State Industries Water Heater 317998 002 User Manual

Installation Instructions and Use & Care Guide  
RESIDENTIAL GAS WATER HEATERS  
HIGH EFFICIENCY ATMOSPHERIC VENT  
GAS WATER HEATER  
(FLAMMABLE VAPOR IGNITION RESISTANT)  
FOR SPACE HEATING AND POTABLE WATER HEATING ONLY.  
NOT FOR USE IN MOBILE HOMES.  
This water heater complies with ANSI Z21.10.1-current  
edition regarding the accidental or unintended ignition of  
ammable vapors, such as those emitted by gasoline.  
For Your Safety  
AN ODORANT IS ADDED TO THE GAS USED  
BY THIS WATER HEATER.  
WARNING: If the information in these  
instructions is not followed exactly, a fire  
or explosion may result causing property  
damage, personal injury or death.  
• Safety Instructions  
• Installation  
• Operation  
• Care and Maintenance  
• Troubleshooting  
• Parts List  
— Do not store or use gasoline or other  
flammable vapors and liquids in the  
vicinity of this or any other appliance.  
INSTALLER:  
AFFIX THESE INSTRUCTIONS TO OR ADJACENT  
TO THE WATER HEATER.  
— WHAT TO DO IF YOU SMELL GAS  
• Do not try to light any appliance.  
OWNER:  
RETAIN THESE INSTRUCTIONS AND WARRANTY  
FOR FUTURE REFERENCE. RETAIN THE  
ORIGINAL RECEIPT AS PROOF OF PURCHASE.  
• Do not touch any electrical switch;  
do not use any phone in your  
building.  
WARNING: Gas leaks can not always be detected by  
smell.  
• Immediately call your gas supplier  
from a neighbor’s phone. Follow the  
gas supplier’s instructions.  
Gas suppliers recommend that you use a gas detector  
approved by UL or CSA.  
For more information, contact the your gas supplier.  
• If you cannot reach your gas  
supplier, call the fire department.  
If a gas leak is detected, follow the “WHAT TO DO IF YOU  
SMELL GAS” instructions.  
— Installation and service must be  
performed by a qualified installer,  
service agency or the gas supplier.  
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED.  
IF YOU ARE UNSUCCESSFUL, CONTACT RESIDENTIAL TECHNICALASSISTANCE AT 1-800-365-0024 OR WWW.STATEWATERHEATERS.COM.  
PRINTED IN THE U.S.A 0410  
PART NO. 317998-002  
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SAFE INSTALLATION, 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 water heater to warn you and  
others of a potential 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.  
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety  
messages that follow this symbol to avoid possible injury or death.  
DANGER indicates an imminently hazardous situation which, if not avoided, will  
result in death or injury.  
DANGER  
WARNING indicates a potentially hazardous situation which, if not avoided, could  
result in death or injury.  
WARNING  
CAUTION indicates a potentially hazardous situation which, if not avoided, could  
result in minor or moderate injury.  
CAUTION  
CAUTION used without the safety alert symbol indicates a potentially hazardous  
situation which, if not avoided, could result in property damage  
CAUTION  
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.  
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of  
substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses  
to warn of potential exposure to such substances.  
WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other  
reproductive harm.  
This appliance can cause low-level exposure to some of the substances included in the Act.  
IMPORTANT DEFINITIONS  
Qualified Technician: A qualified technician must have ability equivalent to a licensed tradesman in the 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 technician must also be  
familiar with the design features and use of flammable vapor ignition resistant water heaters, and have a thorough  
understanding of this instruction manual.  
Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the 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 service agency must also have a  
thorough understanding of this instruction manual, and be able to perform repairs strictly in accordance with the  
service guidelines provided by the 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  
offer service and inspection of appliances within the building.  
SAFETY PRECAUTIONS  
WARNING  
FIRE AND EXPLOSION HAZARD  
Can result in serious injury or death  
Do not store or use gasoline or other  
flammable vapors and liquids in the vicinity of this  
or any other appliance. Storage of or use of  
gasoline or other flammable vapors or liquids in the  
FLAMMABLES  
Flammable Vapors  
vicinity of this or any other appliance can result in  
serious injury or death.  
Read and follow water heater warnings and instructions.  
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Fire or Explosion Hazard  
Do not store or use gasoline or other flammable vapors and  
liquids in the vicinity of this or any other appliance.  
Avoid all ignition sources if you smell Natural or LP gas.  
Do not expose water heater control to excessive gas  
pressure.  
Use only gas shown on rating plate.  
Maintain required clearances to combustibles.  
Keep ignition sources away from faucets after extended  
period of non-use.  
Read instruction manual before  
installing, using or servicing  
water heater.  
4
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TYPICAL INSTALLATION  
GET TO KNOW YOUR WATER HEATER - GAS MODELS  
A
B
C
D
E
F
G
H
I
Vent Pipe  
Draft hood  
K
L
Outer door  
Union  
U
V
Main Burner  
Flue  
Anode (Not Shown)  
Hot Water Outlet  
Insulation  
Gas Supply Piping  
Manual Gas Shut-off Valve  
Ground Joint Union  
Drip Leg (Sediment Trap)  
Inner Door  
M
N
O
P
Q
R
S
T
Inlet Water Shut-off Valve  
Cold Water Inlet  
Inlet Dip Tube  
Temperature & Pressure Relief Valve  
Rating Plate  
Flue Bafe  
Gas Control Valve/Thermostat  
Drain Valve  
W Suitable Metal Drain Pan  
X
Y
Control Display  
Power Supply Transformer  
(Shown detached from Heater)  
YY Pressure Switch  
(Shown detached from Heater)  
Air Intake Chamber  
Z
ZZ FV Sensor (Shown without Bracket)  
J
*
*
INSTALL IN ACCORDANCE  
WITH LOCAL CODES.  
DRIP LEG AS REQUIRED  
BY LOCAL CODES.  
(S) GAS CONTROL VALVE/THERMOSTAT  
*
ALL PIPING MATERIALS  
TO BE SUPPLIED BY  
CUSTOMERS.  
TO VENT TERMINATION  
ON ROOF  
INSTALL THERMAL EXPANSION  
TANK IF WATER HEATER IS  
INSTALLED IN A CLOSED  
WATER SYSTEM  
A
IMPORTANT:  
WHEN BRUSHING ON AN  
APPROVED NONCORROSIVE  
LEAK DETECTION SOLUTION,  
DO NOT SPLASH SOLUTION  
ONTO ELECTRICAL CON-  
NECTIONS (SEE PAGE 27).  
L
M
N
B
D
PRESSURE  
SWITCH/FAN,  
FV SENSOR  
CONNECTOR  
MANIFOLD TUBE  
POWER SUPPLY  
TRANSFORMER  
CONNECTOR  
IGNITER/  
FLAME  
SENSE  
VACUUM RELIEF  
O
VALVE  
*INSTALL PER  
LOCAL CODES  
DISPLAY, ANODE  
ROD CONNECTOR  
CONNECTOR  
P
E
R
(U) NATURAL GAS BURNER ASSEMBLY  
X
MANIFOLD DOOR GASKET  
MANIFOLD DOOR ASSEMBLY  
MANIFOLD COMPONENT  
BLOCK W/ RETAINER CLIP  
Q
Z
BURNER  
IGNITER / FLAME SENSE  
CONNECTOR WIRE  
FLAME SENSE  
F
G
DISCHARGE PIPE  
(DO NOT CAP OR PLUG.)  
MANIFOLD  
TUBE  
S
H
HOT SURFACE  
IGNITER  
IGNITER / FLAME SENSE  
CONNECTOR WIRE  
V
T
U
MANIFOLD DOOR ASSEMBLY  
I
6” MAXIMUM  
AIR GAP  
BURNER  
MANIFOLD TUBE  
FLOOR DRAIN  
YY  
W
J
ZZ  
VIEW PORT  
Y
K
IMPORTANT: DO NOT USE AN EXTENSION CORD TO CONNECT  
THE WATER HEATER TO AN ELECTRICAL OUTLET.  
FIGURE 1.  
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INSTALLING YOUR GAS WATER HEATER  
Unpacking the Water Heater  
Important Information About This Water Heater  
This gas water heater was manufactured to voluntary  
safety standards to reduce the likelihood of a flammable  
vapor ignition incident. New technology used in meeting  
these standards makes this product more sensitive to  
installation errors or improper installation environments.  
Please review the Installation Checklist found at the end of  
the installation instructions section and make any required  
installation upgrades or changes.  
WARNING  
Excessive Weight Hazard  
Use two or more people to move and install the water heater.  
Failure to do so can result in injury (including back injury).  
Consumer Information  
IMPORTANT: Do not remove any permanent instructions,  
labels, or the data label from either the outside of the  
water heater or on the inside of water heater panels.  
This water heater is design-certified by CSA International  
as a Category I, non-direct vented water heater which  
takes its combustion air either from the installation area or  
from air ducted to the unit from the outside.  
This water heater must be installed according to all local  
and state codes or, in the absence of local and state  
codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA  
54)-current edition. This is available from the following:  
CSA America, Inc.  
Remove exterior packaging and place installation com-  
ponents aside.  
Inspect all parts for damage prior to installation and  
start-up.  
Completely read all instructions before attempting to  
assemble and install this product.  
8501 East Pleasant Valley Road  
Cleveland, OH 44131  
National Fire Protection Agency  
After installation, dispose of/recycle all packaging  
materials.  
1 Batterymarch Park  
Quincy, MA 02269  
Check your phone listings for the local authorities having  
jurisdiction over your installation.  
Consumer Responsibilities  
This manual has been prepared to acquaint you with the  
installation, operation, and maintenance of your gas water  
heater and provide important safety information in these  
areas.  
Read all of the instructions thoroughly before attempting  
the installation or operation of this water heater.  
Do not discard this manual. You or future users of this  
water heater will need it for future reference.  
Service to the FVIR System should only be performed by a  
qualified technician.  
Examples of a qualified technician include: licensed  
plumbers, authorized gas company personnel, and  
authorized service personnel.  
IMPORTANT: The manufacturer and seller of this water  
heater will not be liable for any damages, injuries, or  
deaths caused by failure to comply with the installation and  
operating instructions outlined in this manual.  
If you lack the necessary skills required to properly install  
this water heater, or you have difficulty following the  
instructions, you should not proceed but have a qualified  
technician perform the installation of this water heater.  
Massachusetts code requires this water heater to be  
installed in accordance with Massachusetts Plumbing and  
Fuel Gas Code 248 CMR Section 2.00 and 5.00.  
A rating plate identifying your water heater can be found  
on the front of your water heater. When referring to your  
water heater, always have the information listed on the  
rating plate readily available. Retain your original receipt  
as proof of purchase.  
6
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If flammable liquids or vapors have spilled or leaked in  
the area of the water heater, leave the area immediately  
and call the fire department from a neighbor’s home. Do  
not attempt to clean the spill until all ignition sources have  
been extinguished.  
Location Requirements  
WARNING  
Carbon Monoxide Poisoning Hazard  
Do not install in a mobile home.  
