediment trap shall be either a tee fitting with
a capped nipple in the bottom outlet or other device recognized
as an effective sediment trap. If a tee fitting is used, it shall
be installed in conformance with one of the methods of
installation , see Figures 29 and 30.
FIGURE 29. GAS PIPING WITH FLEXIBLE CONNECTOR.
Use pipe joint compound or teflon tape marked as being
resistant to the action of petroleum [Propane (L.P.)] gases.
FIGURE 30. GAS PIPING WITH ALL
BLACK IRON PIPE TO GAS CONTROL.
The appliance and its gas connection must be leak tested
before placing the appliance in operation.
Contaminants in the gas lines may cause improper operation
of the gas control valve that may result in fire or explosion.
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 drip leg (sometimes called a sediment trap)
must be incorporated in the piping. The drip leg must be readily
accessible. Install in accordance with the “Gas Piping” section.
Refer to the current edition of the National Fuel Code, ANSI
Z223.1/NFPA 54.
The appliance and its individual shut-off valve shall be
disconnected from the gas supply piping system during any
pressure testing of that system at test pressures in excess of
1/2 pound per square inch (3.5kPa). It shall be isolated from
the gas supply piping system by closing its individual manual
Shut-off valve during any pressure testing of the gas supply
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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 LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGEDAT FAUCETS.
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
•
If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to push down or turn the gas control
knob. Never use tools. If the knob will not push down 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
control system and any gas control which has been
under water.
•
•
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.
LIGHTING INSTRUCTIONS
GAS CONTROL
FIGURE D.
TOP VIEW
1.
STOP! Read the safety information above on this
label.
the gas control knob down for about one (1) minute after the
pilot is lit. Release the gas control knob and it will pop back
up. Pilot should remain lit. If it goes out, repeat Steps 3 through
8. It may take several minutes for air to clear the lines, before
the pilot will light.
2. Set the thermostat to the lowest setting by turning
thermostat dial fully clockwise until it stops.
3. Push the gas control knob down slightly and turn clockwise
to "OFF", see Figure A.
• If knob does not pop up when released, stop and
immediately call your service technician or gas
supplier.
NOTE: Gas control knob CANNOT be turned from "PILOT"
to "OFF" unless it is pushed down slightly. Do not force.
4. Remove the inner and outer doors located below and
behind the gas control unit.
• If the pilot will not stay lit after several tries, turn the gas
control knob to "OFF", see Figure A and call your service
technician or gas supplier.
5. Wait five (5) minutes to clear out any gas. If you then
smell gas
STOP! Follow "B" in the safety information
this label. If you do not smell gas, go to
9. Replace inner and outer burner doors.
above on
the next step.
10. At arm's length away, turn gas control knob
6. Find Pilot. Follow metal tube from the bottom, right of the
gas control to the pilot burner (Figure D).
counterclockwise
to “ON”, see Figure C.
11. Set thermostat to desired setting, (See Figure 1).
7. Turn gas control knob counterclockwise
see Figure B.
to "PILOT",
CAUTION: Hotter water increases the risk
of scald injury. Consult the instruction
manual before changing temperature.
8. Push gas control knob down all the way and hold it down.
Immediately light the pilot with a match. Continue to hold
TO TURN OFF GAS TO APPLIANCE
1. Set thermostat to the lowest setting.
2. Push gas control knob down slightly and turn clockwise
to “OFF”, see Figure A. Do not force.
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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 LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGEDAT FAUCETS.
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
•
If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to push down or turn the gas control
knob. Never use tools. If the knob will not push down 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
control system and any gas control which has been
under water.
•
•
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.
LIGHTING INSTRUCTIONS
FIGURE D.
TOP VIEW
GAS CONTROL
1.
STOP! Read the safety information above on
this label.
the gas control knob down for about one (1) m i n u t e
after the pilot is lit. Release the gas control knob and it
will pop back up. Pilot should remain lit. If it goes out,
repeat Steps 3 through 8. It may take several minutes for
air to clear the lines, before the pilot will light.
2. Set the thermostat to the lowest setting by turning
thermostat dial fully clockwise until it stops.
3. Push the gas control knob down slightly and turn clockwise
to "OFF", see Figure A.
NOTE: Gas control knob CANNOT be turned from "PILOT"
to "OFF" unless it is pushed down slightly. Do not force.