WARNING  
Doing so can result in carbon monoxide poisoning and death.  
Fire or Explosion Hazard  
• Read instruction manual before installing, using or  
servicing water heater.  
The FVIR System is designed to reduce the risk of  
flammable vapor-related fires. Flammable liquids (such as  
gasoline, solvents, propane, etc,) emit flammable vapors  
which can be ignited by a gas water heater’s hot surface  
igniter or main burner. The resulting flashback and fire can  
cause death or serious burns to anyone in the area.  
• Improper use may result in fire or explosion.  
• Maintain required clearances to combustibles.  
Keep combustibles such as boxes, magazines, clothes, etc. away  
from the water heater area.  
FIGURE 1A.  
Site Location  
FV Sensor  
Select a location near the center of the water piping  
system. The water heater must be installed indoors  
and in a vertical position on a level surface. DO NOT  
install in bathrooms, bedrooms, or any occupied room  
normally kept closed.  
This heater is equipped with a FV sensor for detecting the  
presence of flammable vapors. When the sensor detects  
those vapors, the unit will shut down and not operate.  
Should this happen, please refer to the troubleshooting  
guide on pages 31-32 (numbers 9,11,12). Even though this  
water heater is a flammable vapors ignition resistant water  
heater and is designed to reduce the chances of flamm-  
able vapors being ignited, gasoline and other flammable  
substances should never be stored or used in the same  
vicinity or area containing a gas water heater or other open  
flame or spark producing appliance.  
Locate the water heater as close to the chimney or gas  
vent as practical. Consider the vent system piping and  
combustion air supply requirements when selecting the  
water heater location. The venting system must be able  
to run from the water heater to termination with minimal  
length and elbows.  
Locate the water heater near the existing gas piping.  
If installing a new gas line, locate the water heater to  
minimize the pipe length and elbows.  
WARNING  
The water heater should be located in an area not  
subject to freezing temperatures. Water heaters  
located in unconditioned spaces (i.e., attics,  
basements, etc.) may require insulation of the water  
piping and drain piping to protect against freezing.  
The drain and controls must be easily accessible for  
operation and service. Maintain proper clearances as  
specified on the water heater.  
FLAMMABLES  
Flammable Vapors  
Do not locate the water heater near an air-moving  
device. The operation of air-moving devices such  
as exhaust fans, ventilation systems, clothes dryers,  
fireplaces, etc., can affect the proper operation of the  
water heater. Special attention must be given to condi-  
tions these devices may create. Flow reversal of flue  
gases may cause an increase of carbon monoxide  
inside of the dwelling (Figure 2).  
FIRE AND EXPLOSION HAZARD  
Can result in serious injury or death  
Do not store or use gasoline or other flammable  
vapors and liquids in the vicinity of this or any other  
appliance. Storage of or use of gasoline or other  
flammable vapors or liquids in the vicinity of this or  
any other appliance can result in serious injury or  
death.  
The water heater is to be located as close as possible  
to a 120VAC outlet. NOTE: all electrical wiring should  
be in accordance to the NEC and all local/state  
electrical codes (extension cord is not allowed).  
Read and follow water heater warnings and  
instructions  
NOTE: This water heater must be installed according to all  
local and state codes or, in the absence of local and state  
codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA  
54)-current edition and the “National Electrical Code”, ANSI/  
NFPS 70 current edition.  
Do not use or store flammable products such as gasoline,  
solvents, or adhesives in the same room or area near the  
water heater. If such flammables must be used, all gas  
burning appliances in the vicinity must be shut off and their  
pilot lights extinguished. Open the doors and windows for  
ventilation while flammable substances are in use.  
7
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EXHAUST FAN  
REVERSE FLOW  
OF GASES  
IMPORTANT: The water heater should be located in an area  
where leakage of the tank or connections will not result in  
damage to the area adjacent to the water heater or to lower  
floors of the structure. Due to the normal corrosive action of  
water, the tank will eventually leak after an extended period  
of time. Also any external plumbing leak, including those  
from improper installation, may cause early failure of the  
tank due to corrosion if not repaired. If the homeowner is  
uncomfortable with making the repair a qualified technician  
should be contacted. A suitable metal drain pan should be  
installed under the water heater as shown below, to help  
protect the property from damage which may occur from  
condensate formation or leaks in the piping connections  
or tank. The pan must limit the water level to a maximum  
depth of 1-3/4” and be two inches wider than the heater and  
piped to an adequate drain. Locate the water heater near a  
suitable indoor drain. Outside drains are subject to freezing  
temperatures which can obstruct the drain line. The piping  
should be at least 3/4” ID and pitched for proper drainage.  
FIGURE 2.  
Clearances and Accessibility  
NOTE: Minimum clearances from combustible materials  
are stated on the label on the front of the heater adjacent  
to the gas control valve/thermostat of the water heater.  
The water heater is certified for installation on a  
combustible floor.  
IMPORTANT: If installing over carpeting, the carpeting  
must be protected by a metal or wood panel beneath  
the water heater. The protective panel must extend  
beyond the full width and depth of the water heater by  
at least five inches (127mm) in any direction; or if in an  
alcove or closet installation, the entire floor must be  
covered by the panel.  
Figure 2A may be used as a reference guide to locate  
the specific clearance locations. A minimum of 5 inch-  
es of front clearance should be provided for inspection  
and service.  
6” min. at  
FIGURE 1B.  
Pipe to an  
adequate drain  
Single Wall  
Vent Pipe  
12” min.  
Top to  
Ceiling  
1-3/4”  
max.  
0” min.  
Back  
At least 2” greater  
than the water heater.  
0” min.  
Sides  
Water heater life depends upon water quality, water usage,  
water temperature 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 metal 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 metal drain pan. These devices  
are available from some plumbing supply wholesalers and  
retailers, and detect and react to leakage in various ways:  
0” min.  
Air Inlet  
Chamber  
5” min.  
Front  
Top View  
Sensors mounted in the metal drain pan that trigger an  
alarm or turn off the incoming water to the water heater  
when water is detected.  
Minimum Clearance Locations  
FIGURE 2A.  
Sensors mounted in the metal drain pan that turn off  
the water supply to the entire home when water is  
detected in the metal drain pan.  
State of California  
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.  
NOTE: The water heater must be braced, anchored, or  
strapped to avoid moving during an earthquake. Contact  
local utilities for code requirements in your area, visit http://  
instructions.  
Devices that will turn off the gas supply to a gas water  
heater while at the same time shutting off its water  
supply.  
8
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GAS SUPPLY  
WARNING  
Manual Gas  
Shut-Off Valve  
Ground Joint Union  
Install a readily acces-  
sible manual shut-off  
valve in the gas supply  
line as recommended  
by the local utility.  
Discharge Pipe  
(Do Not plug or cap)  
Explosion Hazard  
Use a new CSA approved gas supply line.  
Install a shut-off valve.  
Check with local utility  
for minimum height.  
3” Minimum  
Drip Leg  
6” Max. Air Gap  
Suitable Drain  
Do not connect a natural gas water heater to an L.P. gas  
supply.  
FIGURE 3.  
Do not connect an L.P. gas water heater to a natural gas  
supply.  
Gas Pressure  
Failure to follow these instructions can result in death,  
explosion, or carbon monoxide poisoning.  
WARNING  
Gas Requirements  
IMPORTANT: Read the rating plate to be sure the water  
heater is made for the type of gas you will be using in  
your home. This information will be found on the rating  
plate located near the gas control valve/thermostat. If the  
information does not agree with the type of gas available,  
do not install or light. Call your dealer.  
Explosion Hazard  
Gas leaks can not always be detected by smell.  
NOTE: An odorant is added by the gas supplier to the gas  
used by this water heater. This odorant may fade over an  
extended period of time. Do not depend upon this odorant  
as an indication of leaking gas.  
Gas suppliers recommend that you use a gas  
detector approved by UL or CSA.  
For more information, contact your gas supplier.  
If a gas leak is detected, follow the “What to do if you  
smell gas” instructions on the cover of this manual.  
Gas Piping  
The gas piping must be installed according to all local and  
state codes or, in the absence of local and state codes, the  
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current  
edition.  
Tables 1 and 2 on the following page provide a sizing  
reference for commonly used gas pipe materials. Consult  
the “National Fuel Gas Code” for the recommended gas  
pipe size of other materials.  
IMPORTANT: The gas supply pressure must not exceed the  
maximum supply pressure as stated on the water heater’s rating  
plate. The minimum supply pressure is for the purpose of input  
adjustment.  
Gas Pressure Testing  
NOTE: Use pipe joint compound or teflon tape marked  
as being resistant to the action of petroleum gases (See  
Figure 3.)  
1. Install a readily accessible manual shut-off valve in the  
gas supply line as recommended by the local utility.  
Know the location of this valve and how to turn off the  
gas to this unit.  
2. Install a drip leg (if not already incorporated as part of  
the water heater) as shown. The drip leg must be no  
less than three inches long for the accumulation of dirt,  
foreign material, and water droplets.  
3. Install a ground joint union between the gas control  
valve/thermostat and the manual shut-off valve. This  
is to allow easy removal of the gas control valve/  
thermostat.  
IMPORTANT: This water heater and its gas connection must  
be leak tested before placing the appliance in operation.  
If the code requires the gas lines to be tested at a  
pressure exceeding 14” W.C., the water heater and its  
manual shut-off valve must be disconnected from the gas  
supply piping system and the line capped.  
If the gas lines are to be tested at a pressure less than  
14” W.C., the water heater must be isolated from the gas  
supply piping system by closing its manual shut-off valve.  
NOTE: Air may be present in the gas lines and could prevent  
the burner from lighting on initial start-up. The gas lines should  
be purged of air by a qualified technician after installation of  
the gas piping system. While purging the gas piping system  
of air, insure that the fuel is not spilled in the area of the  
water heater installation, or any source of ignition (NOTE:  
spilled fuel may trip the FV Sensor preventing heater from  
starting). If the fuel is spilled while purging the piping  
system of air follow the “WHAT TO DO IF YOU SMELL  
GAS” instructions on the cover of this manual.  
4. Turn the gas supply on and check for leaks. Test all  
connections by brushing on an approved noncorrosive  
leak-detection solution. Bubbles will show a leak.  
Correct any leak found.  
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Gas Pipe Capacity Table  
WARNING  
WARNING  
Explosion Hazard  
Use a new CSA approved gas supply line.  
Install a shut-off valve.  
Explosion Hazard  
Gas leaks can not always be detected by smell.  
Gas suppliers recommend that you use a gas  
detector approved by UL or CSA.  
Do not connect a natural gas water heater to an L.P. gas  
supply.  
For more information, contact your gas supplier.  
If a gas leak is detected, follow the “What to do if you  
smell gas” instructions on the cover of this manual.  
Do not connect an L.P. gas water heater to a natural gas  
supply.  
Failure to follow these instructions can result in death,  
explosion, or carbon monoxide poisoning.  
10  
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COMBUSTION AIR & VENTILATION  
TABLE 3  
Minimum  
Square  
Feet with  
8’ Ceiling  
WARNING  
Typical Room  
with 8’ Ceiling  
BTUH Input  
Carbon Monoxide Warning  
Water heater must be vented to outdoors.  
30,000  
45,000  
60,000  
75,000  
90,000  
105,000  
120,000  
135,000  
188  
281  
375  
469  
563  
657  
750  
844  
9 x 21  
14 x 20  
15 x 25  
15 x 31  
20 x 28  
20 x 33  
25 x 30  
28 x 30  
Vent must be installed by a qualified technician using  
the installation instructions.  
Examples of a qualified technican include: gas  
technicians, authorized gas company personel, and  
authorized service persons.  
Failure to so do can result in death or carbon monoxide  
poisoning.  
IMPORTANT: Air for combustion and ventilation must not  
come from a corrosive atmosphere. Any failure due to  
corrosive elements in the atmosphere is excluded from  
warranty coverage.  
The following types of installation (not limited to the  
following) will require outdoor air for combustion due to  
chemical exposure and may reduce but not eliminate the  
presence of corrosive chemicals in the air:  
IMPORTANT:  
The area must be open and be able to provide the  
proper air requirements to the water heater. Areas that  
are being used for storage or contain large objects  
may not be suitable for water heater installation.  
Water heaters installed in open spaces in buildings  
with unusually tight construction may still require out-  
door air to function properly. In this situation, outside  
air openings should be sized the same as for a con-  
fined space.  
beauty shops  
photo processing labs  
buildings with indoor pools  
water heaters installed in laundry, hobby, or craft  
rooms  
Modern home construction usually requires supplying  
outside air into the water heater area.  
water heaters installed near chemical storage areas  
Combustion air must be free of acid-forming chemicals such  
as sulfur, fluorine, and chlorine. These elements are found  
in aerosol sprays, detergents, bleaches, cleaning solvents,  
air fresheners, paint, and varnish removers, refrigerants,  
and many other commercial and household products. When  
burned, vapors from these products form highly corrosive acid  
compounds. These products should not be stored or used  
near the water heater or air inlet.  
Combustion and ventilation air requirements are determined  
by the location of the water heater. The water heater may  
be located in either an open (unconfined) area or in a  
confined area or small enclosure such as a closet or small  
room. Confined spaces are areas with less than 50 cubic  
feet for each 1,000 BTUH of the total input for all gas-using  
appliances.  
Confined Space  
For the correct and proper operation of this water heater,  
ample air must be supplied for the combustion, ventilation,  
and dilution of flue gases. Small enclosures and confined  
areas must have two permanent openings so that sufficient  
fresh air can be drawn from outside of the enclosure. One  
opening shall be within 12 inches of the top and one within  
12 inches of the bottom of the enclosure as shown in  
Figure 4.  
The size of each opening (free area) is determined by the  
total BTUH input of all gas utilization equipment (i.e., water  
heaters, furnaces, clothes dryers, etc.) and the method by  
which the air is provided. The BTUH input can be found  
on the water heater rating plate. Additional air can be  
provided by two methods:  
Unconfined Space  
A water heater in an unconfined space uses indoor air for  
combustion and requires at least 50 cubic feet for each  
1,000 BTUH of the total input for all gas appliances. The  
table below shows a few examples of the minimum square  
footage (area) required for various BTUH inputs.  
1. All air from inside the building.  
2. All air from outdoors.  
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Attic or crawl spaces cannot be closed and must be  
properly ventilated to the outside.  
12” Max.  
Ductwork must be of the same cross-sectional area as  
the free area of the opening to which they connect. The  
minimum dimension of rectangular air ducts cannot be less  
than three inches.  
Permanent  
openings to  
the outside or  
additional  
rooms within  
the building  
The size of each of the two openings is determined by the  
method in which the air is to be provided. Refer to Table  
4 to calculate the minimum free area for each opening.  
Figures 6, 7, 8A and 8B are typical examples of each  
method.  
Closet  
or other  
confined  
space  
12” Max.  
Louvers and Grilles  
In calculating free area for ventilation and combustion  
air supply openings, consideration must be given to the  
blocking effect of protection louvers, grilles, and screens.  
These devices can reduce airflow, which in turn may  
require larger openings to achieve the required minimum  
free area. Screens must not be smaller than 1/4” mesh. If  
the free area through a particular design of louver or grille  
is known, it should be used in calculating the specified  
free area of the opening. If the design and free area are  
not known, it can be assumed that most wood louvers will  
allow 20 - 25% of free area while metal louvers and grilles  
will allow 60 - 75% of free area.  
FIGURE 4.  
All Air from Inside the Building  
When additional air is to be provided to the confined area  
from additional room(s) within the building, the total volume  
of the room(s) must be of sufficient size to properly provide  
the necessary amount of fresh air to the water heater  
and other gas utilization equipment in the area. If you are  
unsure that the structure meets this requirement, contact  
your local gas utility company or other qualified agency for  
a safety inspection.  
Each of the two openings shall have a minimum free area  
of 1 square inch per 1,000 BTUH of the total input rating of  
all gas utilization equipment in the confined area, but not  
less than 100 square inches (Figure 5).  
Louvers and grilles must be locked open or interconnected  
with the equipment so that they are opened automatically  
during equipment operation.  
Keep louvers and grilles clean and free of debris or other  
obstructions.  
TABLE 4  
Minimum Free Area of Permanent Openings for  
Ventilation and Combustion Air Supply - All Air from  
Outdoors Only.  
Confined  
Space  
Based on total BTUH input rating for all utilizing  
equipment within the conned space.  
Permanent  
Openings  
Minimum Free Area  
Opening Source  
*Direct to outdoors  
Vertical Ducts  
Per Opening (sq. in.) Reference Drawing  
1 sq. in, per 4000 BTUH  
1 sq. in, per 4000 BTUH  
1 sq. in, per 2000 BTUH  
1 sq. in, per 3000 BTUH  
Figure 6  
Figure 7  
1 Square  
inch/1000  
BTUH  
(min. 100  
sq. in.)  
Horizontal Ducts  
Single Opening  
Figure 8A  
Figure 8B  
Example: A water heater with an input rating of 50,000 BTUH using  
horizontal ducts would require each opening to have a minimum free  
area of 25 square inches.  
Minimum free area = 50,000 BTUH x 1 sq. in. / 2000 BTUH = 25 sq. in.  
FIGURE 5.  
These openings connect directly with the outdoors through  
a ventilated attic, a ventilated crawl space, or through an  
outside wall.  
*
All Air from Outdoors  
Consult the local codes of your area for specific ventilation  
and combustion air requirements.  
Outdoor fresh air can be provided to a confined area either  
directly or by the use of vertical and horizontal ducts. The  
fresh air can be taken from the outdoors or from crawl or  
attic spaces that freely communicate with the outdoors.  
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Alternative  
Opening  
Location  
Gable Vent  
to Outdoors  
Install Above  
Insulation  
Confined  
Space  
1 sq. in. per  
3000 BTUH  
Confined  
Space  
Outlet Air  
to the Attic  
1 sq. in. per  
4000 BTUH  
Inlet Air  
from the  
Crawl Space  
Alternative  
Air Inlet  
All Air From Outdoors - Using A Single Permanent Opening  
FIGURE 8B.  
Open  
Foundation  
Vent  
1 sq. in. per  
4000 BTUH  
Vent Pipe System  
All Air From Outdoors: Inlet Air From Ventilated  
Crawl Space/Outlet Air To Ventilated Attic  
This water heater uses a non-direct, single-pipe vent  
system to remove exhaust gases created by the burning of  
fossil fuels. Air for combustion is taken from the immediate  
water heater location or is ducted in from the outside (see  
“Combustion Air Supply and Ventilation”).  
This water heater must be properly vented for the removal  
of exhaust gases to the outside atmosphere. Correct  
installation of the vent pipe system is mandatory for the  
proper and efficient operation of this water heater and is  
an important factor in the life of the unit.  
The vent pipe must be installed according to all local and  
state codes or, in the absence of local and state codes, the  
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current  
edition. The vent pipe installation must not be obstructed  
so as to prevent the removal of exhaust gases to the  
outside atmosphere.  
FIGURE 6.  
Gable Vent  
to Outdoors  
Install Above  
Insulation  
Outlet Air  
Confined  
Space  
to the Attic  
1 sq. in. per  
4000 BTUH  
Inlet Air Duct  
1 sq. in. per  
4000 BTUH  
IMPORTANT: The use of vent dampers is not  
recommended by the manufacturer of this water heater.  
Although some vent dampers are certified by CSA  
International, this certification applies to the vent damper  
device only and does not mean they are certified for use  
on this water heater.  
12” Max.  
All Air from Outdoors Through Ventilated Attic  
FIGURE 7.  
U.L. recognized fuel gas and carbon monoxide (CO)  
detectors are recommended in all applications and should  
be installed using the manufacturer’s instructions and local  
codes, rules, or regulations.  
1 sq. in. per  
2000 BTUH  
IMPORTANT: If you lack the necessary skills required  
to properly install this venting system, you should not  
proceed, but get help from a qualified technician.  
Confined  
Outlet  
Space  
Draft Hood Installation  
Outdoor  
Air Ducts  
Sheet Metal Screws (Four Provided)  
Draft Hood  
Legs  
Inlet  
Legs  
1 sq. in. per  
2000 BTUH  
Slot  
Slot  
Jacket Top  
All Air From Outdoors Using Horizontal Ducts  
Install The Draft Hood With The Four Screws Provided.  
FIGURE 8A.  
FIGURE 9  
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Align the legs of the draft hood with the slots provided.  
Insert the legs and secure the draft hood to the water  
heater’s top with the four screws provided as shown in  
Figure 9. Do not alter the draft hood in any way. If you are  
replacing an existing water heater, be sure to use the draft  
hood supplied with this water heater.  
The connector must be installed above the extreme  
bottom of the chimney to prevent potentially blocking  
the flue gases.  
The connector must be firmly attached and sealed to  
prevent it from falling out.  
To aid in removing the connector, a thimble or slip joint  
may be used.  
The connector must not extend beyond the inner edge  
of the chimney as it may restrict the space between it  
and the opposite wall of the chimney (Figure 10).  
Vent Pipe Size  
It is important that you follow the guidelines in these  
instructions for sizing a vent pipe system. If a transition  
to a larger vent size is required, the vent transition  
connection must be made at the draft hood outlet.  
2 FT. Minimum Above Any Object  
3 FT.  
Within 10 FT. Horizontally  
Minimum  
Vent Connectors  
Support Strap  
1. Type B, Double wall, U.L. Listed Vent Pipe.  
2. Single wall Vent Pipe.  
Maintain the manufacturer’s specified minimum clearance  
from combustible materials when using type B double wall  
vent pipe.  
Vent connectors made of type B, double wall vent pipe  
material may pass through walls or partitions constructed  
of combustible material if the minimum listed clearance is  
maintained.  