4. Remove the inner and outer doors located below and
behind the gas control unit.
•
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 to "OFF" (Figure A) and call your
service technician or gas supplier.
5. Wait five (5) minutes to clear out any gas. If you then
smell gas
STOP! Follow "B" in the safety information
this label. If you do not smell gas, go to
above on
9. Replace inner and outer burner doors.
the next step.
10. At arm's length away, turn the gas control knob
6. Find Pilot. Follow metal tube from the bottom, right of the
gas control to the pilot burner, see Figure D.
counterclockwise
to “ON”, see Figure C.
11. Set thermostat to desired setting, (See Figure 1).
7. Turn gas control knob counterclockwise
see Figure B.
to "PILOT",
CAUTION: Hotter water increases the risk of
scald injury. Consult the instruction manual
before changing temperature.
8. Push gas control knob down all the way and hold it down.
Immediately light the pilot with a match. Continue to hold
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Push the gas control knob down slightly and turn
clockwise
to "OFF", see Figure A. Do not force.
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TEMPERATURE REGULATION
Short repeated heating cycles caused by small hot water uses
on the thermostat, read the “Temperature Regulation” section
in this manual, see Figures 31 and 32.
can cause temperatures at the point of use to exceed the
thermostat setting by up to 30°F (16.7°C). If you experience this
type of use you should consider using lower temperature
settings to reduce scald hazards.
Never allow small children to use a hot water tap, or to draw
their own bath water. Never leave a child or handicapped person
unattended in a bathtub or shower.
Any water heater’s intended purpose is to heat water. Hot
water is needed for cleansing, cleaning, and sanitizing (bodies,
dishes, clothing). Untempered hot water can present a scald
hazard. Depending on the time element, and the people
involved (adults, children, elderly, infirm, etc.) scalding may occur
at different temperatures.
NOTE: A water temperature range of 120°F-140°F (49°C-60°C)
is recommended by most dishwasher manufacturers.
The thermostat of this water heater has been factory set at its
lowest position (PILOT LIGHTING). It is adjustable and must
be reset to the desired temperature setting to reduce the risk of
scald injury. The mark ( ) indicative of approximately 120°F
(49°C) is preferred starting point.
Turn the water temperature dial clockwise (
the temperature, or counterclockwise (
temperature.
) to decrease
) to increase the
Should overheating occur or the gas supply fail to shut off, turn
off the manual gas control valve to the appliance.
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, and
other sanitizing needs can scald and 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 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, see
Figure 2 on page 6. Follow manufacturer’s instructions for
installation of the valves. Before changing the factory setting
FIGURE 31.
Temperature
Settings
Time to Produce 2nd & 3rd
Degree Burns on Adult Skin
VERYHOT=approx.160°F(71°C)
C = approx. 150°F (66°C)
B = approx. 140°F (60°C)
A = approx. 130°F (54°C)
= approx. 120°F (49°C)
About 1/2 second
About 1-1/2 seconds
Less than 5 seconds
About 30 seconds
More than 5 minutes
- - - - - - - - - - - - - - - -
LOW = approx. 80°F (27°C)
FIGURE 32.
FOR YOUR INFORMATION
START UPCONDITIONS
DRAFT HOOD OPERATION
CONDENSATION
Whenever the water heater is filled with cold water, some
condensate will form while the burner is on. A water heater may
appear to be leaking when in fact the water is condensation.
This usually happens when:
Check draft hood operation by performing a worst case
depressurization of the building. With all doors and windows
closed, and with all air handling equipment and exhaust fans
operating such as furnaces, clothes dryers, range hoods and
bathroom fans, a match flame should still be drawn into the
draft hood of the water heater with its burner firing. If the flame
is not drawn toward the draft hood, shut off the water heater and
make necessary air supply changes to correct.
a. A new water heater is filled with cold water for the first time.
b. Burning gas produces water vapor in water heaters, particularly
high efficiency models where flue temperatures are lower.
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c. Large amounts of hot water are used in a short time and the
refill water in the tank is very cold.
expansion tank or device to relieve the pressure built by thermal
expansion in the water system. Expansion tanks are available
for ordering through a local plumbing contractor. Contact the
local water heater supplier or service agency for assistance in
controlling these situations.
Moisture from the products of combustion condense on the
cooler tank surfaces and form drops of water which may fall onto
the burner or other hot surfaces to produce a “sizzling” or “frying”
noise.
STRANGE SOUNDS
Excessive condensation can cause pilot outage due to water
running down the flue tube onto the main burner and putting out
the pilot.
Possible noises due to expansion and contraction of some
metal parts during periods of heat-up and cool-down do not
necessarily represent harmful or dangerous conditions.
Because of the suddenness and amount of water, condensation
water may be diagnosed as a “tank leak”. After the water in the
tank warms up (about 1-2 hours), the condition should disappear.
Condensation causes sizzling and popping within the burner
area during heating and cooling periods and should be
considered normal. See “Condensation” in this section.
Do not assume the water heater is leaking until there has been
enough time for the water in the tank to warm up.
OPERATIONAL CONDITIONS
An undersized water heater will cause more condensation. The
water heater must be sized properly to meet the family’s demands
for hot water including dishwashers, washing machines and
shower heads.
SMELLYWATER
In each water heater there is installed at least one anode rod
(see parts sections) for corrosion protection of the tank. Certain
water conditions will cause a reaction between this rod and
the water. The most common complaint associated with the
anode rod is one of a “rotten egg smell” in the hot water. This
odor is derived from hydrogen sulfide gas dissolved in the
water. The smell is the result of four factors which must all be
present for the odor to develop:
Excessive condensation may be noticed during the winter and
early spring months when incoming water temperatures are at
their lowest.
Good venting is essential for a gas fired water heater to operate
properly as well as to carry away products of combustion and
water vapor.
a. a concentration of sulfate in the supply water.
b. little or no dissolved oxygen in the water.
SMOKE / ODOR
c. a sulfate reducing bacteria which has accumulated within
the water heater (this harmless bacteria is nontoxic to
humans).
It is not uncommon to experience a small amount of smoke and
odor during the initial start-up. This is due to burning off of oil
from metal parts, and will disappear in a short while.
d. an excess of active hydrogen in the tank. This is caused by
the corrosion protective action of the anode.
THERMALEXPANSION
Smelly water may be eliminated or reduced in some water
heater models by replacing the anode(s) with one of less active
material, and then chlorinating the water heater tank and all
hot water lines. Contact the local water heater supplier or
service agency for further information concerning an Anode
Replacement Kit and this chlorination treatment.
If the smelly water persists after the anode replacement and
chlorination treatment, we can only suggest that chlorination
or aeration of the water supply be considered to eliminate the
water problem.
Water supply systems may, because of such events as high
line pressure, frequent cut-offs, the effects of water hammer
among others, have installed devices such as pressure
reducing valves, check valves, back flow preventers, etc. to
control these types of problems. When these devices are not
equipped with an internal by-pass, and no other measures are
taken, the devices cause the water system to be closed. As
water is heated, it expands (thermal expansion) and closed
systems do not allow for the expansion of heated water.
Do not remove the anode leaving the tank unprotected. By
doing so, all warranty on the water heater tank is voided.
“AIR” IN HOT WATER FAUCETS
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. This is an unacceptable
condition and must be corrected.
It is recommended that any devices installed which could create
a closed system have a by-pass and/or the system have an
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HYDROGEN GAS: Hydrogen gas can be produced in a hot
water system that has not been used for a long period of time
(generally two weeks or more). Hydrogen gas is extremely
flammable and explosive. 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 connected to the hot water
system are used (such as a dishwasher or washing machine).
If hydrogen gas is present, there will probably be an unusual
sound similar to air escaping through the pipe as the hot water
faucet is opened. There must be no smoking or open flame
near the faucet at the time it is open.
HIGH WATER TEMPERATURE SHUT OFF SYSTEM
This water heater is equipped with an automatic gas Shut-off
system. This system works when high water temperatures
are present. The high 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. Turn
“OFF” the entire gas supply to the water heater. Contact your
gas supplier or service agency.
PERIODIC MAINTENANCE
correct the problem and clean or replace the flue and venting
before resuming operation of the water heater.
VENTING SYSTEM INSPECTION
BURNER INSPECTION
Flood damage to a water heater may not be readily visible or
immediately detectable. However, over a period of time a
flooded water heater will create dangerous conditions which
can cause DEATH, SERIOUS BODILY INJURY, OR PROPERTY
DAMAGE. Contact a qualified installer or service agency to
replace a flooded water heater. Do not attempt to repair the
unit! It must be replaced!