Seal  
Maintain  
Clearance*  
Do Not Extend  
Vent Beyond Edge  
Of Chimney  
Vent  
Connector  
Slope Up  
1/4 Inch  
Per Foot  
Minimum  
Maintain a six inch minimum clearance from all  
combustible materials when using single wall vent pipe.  
IMPORTANT: Single wall vent pipe cannot be used for  
water heaters located in attics and may not pass through  
attic spaces, crawl spaces or any confined or inaccessible  
location. A single wall metal vent connector cannot pass  
through any interior wall.  
Chimney Termination Vent System  
FIGURE 10.  
Do not terminate the vent connector in a chimney that has  
not been certified for this purpose. Some local codes may  
prohibit the termination of vent connectors in a masonry  
chimney.  
When installing a vent connector, please note the following  
(See Figures 10-12):  
Install the vent connector avoiding unnecessary bends,  
which create resistance to the flow of vent gases.  
Install without dips or sags with an upward slope of at  
least 1/4-inch per foot.  
Joints must be fastened by sheet metal screws or other  
approved means. It must be supported to maintain  
clearances and prevent separation of joints and  
damage.  
Vertical Exhaust Gas Vent  
Vertical exhaust gas vents must be installed with  
U.L. listed type B vent pipe according to the vent  
manufacturer’s instructions and the terms of its listing.  
It must be connected to the water heater’s draft hood by a  
listed vent connector or by directly originating at the draft  
hood opening.  
The length of the vent connector cannot exceed 75% of  
the vertical vent height.  
The vent connector must be accessible for cleaning,  
inspection, and replacement.  
Vent connectors cannot pass through any ceiling, floor,  
firewall, or fire partition.  
It is recommended (but not mandatory) that a minimum  
12 inches of vertical vent pipe be installed on the draft  
hood prior to any elbow in the vent system.  
Vertical gas vents must terminate with a listed cap or  
other roof assembly and be installed according to their  
manufacturer’s instructions.  
Gas vents must be supported to prevent damage, joint  
separation, and maintain clearances to combustible  
materials (Figures 11 and 12).  
IMPORTANT: This gas vent must be terminated in a  
vertical position to facilitate the removal of the burnt gases.  
IMPORTANT: Existing vent systems must be inspected for  
obstructions, corrosion, and proper installation.  
An unused chimney flue or masonry enclosure may be used  
as a passageway for the installation of a gas vent (Figure 12).  
Common (combined) venting is allowable with vertical type  
B vent systems and lined masonry chimneys as long as  
proper draft for the water heater is established under all  
conditions of operation. CAUTION: DO NOT common vent  
this water heater with any power vented appliance.  
Chimney Connection  
IMPORTANT: Before connecting a vent to a chimney,  
make sure the chimney passageway is clear and free of  
obstructions. The chimney must be cleaned if previously  
used for venting solid fuel appliances or fireplaces. Also  
consult local and state codes for proper chimney sizing  
and application or, in the absence of local and state  
codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA  
54)-current edition.  
Figures 10-12 are examples of vent pipe system  
installations and may or may not be typical for your  
specific application. Consult the “National Fuel Gas Code”,  
NFPA 54, ANSI Z223.1-current edition and the guidelines  
set forth by prevailing local codes.  
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2 FT. Minimum Above  
Any Object Within  
10 FT. Horizontally  
WATER SYSTEM PIPING  
3 FT.  
Piping Installation  
Minimum  
Piping, fittings, and valves should be installed according  
to the installation drawing (Figure 13). If the indoor  
installation area is subject to freezing temperatures, the  
water piping must be protected by insulation.  
Support Strap  
Type B Double  
Wall Vent Pipe  
Maintain  
Clearance*  
The water supply pressure should not exceed 80 psi. If  
this occurs, a pressure reducing valve with a bypass may  
need to be installed in the cold water inlet line. This should  
be placed on the supply to the entire house in order to  
maintain equal hot and cold water pressures.  
**Maintain  
Specified  
Clearance  
Vent  
Connector  
Slope Up  
1/4 Inch  
Per Foot  
Minimum  
IMPORTANT: Heat cannot be applied to the water fittings  
on the heater as they may contain nonmetallic parts. If  
solder connections are used, solder the pipe to the adapter  
before attaching the adapter to the hot and cold water  
fittings.  
Venting Gas Vent System With Type B Double Wall Vent Pipe.  
FIGURE 11.  
IMPORTANT: Always use a good grade of joint compound  
and be certain that all fittings are drawn up tight.  
1. Install the water piping and fittings as shown in Figure  
13. Connect the cold water supply (3/4” NPT) to the  
cold water inlet fitting. Connect the hot water piping  
(3/4” NPT) to the hot water outlet fitting.  
Listed Vent Cap  
Maintain Manufacturer’s  
Specified Minimum Clearance  
IMPORTANT: Some models may contain energy saving  
heat traps to prevent the circulation of hot water within the  
pipes. Do not remove the inserts within the heat traps.  
**Maintain  
Specified  
Clearance  
Support Strap  
Seal  
Maintain  
Clearance*  
2. The installation of unions in both the hot and cold water  
supply lines is recommended for ease of removing the  
water heater for service or replacement.  
Vent Connector  
Vent  
3. The manufacturer of this water heater recommends  
installing a mixing valve or an anti-scald device in the  
domestic hot water line as shown in Figure 14. These  
valves reduce the point-of-use temperature of the  
water by mixing cold and hot water and are readily  
available for use.  
Connector  
Slope Up  
1/4 Inch  
Per Foot  
Minimum  
Unused Chimney  
Flue Or Masonry  
Enclosure  
4. If installing the water heater in a closed water system,  
install an expansion tank in the cold water line as  
specified under Closed System/Thermal Expansion.  
Venting Through Chimney With Type B Double Wall Vent Pipe.  
5. Install a shut-off valve in the cold water inlet line. It  
should be located close to the water heater and be  
easily accessible. Know the location of this valve and  
how to shut off the water to the heater.  
FIGURE 12.  
Maintain vent pipe clearance requirements to local, state  
and/or the “National Fuel Gas Code”, ANSI Z223.1(NFPA  
54)-current edition.  
*
6. A temperature and pressure relief valve must be  
installed in the opening marked “Temperature and  
Pressure (T & P) Relief Valve” on the water heater.  
A discharge line must be added to the opening of  
the T&P Relief Valve. Follow the instructions under  
Temperature and Pressure Relief Valve.  
** NFPA 211, Standard for Chimneys, Fireplaces, Vents, and  
Solid Fuel-Burning Appliances states that these chimneys are  
intended to be installed in accordance with the installation  
instructions provided with each chimney support assembly.  
Minimum air space clearance to combustible materials should be  
maintained as marked on the chimney sections.  
7. After piping has been properly connected to the water  
heater, remove the aerator at the nearest hot water  
faucet. Open the hot water faucet and allow the tank  
to completely fill with water. To purge the lines of  
any excess air, keep the hot water faucet open for  
3 minutes after a constant flow of water is obtained.  
Close the faucet and check all connections for leaks.  
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In a closed system use a  
thermal expansion tank  
Closed System/Thermal Expansion  
Cold Water  
Inlet Valve  
Pressure Reducing  
Valve with Bypass  
Hot Water  
Outlet  
Cold Water Supply  
to Fixture  
Main Water  
Supply  
Temperature and Pressure (T&P)  
Relief Valve (Optional Top T&P  
Relief Valve Not Shown)  
Massachusetts:  
Install a vacuum relief  
in cold water line per  
section 19 MGL 142  
As water is heated, it expands (thermal expansion). In a closed  
system, the volume of water will grow. As the volume of water  
grows, there will be a corresponding increase in water pressure  
due to thermal expansion. Thermal expansion can cause  
premature tank failure (leakage). This type of failure is not  
covered under the limited warranty. Thermal expansion can also  
cause intermittent temperature-pressure relief valve operation:  
water discharged from the valve due to excessive pressure build  
up. The temperature-pressure relief valve is not intended for the  
constant relief of thermal expansion. This condition is not covered  
under the limited warranty.  
Discharge line  
(Do Not Cap or Plug)  
1“ Min.  
Drain line 3/4”  
ID Min.  
Metal Drain  
Pan 1-3/4”  
Depth Max.  
6“ Min.  
Drain  
Typical water piping installation  
FIGURE 13.  
A properly-sized thermal expansion tank should be installed  
on all closed systems to control the harmful effects of thermal  
expansion. Contact a plumbing service agency or your retail  
supplier regarding the installation of a thermal expansion tank.  
Mixed Water  
To Fixtures  
Unmixed  
Hot Water  
Temperature and Pressure Relief Valve  
Cold Water  
Inlet  
Explosion Hazard  
Hot Water  
Outlet  
Temperature-pressure relief  
valve must comply with ANSI  
Z21.22-CSA 4.4 and ASME  
code.  
• Properly sized temperature-  
pressure relief valve must be  
installed in opening provided.  
Mixing Valve  
(Set To 1200 F)  
• Can result in overheating  
and excessive tank pressure.  
Follow The Mixing Valve  
Manufacturer’s Instructions  
• Can cause serious injury or  
death.  
FIGURE 14.  
Please note the following:  
The system should be installed only with piping that is  
suitable for potable (drinkable) water such as copper,  
CPVC, or polybutylene. This water heater must not be  
installed using iron piping or PVC water piping.  
Temperature and  
Pressure Relief Valve  
(T&P)  
Use only pumps, valves, or fittings that are compatible  
with potable water.  
Discharge line 3/4” Min.  
Do not cap or plug.  
It is recommend that only full flow ball or gate valves  
are used in water piping installations. The use of valves  
that may cause excessive restriction to water flow is not  
recommended.  
Metal Drain Pan  
Use only 95/5 tin-antimony or other equivalent solder.  
Any lead based solder must not be used.  
6” Max.  
Drain  
Piping that has been treated with chromates, boiler seal,  
or other chemicals must not be used.  
FIGURE 15A.  
Chemicals that may contaminate the potable water  
supply must not be added to the piping system.  
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For protection against excessive pressures and  
pipe. Also ensure that the base of insulation is flush with  
the water heater. Once seated, secure the insulation with  
duct tape, electrical tape, or equivalent.  
temperatures, a temperature and pressure relief valve must  
be installed in the opening marked “T & P RELIEF VALVE”  
(see Figure 15A). This valve must be design certified by  
a nationally recognized testing laboratory that maintains  
periodic inspection of the production of listed equipment or  
materials as meeting the requirements for Relief Valves for  
Hot Water Supply Systems, ANSI Z21.22. The function of  
the temperature and pressure relief valve is to discharge  
water in large quantities in the event of excessive  
7. Repeat steps 5 through 6 for the hot water (outlet) pipe.  
8. Add additional sections of pipe insulation as needed.  
Manual Relief Lever  
T&P Relief Valve  
temperature or pressure developing in the water heater.  
The valve’s relief pressure must not exceed the working  
pressure of the water heater as stated on the rating plate.  