At least once a year a visual inspection should be made of the
main burner and pilot burner, see Figure 33.
You should check for sooting. Soot is not normal and will
impair proper combustion.
Soot build-up indicates a problem that requires correction
before further use. Turn “OFF” gas to water heater and leave
off until repairs are made, because failure to correct the cause
of the sooting can result in a fire causing death, serious injury,
or property damage.
At least once a year a visual inspection should be made of the
venting system. You should look for:
NATURAL
1. Obstructions which could cause improper venting. The
combustion and ventilation air flow must not be obstructed.
2. Damage or deterioration which could cause improper
venting or leakage of combustion products.
3. Rusted flakes around top of water heater.
Be sure the vent piping is properly connected to prevent escape
of dangerous flue gases which could cause deadly
asphyxiation.
PROPANE
Obstructions and deteriorated vent systems may present
serious health risk or asphyxiation.
Chemical vapor 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 sodium chloride, waxes, bleach and process chemicals
are typical compounds which are potentially corrosive.
If after inspection of the vent system you found sooting or
deterioration, something is wrong. Call the local gas utility to
FIGURE 33.
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intact. Replacement of a depleted anode rod can extend the
life of your water heater. Inspection should be conducted by a
qualified technician, and at a minimum the anode(s) should
be checked annually after the warranty period.
BURNER CLEANING
If inspection of the burner shows that cleaning is required, turn
the gas control knob clockwise (
depressing slightly.
) to the “OFF” position,
TEMPERATURE-PRESSURE
RELIEF VALVE OPERATION
NOTE: The knob cannot be turned from “PILOT” to “OFF”
unless knob is depressed slightly. DO NOT FORCE.
Loose deposits on or around the burner can be removed by
carefully using the hose of a vacuum cleaner inserted through
the access door of the water heater. If the burner needs to be
removed for additional cleaning, call a service agency to remove
and clean the burner and correct the problem that required the
burner to be cleaned.
HOUSEKEEPING
Vacuum around base of water heater for dust, dirt, and lint on a
regular basis.
The temperature-pressure relief valve must be manually
operated at least once a year.
When checking the temperature-pressure relief valve operation,
make sure that (1) no one is in front of or around the outlet of
the temperature-pressure relief valve discharge line, and (2)
that the water discharge will not cause any property damage,
as the water may be extremely hot, see Figure 34.
INSTALLED IN SUITABLEAREA: To insure sufficient ventilation
and combustion air supply, proper clearances from the water
heater must be maintained. See “Locating the New Water
Heater” section. Combustible materials such as clothing,
cleaning materials, or flammable liquids, etc. must not be
placed against or adjacent to the water heater which can cause
a fire.
FIGURE 34.
If after manually operating the valve, it fails to completely reset
and continues to release water, immediately close the cold
water inlet to the water heater, follow the draining instructions,
and replace the temperature-pressure relief valve with a new
one.
ANODE ROD INSPECTION
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 agency for further information. Do
not plug the temperature-pressure relief valve.
DRAINING
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 the water’s taste or color. The rod
must be maintained to keep the tank in operating condition.
Anode deterioration depends on water conductivity, not
necessarily water condition. A corroded or pitted anode rod
indicates high water conductivity and should be checked and/
or replaced more often than an anode rod that appears to be
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The water heater should be drained if being shut down during
freezing temperatures. Also periodic draining and cleaning of
sediment from the tank may be necessary.
valve and retighten using a wrench. DO NOT OVER
TIGHTEN.
6. Follow instructions in the “Filling The Water Heater” section.
7. Check for leaks.
1. Turn the gas control knob to the “OFF” position.
2. CLOSE the cold water inlet valve to the water heater.
8. Follow the lighting instructions in the “Lighting and Operating
Instructions” section to restart the water heater.
3. OPEN a nearby hot water faucet and leave open to allow for
draining.
4. Connect a hose to the drain valve and terminate to an
adequate drain.
5. OPEN the 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.
FIGURE 35.
SERVICE
6. Close the drain valve.
7. Follow instructions in the “Filling The Water Heater” section.
Before calling for repair service, read the "Start Up Conditions"
and "Operational Conditions" found in the "For Your Information"
section of this manual.
8. Follow the lighting instructions on the label or see pages 20
and 21 under “Lighting and Operating Instructions” to restart
the water heater.
If a condition persists or you are uncertain about the operation
of the water heater contact a service agency. If you are not
thoroughly familiar with gas codes, your water heater, and safety
practices, contact your gas supplier or qualified installer to
check the water heater.
DRAIN VALVE WASHER REPLACEMENT-
FOR SELECTED MODELS WITH PLASTIC DRAIN VALVES
(See Figure 35)
Use the”Leakage Checkpoints” guide to check a “Leaking”
water heater. Many suspected “Leakers” are not leaking tanks.
Often the source of the water can be found and corrected.
1. Turn “OFF” gas supply to water heater.
2. Follow “Draining” instructions.
Read this manual first. Then before checking the water heater
make sure the gas supply has been turned “OFF”, and never
turn the gas “ON” before the tank is completely full of water.
3. Turning counter clockwise (
the screw handle.
), remove the hex cap below
Never use this water heater unless it is completely filled with
water. To prevent damage to the tank, the tank must be filled
with water. Water must flow from the hot water faucet before
turning “ON” gas to the water heater.
4. Remove the washer and put the new one in place.
5. Screw the handle and cap assembly back into the drain
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LEAKAGE CHECKPOINTS
A. Water at the draft hood is water vapor which has condensed
out of the combustion products. This is caused by a problem
in the vent. Contact the gas utility.
B. *Condensation may be seen on pipes in humid weather or
pipe connections may be leaking.
C. *The anode rod fitting may be leaking.
D. Small amounts of water from the temperature-pressure relief
valve may be due to thermal expansion or high water pressure
in your area.
E. *The temperature-pressure relief valve may be leaking at the
tank fitting.
F. Water from a drain valve may be due to the valve being slightly
opened.
G. *The drain valve may be leaking at the tank fitting.
H. Combustion products contain water vapor which can
condense on 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 after installation and when incoming
water is cold.
I. Water in the water heater bottom or on the floor may be from
condensation, loose connections, or the relief valve. DO NOT
replace the water heater until a full inspection of all possible
water sources is made and necessary corrective steps taken.
Leakage from other appliances, water lines, or ground seepage
should also be checked.
*
To check where threaded portion enters tank, insert cotton
swab between jacket opening and fitting. If cotton is wet,
follow “Draining” instructions in the “Periodic Maintenance”
section and then remove fitting. Put pipe dope or teflon tape
on the threads and replace. Then follow “Filling the Water
Heater” instructions in the “Installing the New Water Heater”
section.
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TROUBLESHOOTING GUIDELINES
These guidelines should be utilized by a qualified service agent.
Problem
Cause
Solution
Improperly sealed, hot or cold supply connection,
relief valve, drain valve, or thermostat threads.
Leakage from other appliances or water lines.
Condensation of flue products.
Tighten threaded connections.
WATER LEAKS
Inspect other appliances near water heater.
Refer to CONDENSATION.
Thermal expansion in closed water system.
Improperly seated valve.
Install thermal expansion tank (DO NOT plug T&P valve).
Check relief valve for proper operation
(DO NOT plug T&P valve).
LEAKING T&P VALVE
SMELLY ODORS
High sulfate or mineral content in water supply.
Bacteria in water supply.
Drain and flush heater thoroughly, then refill.
Chlorinate or aerate water supply.
Refer to LIGHTING INSTRUCTIONS.
Turn on main gas Shut-off valve.
Replace pilot assembly and/or thermocouple.
Locate pilot, move match closer.
Replace pilot assembly and/or thermocouple.
Replace Gas Control.
Gas control knob not positioned correctly.
Main gas supply off.
PILOT WILL NOT LIGHT
Thermocouple malfunction.
Match not close to pilot
Thermocouple malfunction.
Defective Gas Control.
BURNER WILL NOT
STAY LIT
Dirty pilot burner.
Clean pilot assembly.
Thermocouple malfunction.
Thermocouple tip is not in contact with pilot flame.
Defective Gas Control.
Replace pilot assembly and/or thermocouple.
Insert thermocouple correctly.
PILOT OUTAGE
Replace Gas Control.
Heater not lit or thermostat not on.
Thermostat set too low.
Refer to LIGHTING INSTRUCTIONS.
Refer toTEMPERATURE REGULATION.
Reduce hot water use.