IMPORTANT: Only a new temperature and pressure relief  
valve should be used with your water heater. Do not use an  
old or existing valve as it may be damaged or not adequate  
for the working pressure of the new water heater. Do not  
place any valve between the relief valve and the tank.  
T&P Relief Valve  
Drain Line  
T&P Relief Valve Insulation  
The Temperature & Pressure Relief Valve:  
FIGURE 15B.  
Must not be in contact with any electrical part.  
Must be connected to an adequate discharge line.  
Combination Space Heating/Potable  
Water System  
Must not be rated higher than the working pressure  
shown on the rating plate of the water heater.  
Some water heater models are equipped with inlet/outlet  
connections for use with space heating applications. If this  
water heater is to be used to supply both space heating  
and domestic potable (drinking) water, the instructions  
listed below must be followed.  
The Discharge Line:  
Must not be smaller than the pipe size of the relief  
valve or have any reducing coupling installed in the  
discharge line.  
Must not be capped, blocked, plugged or contain any  
valve between the relief valve and the end of the dis-  
charge line.  
Be sure to follow the manual(s) shipped with the air  
handler system.  
This water heater is not to be used as a replacement  
for an existing boiler installation.  
Must terminate a maximum of six inches above a floor  
drain or external to the building. In cold climates, it is  
recommended that the discharge pipe be terminated at  
an adequate drain inside the building.  
Do not use with piping that has been treated with  
chromates, boiler seal or other chemicals and do not  
add any chemicals to the water heater piping.  
Must be capable of withstanding 250°F (121°C) without  
distortion.  
If the space heating system requires water  
temperatures in excess of 120°F, a mixing valve  
or an anti-scald device should be installed per its  
manufacturer’s instructions in the domestic (potable)  
hot water supply to limit the risk of scald injury.  
Must be installed to allow complete drainage of both  
the valve and discharge line.  
T&P Relief Valve and Pipe Insulation  
Pumps, valves, piping and fittings must be compatible  
with potable water.  
1. Locate the temperature and relief valve on the water  
heater (also known as a T&P Relief Valve, Figure 15B).  
2. Locate the slit running the length of the insulation.  
A properly installed flow control valve is required to  
prevent thermosiphoning. Thermosiphoning is the  
result of a continuous flow of water through the air  
handler circuit during the off cycle. Weeping (blow off)  
of the temperature and pressure relief valve (T & P)  
or higher than normal water temperatures are the first  
signs of thermosiphoning.  
3
Spread this slit open and slip it up under the T&P Relief  
Valve. See Figure 15B. Apply gentle pressure to the  
insulation to ensure it is fully seated on the T&P Relief  
Valve. Once sealed secure the insulation with a section  
of duct tape, electrical tape, or equivalent.  
The domestic hot water line from the water heater  
should be vertical past any mixing valve or supply line to  
the air handler to remove air bubbles from the system.  
Otherwise, these bubbles will be trapped in the air  
handler heat exchanger coil, reducing the efficiency.  
IMPORTANT: The insulation or tape must not block the  
discharge opening or hinder access to the manual relief  
lever. Ensure a discharge pipe is installed into the T&P  
valve discharge opening per the instructions manual.  
Do not connect the water heater to any system or  
components previously used with non-potable water  
heating appliances when used to supply potable water.  
4. Locate the hot water (outlet) & cold water (inlet) pipes to  
the water heater.  
5. Locate the slit running the length of a section of pipe  
insulation.  
6. Spread the slit open and slip the insulation over the cold  
water (inlet) pipe. Apply gentle pressure along the length  
of the insulation to ensure it is fully seated around the  
Some jurisdictions may require a backflow preventer in the  
incoming cold water line. This may cause the temperature  
and pressure relief valve on the water heater to  
discharge or weep due to expansion of the heated water.  
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A diaphragm-type expansion tank suitable for potable  
water will normally eliminate this weeping condition.  
Please read and follow the manufacturer’s instructions for  
the installation of such tanks.  
Electrical Connections  
WARNING  
Must Be Vertical To  
Domestic  
Hot Water  
Out  
Remove Air Bubbles  
Expansion Tank  
Cold Water Inlet  
Electric Shock Hazard  
Vacuum  
Relief  
Mixing  
Valve  
Disconnect power before  
servicing.  
Valve  
Flow Control  
Pump  
Valve  
Hot  
Out  
Water  
Out  
In  
Replace all parts and panels  
before operating.  
Unions  
Coil  
To Air  
Handler  
Failure to do so can result in  
death or electrical shock.  
Air  
Handler  
Shut-Off  
Valve  
Before plugging in the water heater, always make sure:  
The Voltage and frequency correspond to that specified  
on the water heater.  
MASSACHUSETTS CODE  
DOES NOT ALLOW THIS  
TYPE OF INSTALLATION.  
The electrical outlet has the proper overload fuse or  
breaker protection.  
Typical Mixing Valve Installation Combination  
Space Heating/Potable Water Heating System  
Unit is to connect to a 120VAC electrical supply outlet  
(extension cord is not allowed).  
FIGURE 16  
Also see Water System Piping for additional instructions on  
the safe and correct installation and operation of this water  
heater.  
IMPORTANT: Do not use an extension cord to connect the  
water heater to an electrical outlet.  
The water heater and the outlet are properly grounded.  
Installed in accordance with prevailing provisions of  
local codes, or in the absence of such, National Electric  
Code, ANSI/NFPS 70 current edition.  
Solar Installation  
If this water heater is used as a solar storage heater  
or as a backup for the solar system, the water supply  
temperatures to the water heater tank may be in excess of  
120°F. A mixing valve or other temperature limiting valve  
must be installed in the water supply line to limit the supply  
temperature to 120°F.  
Completely fill the tank with water and check all con-  
nections for leaks. Open the nearest hot water faucet and  
let it run for three (3) minutes to purge the water lines of  
air and sediment and to ensure complete filling of the tank.  
The Electrical power may then be turned on. Verify proper  
operation after servicing.  
NOTE: Solar water heating systems can often supply  
water with temperatures exceeding 180°F and may result  
in water heater malfunction.  
Wiring Diagram  
Gas Control  
Air Intake  
Valve / Thermostat  
Chamber Fan  
Anode  
Rod  
Pressure  
Switch  
Control Display  
CAUTION:  
DO NOT USE AN EXTENSION  
CORD TO CONNECT THE  
TRANSFORMER TO AN  
ELECTRICAL OUTLET.  
Igniter/Flame  
Sense Connector  
FV  
Sensor  
CAUTION:  
Power Supply  
Transformer  
LABEL ALL WIRES PRIOR TO  
DISCONNECTION WHEN SERVICING  
CONTROLS. WIRING ERRORS CAN CAUSE  
IMPROPER AND DANGEROUS OPERATION.  
VERIFY PROPER OPERATION AFTER SERVICING.  
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IMPORTANT INFORMATION ABOUT THIS WATER HEATER  
This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor  
ignition incident. The new technology used in meeting these standards makes this product more sensitive to installation  
errors. Please review the following checklist and make any required installation upgrades or changes.  
Questions? Contact Residential Technical Assistance by referencing the phone number on the front of the Installation  
Instructions and Use & Care Guide.  
Ductwork is the same cross-sectional area as the  
Installation Checklist  
openings.  
Water Heater Location  
Vent Pipe System  
Water heater location is important and can affect system  
Check for proper drafting at the water heater draft hood.  
performance. Please check the following:  
Refer to the “Checking the Draft” section of this manual for  
the test procedure. If the procedure shows insufficient draft  
Installation area free of corrosive elements and  
is present, please check the following.  
flammable materials.  
Draft hood properly installed.  
Centrally located with the water piping system (For new  
installations). Located as close to the gas piping, vent  
pipe system and 120VAC outlet as possible.  
Vent connectors securely fastened with screws and  
supported properly to maintain six inch clearance.  
Located indoors and in a vertical position. Protected  
Vent connector made of approved material and sized  
from freezing temperatures.  
correctly.  
Proper clearances from combustible surfaces  
Vent pipe system installed according to all local and  
state codes or, in the absence of local and state codes,  
the “National Fuel Gas Code”, ANSI Z223.1(NFPA  
54)-current edition.  
maintained and not installed directly on a carpeted floor.  
Provisions made to protect the area from water damage.  
Metal drain pan installed and piped to an adequate  
drain.  
Flue baffle properly positioned in the flue tube.  
Sufficient room to service the water heater. See  
Check the vent system for restrictions/obstructions  
and check the vent termination height. Refer to the  
“Combustion Air and Ventilation” section of this water  
heater manual for specific requirements.  
Clearances and Accessibility section of this manual.  
Water heater not located near an air moving device.  
Is the installed environment dirty (excessive amounts  
of lint, dirt, dust, etc.)? If so, the air intake chamber  
louvers located on the side of the water heater  
will need to be cleaned periodically. Refer to the  
maintenance section of your water heater’s manual  
for information on cleaning the “Air Intake Chamber  
Louvers”.  
Recheck for sufficient combustion air supply.  
Water System Piping  
Temperature and pressure relief valve properly installed  
with a discharge line run to an open drain and protected  
from freezing.  
All piping properly installed and free of leaks.  
Heater completely filled with water.  
Closed system pressure build-up devices installed.  
Mixing valve (when applicable) installed per  
manufacturer’s instructions (See Water Temperature  
Regulation section).  
Combustion Air Supply and Ventilation  
Check for sufficient combustion air supply. Insufficient air  
for the combustion of gas will result in a inferior burner  
flame “yellow-lazy”, thereby allowing smoking and carbon  
formation (sooting) to build up in the combustion chamber.  
Is the water heater installed in a closet or other small,  
enclosed space? If so:  
Gas Supply and Piping  
Gas type is the same as that listed on the water heater  
Are there openings for make-up air to enter and exit  
rating plate.  
the room/area?  
Gas line equipped with shut-off valve, union, and drip  
Are the openings of sufficient size? Remember, if  
there are other gas-fired or air-consuming appliances  
in the same room, you need more make-up air. Refer  
to the Location Requirements section of this water  
heater manual for specific requirements.  
leg.  
Use pipe joint compound or teflon tape marked as being  
resistant to the action of petroleum gases.  
Adequate pipe size and approved pipe material.  
Fresh air not taken from areas that contain negative  
pressure producing devices such as exhaust fans, dryers,  
fireplaces, etc.  
An approved noncorrosive leak detection solution used  
to check all connections and fittings for possible gas  
leaks. Correct any leak found.  
Is there a furnace/air handler in the same room space  
as the water heater? If so, has a return air duct system  
been attached that exits the room? If so, check for  
leaks on the air duct system. If no air duct system is  
present, correct immediately by contacting a local  
Heating, Ventilation, Air-Conditioning & Refrigeration  
(HVAC-R) authorized service provider.  
Electrical Supply  
Water heater to be located as close as possible to a  
120VAC outlet (extension cord is not allowed).  
Electrical supply installed according to all local and  
state codes or, in the absence of local and state codes,  
the “National Electrical Code”, ANSI/NFPS 70 current  
edition.  