Heater undersized.
Low gas pressure.
Contact your gas supplier.
NOT ENOUGH
HOT WATER
Incoming water is unusually cold.
Leaking hot water pipes or fixtures.
High temperature limit switch activated.
Thermostat set too high.
Allow more time for heater to re-heat.
Have plumber check and repair leaks.
Contact a service agency to determine cause.
Refer toTEMPERATURE REGULATION.
Refer to CONDENSATION.
WATER TOO HOT
WATER HEATER SOUNDS Condensation dripping on burner.
SIZZLING OR
RUMBLING
Sediment or calcium in bottom of heater tank.
Clean sediment from tank. Refer to DRAINING
instructions in Maintenance section of manual.
Improper combustion.
No adjustment available. Contact a service agency
to determine cause.
SOOTING
Lack of supply air.
Improperly installed vent piping.
Downdraft.
Contact a service agency to determine cause.
VENT GAS ODORS
Poor combustion.
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REPAIR PARTS LIST
Key No. Part Description
1
Pipe Nipple
2
Burner Tube
3
Burner Head
4
Thermocouple
Pilot
5
6
Draft Hood
*7
Draft Hood Brace
Inlet Tube
8
9
Flue Baffle Assembly
Anode Rod
10
11
Cleanout Cover (optional)
Cleanout Gasket (optional)
Cleanout Screw (optional)
Inner Door
12
13
14
15
Outer Door
16
Thermostat
17
T & P Relief Valve
Drain Valve
18
19
Flue Reducer (Selected Models)
Front Cover (optional)
Pilot Tube
20
21
22
*23
Orifice
Fitting Breakaway
Drain Pan
21
24
4
2
*25
Instruction Manual
* Not Shown.
3
5
Now that you have purchased this water heater, should a need
ever exist for repair parts or service, simply contact the company
it was purchased from or direct from the manufacturer listed
on the rating plate on the water heater.
22
24
DRAIN PAN
2
21
Be sure to provide all pertinent facts when you call or visit.
3
Selling prices will be furnished on request or parts will be
shipped at prevailing prices and you will be billed accordingly.
The model number of your Gas Water Heater will be found on
the rating place located above the gas control valve.
4
22
5
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE
FOLLOWING INFORMATION:
3/4"T&PRELIEFVALVE
AUTOMATIC,SELF-CLOSINGTYPES
•
•
•
•
MODEL NUMBER
TYPE GAS (NATURALOR PROPANE (L.P.)
SERIAL NUMBER
PRESS.
A=
TEMP
RELIEF
150 LBS.
150 LBS.
2.13"
1.88"
210°F
210°F
PART DESCRIPTION
A
17
THIS ISAREPAIR PARTS LIST, NOTAPACKING LIST.
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RESIDENTIAL GAS WARRANTY
THIS WARRANTY IS APPLICABLE TO THE ORIGINAL OWNER
ONLY. In accordance with the warranty terms and conditions
specified below.
•
•
•
used with factory approved anode(s) installed;
in its original installation location;
in the United States, its territories or possessions, and
Canada;
sized in accordance with proper sizing techniques for
residential water heaters;
bearing a rating plate which has not been altered, defaced
or removed except as required by the warrantor;
used in an open system or in a closed system with a
properly sized and installed thermal expansion tank;
operated with properly installed drip leg in the gas supply
line;
fired with the fuel for which it was factory built;
fired at the factory rated input;
operated with the inner and outer combustion chamber
doors in place.
Reliance Water Heaters (the warrantor) will furnish the ORIGINAL
OWNER, 1) a replacement Reliance water heater of equivalent
size and current model if the glass-lined tank in this water heater
leaks and, 2) a replacement part for any component part which
fails.
•
•
•
•
THE RELIANCE WATER HEATERS REPLACEMENT MODELOR
PART WILL BE WARRANTED FOR ONLY THE UNEXPIRED
PORTION OF THE ORIGINAL WARRANTY. The warranty period
will be determined by the original date of purchase of the water
heater, or in the absence of a Bill of Sale verifying said date, from
the date of manufacture indicated on rating plate affixed to this
water heater. This warranty is not transferrable and applies to
models listed below:
•
•
•
Any accident to the water heater or any part thereof (including
freezing, fire, floods, or lightning), any misuse, abuse or alteration
of it, any operation of it in a modified form, any operation of the
water heater on desalinated (deionized) water, or any damage
caused by attempts to repair tank leaks or parts, will void this
warranty. This warranty does not cover water heaters replaced
for cosmetic reasons or for reasons of noise, taste, odor,
discolored and/or rusty water. This warranty does not apply to
water heaters used to heat pools, whirlpools or hot tubs or used
for space heating where its sizing does not conform with
specifications of the heating component manufacturer.