Fresh air supply free of corrosive elements and  
flammable vapors.  
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OPERATING YOUR WATER HEATER  
Operating Instructions  
Read and understand these directions thoroughly before  
attempting to operate the water heater. Make sure the view  
port is not missing or damaged (See Figure 25). Make  
sure the tank is completely filled with water before  
operating the water heater. The gas control valve/  
thermostat has a “On/Off Switch” and needs to be turned  
on before water heater is operational. Check the label on  
the front of heater near the gas control valve/thermostat for  
the correct gas. Do not use this water heater with any gas  
other than the one listed on the label. If you have any  
questions or doubts, consult your gas supplier or gas utility  
company.  
WARNING  
Explosion Hazard  
Replace view port if glass is missing  
or damaged.  
Failure to do so can result in death,  
explosion or fire.  
FOR YOUR SAFETY READ BEFORE OPERATING  
WARNING: If you do not follow these instructions exactly, a fire or  
explosion may result causing property damage, personal injury  
or loss of life.  
FLAMMABLE  
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.  
This appliance does not have a pilot. It is equipped with  
an ignition device that will automatically light the  
burner. Do not try to light the burner by hand.  
BEFORE OPERATING smell all around the appliance  
area for gas. Be sure to smell next to the floor because  
some gas is heavier than air and will settle on the floor.  
WHAT TO DO IF YOU SMELL GAS:  
Do not try to light any appliance.  
Do not touch any electric switch;  
do not use any phone in your building.  
A.  
If you cannot reach your gas supplier, call the  
fire department.  
Use only your hand to push in the electronic display  
buttons and gas control switch. Never use tools.  
If the control buttons will not push in, don't try to  
repair them, call a qualified service technician. Force  
or attempted repair may result in a fire or explosion.  
C.  
D.  
B.  
Do not use this appliance if any part has been  
under water. Immediately contact a qualified  
installer or service agency to replace a flooded  
water heater. Do not attempt to repair the unit.  
It must be replaced!  
Immediately call your gas supplier from a neighbor’s  
phone. Follow the gas supplier’s instructions.  
OPERATING INSTRUCTIONS  
ON  
OFF  
ON/OFF  
SWITCH  
"GAS CONTROL"  
"ELECTRONIC DISPLAY"  
1.  
STOP! Read the safety information  
above on the label.  
8. Set the ON/OFF switch on the gas control to the  
"ON" postition.  
2.  
3.  
Turn on all electrical power to the appliance.  
Set the ON/OFF switch on the gas control to the  
"ON" position.  
Set the Electronic Display to the desired setting by first  
9.  
Set the Electronic Display to the lowest  
4.  
pressing the COOLER  
and HOTTER  
but-  
setting by first pressing the COOLER  
and  
HOTTER  
buttons together and holding for 1  
tons together and holding for 1 second. Then press  
second. Then press the COOLER  
the lowest setting.  
button to  
the HOTTER  
is reached.  
button until the desired setting  
5.  
6.  
Set the ON/OFF switch on the gas control to the  
"OFF" position.  
This appliance is equipped with a device  
which automatically lights the burner.  
DANGER: Hotter water increases the  
risk scald injury. Consult the instruction  
manual before changing temperature.  
If the appliance will not operate, follow the instruc-  
tions "TO TURN OFF GAS TO APPLIANCE" and  
call your technician or gas supplier.  
10.  
DO NOT TRY TO LIGHT THE BURNER BY HAND.  
Wait five (5) minutes to  
If you then smell gas,  
clear out any gas.  
STOP! Follow "B" in  
7.  
WARNING: TURN OFF ALL  
the safety information above on this label. If you  
don't smell gas, go to the next step.  
ELECTRIC POWER BEFORE SERVICING.  
TO TURN OFF GAS TO APPLIANCE  
Set the Electronic Display to the lowest setting by first  
1.  
2. Set the ON/OFF switch on the gas control to the  
"OFF" postition.  
pressing the COOLER  
tons together and holding for 1 second. Then press  
the COOLER button to the lowest setting.  
and HOTTER  
but-  
3.  
Turn off all electrical power to the appliance if  
service is to be performed.  
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Water Heater Operation  
Checking the Draft  
Figure 17 below shows the water heater’s sequence of  
operation when a call for heat is initiated. The ignition  
control module will attempt to light the burner three times.  
If the ignition control does not detect ignition it will enter  
lockout mode, indicated by display flashing status code  
WARNING  
Burn Hazard  
(see status code 3 page 30 and/or status code 9 page 31).  
Do not touch vent.  
Doing so can result in burns.  
Sequence of Operation  
After successfully lighting the water heater, allow the unit to  
operate for 15 minutes and check the draft hood relief  
opening for proper draft (Figure 18). Make sure all other  
appliances in the area are operating and all doors are closed  
when performing the draft test. Pass a match flame around  
the relief opening of the draft hood. A steady flame drawn  
into the opening indicates proper draft.  
CALL FOR  
HEAT INDICATED  
BY FLASHING OF  
DISPLAY SCREEN  
STATUS CODES  
FLAME SENSE ROD DETECTS  
FLAME OF MAIN BURNER  
CONTROL CHECKS TO ENSURE  
PRESSURE SWITCH IS OPEN  
WATER IN TANK IS HEATED BY  
MAIN BURNER AND  
DRAFT BLOWER IS ENERGIZED  
TEMPERATURE REACHES  
THERMOSTAT SETTING  
CONTROL CHECKS TO ENSURE  
PRESSURE SWITCH IS CLOSED,  
INDICATING BLOWER OPERATING  
AND THERE ARE NO VENTING  
BLOCKAGES (INLET OR OUTLET)  
MAIN VALVE DE-ENERGIZES  
AND DRAFT BLOWER CONTINUES  
FOR A POST PURGE TIME OF  
APPROX. 30 SECONDS  
MAIN VALVE DE-ENERGIZES  
AND BLOWER CONTINUES FOR  
A POST PURGE TIME  
CONTROL ENERGIZES HOT  
SURFACE IGNITER (HSI)  
MAIN VALVE ENERGIZES ALLOW-  
ING THE BURNER TO BE LIT BY  
HSI, DRAFT BLOWER ENERGIZES  
HEATER RETURNS TO  
STANDBY MODE  
DRAFT HOOD  
FIGURE 17.  
RELIEF  
OPENING  
MATCH  
FIGURE 18.  
If the flame flutters or is blown out, combustion products are  
escaping from the relief opening. If this occurs, do not operate  
the water heater until proper adjustments or repairs are made  
to the vent pipe system and/or air supply requirements.  
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heater. Mixing valves are available at plumbing supply or  
hardware stores, see Figure 14. Follow manufacturer’s  
instructions for installation of the valves. Before changing  
the factory setting on the thermostat see Figures 20 and  
21. Using the lowest hot water temperature that meets  
your needs will also provide the most energy efficient  
operation of the water heater.  
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.  
Burner Flames  
Inspect the burner flames through the viewport and  
compare them to the drawings in Figure 19. A properly  
operating burner should produce a soft blue flame. Blue  
tips with yellow inner cones are satisfactory. The tips  
of the flame may have a slight yellow tint. The flame  
should not be all yellow or have a sharp blue-orange  
color. Contaminated air may cause an orange colored  
flame. Contact a qualified technician if the flame is not  
satisfactory.  
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. It is adjustable and must be reset to  
the desired temperature setting to reduce the risk of scald  
injury. The electronic control display temperature should  
be set at approximately 120°F (49°C) and this is the pre-  
ferred starting point, see Figure 20. Some states have a  
requirement for a lower setting. If you need hotter water,  
follow directions for temperature adjustment, but beware of  
the warnings in this section.  
FIGURE 19.  
Emergency Shut Down  
Water  
Temperature  
°F  
Time for 1st  
Degree Burn  
(Less Severe Burns)  
Time for Permanent Burns  
2nd & 3rd Degree  
IMPORTANT: Should overheating occur or the gas supply  
fails to shut off, turn off the heater’s manual gas control  
valve and the electrical power. Call a qualified technician.  
(Most Severe Burns)  
110  
116  
116  
122  
131  
140  
149  
154  
(normal shower temp.)  
(pain threshold)  
35 minutes  
Water Temperature Regulation  
45 minutes  
5 minutes  
25 seconds  
5 seconds  
2 seconds  
1 second  
1 minute  
Water temperature over 125°F (52°C)  
can cause servere burns instantly  
resulting in severe injury or death.  
5 seconds  
2 seconds  
1 second  
Children, the elderly, and the  
physically or mentally disabled are at  
highest risk for scald injury.  
instantaneous  
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978)  
Feel water before bathing or  
showering.  
FIGURE 20.  
Pressing the “COOLER”  
and pressing the “HOTTER”  
temperature.  
button decreases temperature  
button increases the  
Temperature limiting valves are  
available.  
To avoid any unintentional changes in water temperature  
settings, the control has a tamper resistant feature  
for changing the temperature setting. To change the  
temperature setting follow these instructions:  
Read instruction manual for safe  
temperature setting.  
Due to the nature of the typical gas water heater, the water  
temperature in certain situations may vary up to 30°F (16.7  
°C) higher or lower at the point of use such as, bathtubs,  
showers, sink, etc.  
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 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, should be used  
at the hot water taps used by these people or at the water  
1. “Wake Up” the temperature indicators by holding down  
both “COOLER” and “HOTTER” temperature adjust-  
ment buttons at the same time for one second (See  
Figure 21). The display will light up. The display will  
only remain on for 30 seconds if no further buttons are  
pressed. After 30 seconds the control will go back to  
“Sleep” mode.  
2. Release both of the temperature adjustment buttons.  
A. To decrease the temperature press and release the  
COOLER” button until the desired setting is reached.  
B. To increase the temperature press and release the  
HOTTER” button until the desired setting is reached.  
NOTE: Should overheating occur or the gas supply fail  
to shut off, turn off the manual gas control valve to the  
appliance.  
NOTE: During low demand periods when hot water is not  
being used, a lower thermostat setting will reduce energy  
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losses and may satisfy your normal hot water needs. If hot  
water use is expected to be more than normal, a higher  
thermostat setting may be required to meet the increased  
demand. When leaving your home for extended periods  
(vacations, etc.) Set the electronic control display tem-  
perature “COOLER” button to its lowest setting. This  
will maintain the water at low temperatures with minimum  
energy losses and prevent the tank from freezing during  
cold weather.  
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.  
Gas Control Valve/Thermostat Settings  
It is always recommended that a suitable metal drain pan  
be installed under the water heater to protect the area  
from water damage resulting from normal condensation  
production, a leaking tank or piping connections. Refer to  
the “Location Requirements” section.  
HOTTER  
COOLER  
Water Heater Sounds  
During the normal operation of the water heater, sounds or  
noises may be heard. These noises are common and may  
result from the following:  
1. Normal expansion and contraction of metal parts  
during periods of heat-up and cool-down.  
2. Condensation causes sizzling and popping within the  
burner area and should be considered normal.  
3. Sediment buildup in the tank bottom will create varying  
amounts of noise and may cause premature tank  
failure. Drain and flush the tank as directed under the  
“Draining and Flushing” section.  
Electronic Control Display  
FIGURE 21.  
Operational Conditions  
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:  
a. A new water heater is filled with cold water for the first  
time.  
Smoke/Odor  
The water heater may give off a small amount of smoke  
and odor during the initial start-up of the unit. This is due  
to the burning off of oil from metal parts of a new unit and  
will disappear after a brief period of operation.  
b. Burning gas produces water vapor in water heaters, par-  
ticularly high efficiency models where flue temperatures  
are lower.  
c. Large amounts of hot water are used in a short time and  
the refill water in the tank is very cold.  
Safety Shut-off  
This water heater is designed to automatically shut-off in  
the event of the following:  
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.  
1. The burner flame is extinguished for any reason.  
2. The water temperature exceeds 195°F (91°C).  
3. Excessive build up of dust on the louvers of the air  
intake chamber. See Maintenance of your Water  
Heater Section.  
This unit is also equipped with a flammable vapor sensor  
(FV Sensor), designed to shut off the gas supply in the  
event the water heater has been exposed to flammable  
vapors (e.g., spilled gasoline).  
Excessive condensation can cause burner flame problems  
due to water running down the flue tube onto the main  
burner.  
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.  
Do not assume the water heater is leaking until there has  
been enough time for the water in the tank to warm up.  
A high temperature limit switch or ECO (Energy Cut Off) in  
the tank is used to shut off the unit if the water temperature  
exceeds 195°F (91°C). The ECO is a single-use switch,  
which, if activated, requires complete replacement of the  
entire gas control valve/thermostat. If the ECO should  
activate, the water heater cannot be used until the gas  
control valve/thermostat is replaced by a qualified technician.  
Contact your local dealer for service information.  
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.  
Excessive condensation may be noticed during the  
winter and early spring months when incoming water  
temperatures are at their lowest.  
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Powered Anode Operation  
Draining and Flushing  
To protect the glass-lined water tank from corrosion  
through electrolysis, this water heater is equipped with a  
non sacrificial powered anode rod. The powered anode  
rod is non sacrificial and should not need to be replaced  
unless damaged.  
If the powered anode rod has been damaged then the  
powered anode rod should be removed and replaced  
from the water heater tank. IMPORTANT: If the damaged  
powered anode rod has not been replaced but has been  
remove permanently, this will void any warranties.  
Powered Anode System  
It is recommended that the tank be drained and flushed  
every 6 months to remove sediment which may build up  
during operation. The water heater should be drained if  
being shut down during freezing temperatures. To drain the  
tank, perform the following steps:  
To ensure a long, trouble-free  
operating life, this water  
Powered  
Anode  
heater is equipped with a  
powered anode system.  
Rod  
The powered anode rod is of  
a permanent design and does  
not need replacing unless  
damaged.  
1. Turn off the gas to the water heater at the manual gas  
shut-off valve and turn off the electrical power to the  
gas control/thermostat valve.  
2. Open a nearby hot water faucet until the water is not  
longer hot.  
FIGURE 22.  
NOTE: Whether re-installing or replacing the powered  
anode rod, check for any leaks and immediately correct if  
found.  
3. Close the cold water inlet valve.  
4. Connect a hose to the drain valve and terminate it to  
an adequate drain or external to the building.  
5. Open the water heater drain valve and allow all the  
water to drain from the tank. Flush the tank with water  
as needed to remove sediment.  
In replacing the powered anode:  
1. Turn off electrical supply and gas supply to the water  
heater.  
6. Close the drain valve, refill the tank, and restart the  
heater as directed in this manual.  
If the water heater is going to be shut down for an  
extended period, the drain valve should be left open.  
2. Shut off the water supply and open a nearby hot water  
faucet to depressurize the water tank.  
IMPORTANT: Condensation may occur when refilling the  
tank and should not be confused with a tank leak.  
3. Drain approximately 5 gallons of water from tank  
(Refer to the “Draining and Flushing” section for proper  
procedures). Close drain valve.  
4. Remove the wiring connection on the top of the  
powered anode rod and remove the old powered  
anode rod (Figure 22).  
5. Use Teflon® tape or approved pipe sealant on threads  
and install new anode rod.  
Routine Preventive Maintenance  
At least annually, a visual inspection should be made of  
the venting and air supply system, piping systems, and  
main burner. Check the water heater for the following:  
Obstructions, damage, or deterioration in the venting  
system. Make sure the ventilation and combustion air  
supplies are not obstructed.  
6. Turn on water supply and open nearby hot water faucet  
to purge air from water system. Check for any leaks  
and immediately correct any if found.  
Clean any dust or debris from the louvers of the air  
intake chamber.  
Soot and/or carbon on the main burner. Contact a  
qualified technician.  
7. Turn on electrical and gas supplies. Restart the water  
heater as directed under the “Operating Your Water  
Heater.” See the “Repair Parts Illustration” section for  
anode rod location.  
Leaking or damaged water and gas piping.  
Presence of flammable or corrosive materials in the  
installation area.  
Presence of combustible materials near the water  
heater.  
After servicing this water heater, check to make sure  
it is working properly. (See “Operating Your Water  
Heater” section of this manual.)  
TEFLON® is a registered trademark of E.I. Du Pont De Nemours and Company  
IMPORTANT: If you lack the necessary skills required to  
properly perform this visual inspection, you should not  
proceed, but get help from a qualified technician.  
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properly. To prevent water damage, the valve must be pro-  
perly connected to a discharge line which terminates at an  
adequate drain. Standing clear of the outlet (discharged  
water may be hot), slowly lift and release the lever handle  
on the temperature and pressure relief valve to allow the  
valve to operate freely and return to its closed position.  
See Figure 23. If the valve fails to completely reset and  
continues to release water, immediately shut off the  
manual gas control valve and the cold water inlet valve  
and call a qualified technician.  
Temperature and Pressure Relief Valve  
Explosion Harzard  
Temperature-pressure relief  
valve must comply with ANSI  
Z21.22-CSA 4.4 and ASME  
code.  
TEMPERATURE AND PRESSURE  
RELIEF VALVE  
• Properly sized temperature-  
pressure relief valve must be  
installed in opening provided.  
MANUAL RELIEF  
VALVE  
• Can result in overheating  
and excessive tank pressure.  
• Can cause serious injury or  
death.  
DISCHARGE LINE TO DRAIN  
Manually operate the temperature and pressure relief  
valve at least once a year to make sure it is working  
FIGURE 23.  
MAINTENANCE OF YOUR WATER HEATER  
Replacement Parts  
Gas Control Valve/  
Thermostat  
IMPORTANT: The following maintenance procedures are  
for the FVIR System components and should be performed  
by a qualified technician.  
Replacement parts may be ordered through your plumber  
or the local distributor. Parts will be shipped at prevailing  
prices and billed accordingly. When ordering replacement  
parts, always have the following information ready:  
1. model, serial, and product number  
2. type of gas  
3. item number  
4. parts description  
See Repair Parts Section for a list of available repair parts.  
Manifold Tube  
Pressure  
Switch / Fan,  
FV Sensor  
Connector  
Power Supply  
Transformer  
Connector  
Igniter/Flame  
Sense  
Connector  
Control Display,  
Anode Rod  
Connector  
Removing the Manifold/Burner Assembly  
FIGURE 24.  
1. Turn off the gas supply to the water heater at the manual  
gas shut-off valve. This valve is typically located beside  
the water heater. Note the position of the shut-off valve in  
the open/on position then proceed to turn it off (Figure 3).  
2. Disconnect power supply to the heater.  
3. Remove the outer door. Remove the 2 screw securing  
the manifold door assembly to the skirt.  
Removing the Burner from the Manifold/  
Burner Assembly  
Natural Gas Burner  
1. Take off the burner by removing the two (2) screws  
located underneath the burner.  
2. Check the burner to see if it is dirty or clogged. The burner  
may be cleaned with soap and hot water (Figure 25).  
4. Disconnect all wiring connectors from the gas control  
valve/thermostat (Figure 24). Disconnect the manifold  
tube at the gas control valve/thermostat.  
Manifold Door Assembly  
View Port  
5. Grasp the manifold tube and push down slightly to free  
the manifold from the gas control valve/thermostat.  
6. Carefully remove the manifold assembly from the burner  
compartment. NOTE: Be sure not to damage internal  
parts (Figure 28).  
Screws  
7. Check the burner to see if it is dirty or clogged. The  
burner may be cleaned with soap and hot water.  
Igniter/Flame  
Sense Connector  
Burner  
(Bottom View)  
FIGURE 25.  
25  
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Replacing the Flame Sense/Hot Surface igniter Cleaning the Combustion Chamber and Air  
Assembly  
Diverter Assembly  
1. Remove the manifold/burner assembly. See Removing  
the Manifold/Burner Assembly.  
1. Follow procedure outlined in “Removing the Manifold/  
Burner Assembly”.  
2. Use a vacuum cleaner/shop vac to remove all loose  
debris in the combustion chamber (Figure 28). Use  
compressed air to clear any dust or debris that may  
have accumulated on the air diverter assembly.  
2. Lift the retainer clip straight up from the back of  
the manifold component block (using a flat-blade  
screwdriver), then remove the manifold component  
block from the manifold door (Figure 26.)  
3. Remove and keep the screw securing the flame sense/  
hot surface igniter assembly (Figure 26)  
Combustion  
Air Diverter  
4. Remove and discard the old flame sense/hot surface  
igniter assembly.  
Chamber  
Assembly  
5. Route the new flame sense/hot surface igniter con-  
nector wire through manifold/burner door opening as  
shown in figure 26. Secure assembly to bracket using  
screw removed earlier.  
Manifold  
Door Gasket  
Screw  
Retainer Clip  
FIGURE 28.  
3. Reassemble following the procedure under “Replacing  
the Manifold/Burner Assembly”  
Flame Sense/  
Hot Surface  
Igniter Assembly  
Replacing the Manifold/Burner Assembly  
Manifold Component  
Block  
WARNING  
FIGURE 26.  
6. Reposition the manifold component block in the mani-  
fold door opening and secure it with the retainer clip.  
7. See Replacing the Manifold/Burner Assembly.  
Explosion Hazard  
External Inspection & Cleaning of the  
Air Intake Chamber Screen  
Remove any fiberglass between gasket and  
combustion chamber.  
1. At least twice annually inspect the air intake chamber  
screen (Figure 27) for any dust or debris that may have  
accumulated on the louvers. NOTE: If the water heater  
is located in an area that is subjected to lint and dirt,  
it may be necessary to check the air intake chamber  
screen more frequently.  
Replace viewport if glass is missing or damaged.  
Replace two piece wire connector if missing or  
removed.  
Replace door gasket if damaged.  
2. Use a vacuum cleaner with a  
hose attachment to remove any  
dust or debris that may have  
accumulated on the screen.  
Tighten both manifold door screws securely.  
Failure to follow these instructions can result in  
death, explosion, or fire.  