MODEL SERIES:
606
Tank
Parts
6-year
6-year
When the water heater has been used for other than single
family residential application;
1. The tank warranty shall be reduced to 1 year for 6 year
models.
2. The parts warranty shall be reduced to 1 year for all
models.
This warranty gives you specific legal rights, and you may have
other rights which vary under the laws of each state. If any
provision of this warranty is prohibited or invalid under applicable
state law, that provision shall be ineffective to the extent of the
prohibition or invalidity without invalidating the remainder of the
affected provision or the other provisions of this warranty.
CONDITIONS AND EXCEPTIONS
This warranty shall apply only when the water heater is installed
and operated in accordance with 1) all local fire codes and
plumbing codes, ordinances and regulations, 2) the printed
instructions provided with it, 3) good industry practices, and 4)
proper safety practices such as but not limited to a properly
sized drain pan if installed in an area where leakage from the
tank or its connections would result in damage to the area
adjacent to the heater. In addition, a new temperature and
pressure relief valve, certified by the Canadian Gas Association
must have been properly installed and piped to the nearest drain.
SERVICE AND LABOR RESPONSIBILITY
UNDER THIS LIMITED WARRANTY, THE WARRANTOR WILL
PROVIDE ONLYAREPLACEMENT WATER HEATER OR PART
THEREOF. THE OWNER IS RESPONSIBLE FOR ALL OTHER
COSTS. Such costs may include but are not limited to:
a. Labor charges for service, removal, or reinstallation of
the water heater or part thereof.
This warranty shall apply only when the heater is:
•
•
•
owned by the original purchaser;
installed for indoor operation only;
used at temperatures not exceeding the maximum b. Shipping and delivery charges for forwarding the new water
calibrated setting of its thermostat;
used at water pressure not exceeding the working
pressure shown on the heater;
heater or replacement part from the nearest distributor
and returning the claimed defective heater or part to such
distributor.
•
•
filled with potable water, free to circulate at all times and
with the tank free of damaging water sediment or scale
deposits;
c. All cost necessary or incidental for handling and
administrative charges, and for any materials and/or
permits required for installation of the replacement heater
or part.
•
used in
atmosphere;
a
non-corrosive and non-contaminated
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INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF
THE HEATER OR PARTS. THE WARRANTOR SHALL NOT BE
RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE
UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL
PROPERTY, OR OTHER CONSEQUENTIAL DAMAGE. THE
WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS
WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS
OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND
WHETHER ARISING IN CONTRACT OR IN TORT.
LIMITATION ON IMPLIED WARRANTIES
Implied warranties, including any warranty of merchantability
imposed on the sale of this heater under state law are limited
to one year duration for the heater or any of its parts. Some
states do not allow limitations on how long an implied warranty
lasts, so the above limitations may not apply to you.
CLAIM PROCEDURE
IMPORTANT INFORMATION
Any claim under this warranty should be initiated by contacting:
Reliance Water Heaters
500 Lindahl Parkway
Ashland City, Tennessee 37015
Phone: 1.800.365.4054
Model Number ________________________________
Serial Number ________________________________
INSTALLATION INFORMATION
Replacement Parts may be ordered through authorized servicers
or retailers or by contacting:
Date Installed ________________________________
Company’s Name _____________________________
Street or P.O. Box _____________________________
____________________________________________
City, State, and Zip Code _______________________
____________________________________________
Phone Number _______________________________
Plumber’s Name ______________________________
Reliance Water Heaters
500 Lindahl Parkway
Ashland City, TN 37015
Phone: 1.800.821.2017
The warrantor will only honor replacement with identical or
similar water heater or parts thereof, which are manufactured by
the warrantor.
DISCLAIMERS
NO EXPRESS WARRANTY HAS BEEN OR WILL BE
MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO
THE MERCHANTABILITY OF THE HEATER OR THE
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500 Lindahl Parkway
Ashland City, TN 37015
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