1. Check the door gasket for damage or imbedded debris  
prior to installation.  
2. Inspect the view port for damage and replace as  
required.  
Air Intake Chamber  
Screen  
FIGURE 27.  
26  
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3. Insert the manifold/burner assembly into the burner  
compartment making sure that the tip of the manifold  
tube engages in the slot of the bracket inside the  
combustion chamber (Figure 29).  
4. Inspect the door gasket and make sure there is no  
fiberglass insulation between the gasket and the  
combustion chamber.  
5. Replace the two screws, which secure the manifold/  
burner assembly door to the combustion chamber  
and tighten securely. Once the manifold/burner  
assembly door is tightened, visually inspect the door  
gasket between the manifold/burner assembly door  
and the combustion chamber for spaces or gaps that  
would prevent a seal. IMPORTANT: Do not operate  
the water heater if the door gasket does not create a  
seal between the manifold door and the combustion  
chamber.  
6. During the following procedure, do not cross-thread  
or apply any thread sealant to any of the fittings listed  
below. First, reconnect the manifold tubing to the gas  
control valve/thermostat.  
7. Reconnect the flame sense/hot surface igniter wire to  
the gas control valve/thermostat (Figure 24).  
8. Turn gas supply on and refer to the Lighting  
Instructions.  
3. Turn off the gas supply to the water heater at the  
manual gas shut-off valve. This valve is typically located  
beside the water heater. Note the position of the shut-  
off valve in the open/on position then proceed to turn it  
off (Figure 3).  
4. Drain the water heater. Refer to the section of  
“Draining and Flushing” section and follow the  
procedure.  
5. Disconnect the the flame sense/hot surface igniter  
wire, power supply transformer, pressure switch/  
fan and display connector wires from the thermostat  
(Figure 24). Disconnect the manifould tube at the  
thermostat (Figure 24).  
6. Refer to “Gas Piping” section (Figure 3) and disconnect  
the ground joint union in the gas piping. Disconnect the  
remaining pipe from the gas control valve/thermostat.  
7. To remove the gas control valve/thermostat, thread a  
correctly sized pipe into the inlet and use it to turn the gas  
control valve/thermostat (counterclockwise.) Do not use  
pipe wrench or equivalent to grip body. Damage may  
result, causing leaks. Do not insert any sharp objects into  
the inlet or outlet connections. Damage to the gas control  
valve/thermostat may result.  
Replacing the Gas Valve:  
1. To replace the gas control valve/thermostat,  
reassemble in reverse order. When replacing the gas  
control valve/ thermostat, thread a correctly sized  
pipe into the inlet and use it to turn the gas valve  
(clockwise.) DO NOT OVER TIGHTEN or damage may  
result. NOTE: Use an approved TEFLON® tape or pipe  
compound only on the threaded section of the gas  
control valve/thermostat that screws into the tank.  
2. Reconnect the gas piping to the gas control valve/  
thermostat. NOTE: Use an approved Teflon tape or  
pipe compound on the gas piping connections.  
3. Reconnect the manifold tube, flame sense/hot surface  
igniter wire, power supply transformer, pressure switch/  
fan and display connector wires (Figure 24).  
9. With the burner lit, check the gas control valve/  
thermostat supply line, two piece wire connector, and  
manifold tube connections for leaks. Check for leaks by  
brushing on an approved noncorrosive leak detection  
solution. IMPORTANT: Do Not splash solution onto  
the electrical connections. Bubbles forming indicate  
a leak. Correct any leak found. All leaks must be fixed  
immediately.  
10. Replace the outer door (see item K page 5).  
Door Gasket  
Burner  
Slot  
4. Fill the tank completely with water. NOTE: To purge the  
lines of any excess air, keep the hot water faucet open  
for 3 minutes after a constant flow of water is obtained.  
5. Turn on the gas supply and test the gas supply  
connections by brushing on an approved noncorrosive  
leak detection solution. IMPORTANT: Do Not splash  
solution onto the electrical connections. Bubbles  
forming indicate a leak. Correct any leak found.  
6. Check the operation of the burner by following the  
lighting instructions on the front of the water heater.  
With the burner lit, check the gas control valve/  
thermostat supply line, manifold tube connections for  
leaks.  
Viewport  
Manifold Tab  
FIGURE 29.  
Removing and Replacing the Gas Control  
Valve/Thermostat  
IMPORTANT: Use only factory authorized replacement  
parts.  
Removing the Gas Control Valve/Thermostat:  
7. Verify proper operation and then replace the outer door.  
8. If additional information is required, contact Residential  
Technical Assistance by referencing the phone number on  
the water heater or on the front cover of this manual.  
1. Set the gas control valve/thermostat to its lowest setting  
by first depressing the COOLER  
buttons together and hold for 1 second. Then press the  
and HOTTER  
TEFLON® is a registered trademark of E.I. Du Pont De Nemours and Company  
COOLER  
button until the lowest setting appears  
(Figure 21).  
2. Unplug the electrical transformer from the wall outlet.  
27  
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Pressurized Combustion Chamber System  
Operational Checklist  
1. Manifold gasket properly sealed.  
5. No leaks at manifold connection.  
6. Manifold door screws securely tightened.  
2. Viewport not damaged or cracked.  
3. Combustion chamber free of debris and undamaged.  
4. Manifold component block properly installed.  
TROUBLESHOOTING CHART  
PROBLEM  
POSSIBLE CAUSE(S)  
CORRECTIVE ACTION  
1. Transformer unplugged.  
2. No power at outlet.  
1. Plug transformer back into 120 VAC. outlet.  
2. Repair service to outlet.  
NO HOT WATER  
3. Thermostat defective.  
3. Replace Thermostat.  
4. Air Intake Chamber Fan defective. 4. Replace Air Intake Chamber Fan Assembly.  
5. Pressure Switch defective.  
6. Gas Valve/Thermostat Switch in  
“OFF POSITION”.  
5. Replace Pressure Switch Assembly.  
6. Move Gas Valve/Thermostat Switch to “ON  
POSITION”.  
1. Thermostat set too low.  
2. Thermostat defective.  
3. Heater undersized.  
1. Set temperature control higher.  
2. Replace thermostat.  
INSUFFICIENT HOT WATER  
3. Reduce hot water use.  
4. Contact dealer.  
4. Low gas pressure.  
5. Incoming water is unusually cold.  
6. Leaking hot water pipes or fixtures. 6. Have plumber check and repair leaks.  
5. Allow more time for heater to reheat.  
1. Insufficient secondary air.  
2. Water heater flue or vent system  
blocked.  
1. Provide ventilation to water heater. Check flue  
way, flue baffle, and burner.  
2. Clean flue, locate source and correct.  
3. Check with gas utility company.  
4. Replace thermostat.  
3. Low gas pressure.  
SLOW HOT WATER  
RECOVERY  
4. Improper calibration.  
5. Thermostat set too low.  
6. Water heater too small.  
7. Wrong piping connections.  
8. Wasted hot water.  
5. Turn temperature dial to desired setting.  
6. Install adequate heater.  
7. Correct piping-dip tube must be in cold inlet.  
8. Advise customer.  
WATER TOO HOT  
1. Thermostat set too high.  
1. Set temperature control lower.  
see, “WATER TEMPERATURE REGULA-  
TION”, section.  
1. Defective air flow restrictor.  
1. Take unit out of service immediately, call a  
qualified person to service the unit.  
2. Proper dilution air must be provided for  
combustion and dilution of flue temp. See  
“COMBUSTION AIR SUPPLY/VENT PIPE  
SYSTEM”, section.  
2. Not enough dilution air to mix with  
flue gases in inlet elbow.  
VENT PIPE TOO  
HOT(ABOVE 170°F)  
3. Dilution air too hot for mixing with  
flue gases.  
3. Supply air is too hot, check for heat sources  
around intake terminal and blockage of dilu-  
tion air leg.  
4. Wrong burner orifice.  
4. Install correct orifice.  
1. Dirt in burner ports.  
1. Turn off heater and gas, clean burner head.  
2. Check intake venting arrangements for ob-  
structions.  
2. Combustion air path restricted.  
BURNER FLAME  
YELLOW - LAZY  
3. Not enough dilution air for proper  
combustion.  
3. Check intake venting arrangements for ob-  
sructions.  
4. Main burner line clogged.  
4. Clean, locate source and correct.  
5. Obstruction in main burner orifice. 5. Clean or replace orifice.  
6. Burner flame too high.  
7. Flame burns at orifice/thermostat  
not functioning properly.  
6. Replace with correct orifice.  
7. Replace thermostat  
8. Low gas pressure.  
8. Check with gas utility company.  
1. Orifice too large.  
2. High gas pressure.  
3. Water heater flue or vent system  
blocked.  
1. Replace with correct-orifice.  
2. Check with gas utility company.  
3. Clean flue and burner-locate source and cor-  
rect.  
BURNER FLAME FLOATS  
AND LIFTS OFF PORTS  
4. Cold drafts.  
4. Locate source and correct.  
28  
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cont.  
PROBLEM  
POSSIBLE CAUSE(S)  
CORRECTIVE ACTION  
1. Insufficient secondary air.  
1. Provide ventilation to water heater. Check  
flue.  
COMBUSTION ODORS  
2. Water heater flue or vent system  
blocked.  
3. Heater installed in a confined area. 3. Provide fresh air ventilation.  
2. Clean, located source and correct.  
1. Improperly sealed, hot or cold sup- 1. Tighten threaded connections.  
ply connections, relief valve, drain  
valve or thermostat threads.  
WATER LEAKS  
2. Leakage from other appliances or  
water lines.  
2. Inspect other appliances near water heater.  
3. Condensation of flue products.  
3. See “OPERATIONAL CONDITIONS”, sec-  
tion.  
4. Excessive water pressure.  
4. Use a pressure reducing valve and relief  
valve.  
5. Heater stacking.  
6. Closed water system.  
5. Lower the thermostat setting.  
6. See “Closed System/Thermal Expansion”.  
1. Thermal expansion in closed water 1. Install thermal expansion tank (DO NOT plug  
system.  
2. Improperly seated valve.  
T&P valve).  
LEAKING T&P  
2. Check relief valve for proper operation (DO  
NOT plug T&P valve.  
1. High sulfate or mineral content in  
water supply.  
2. Bacteria in water supply.  
1. Drain and flush heater thoroughly then refill.  
2. Chlorinate water supply.  
HOT WATER ODORS  
1. Condensation dripping on burner.  
1. See “OPERATIONAL CONDITIONS”, sec-  
tion.  
WATER HEATER SOUNDS  
SIZZLING-RUMBLING  
2. Sediment at bottom of heater tank. 2. See “MAINTENANCE OF YOUR WATER  
HEATER”, section.  
1. Insufficient secondary air.  
1. Provide ventilation to water heater. Check flue  
way, flue baffle, burner.  
SMOKING AND CARBON  
FORMATION (SOOTING)  
2. Low gas pressure.  
3. Water heater flue or vent system  
blocked.  
2. Check with gas utility company.  
3. Clean, locate source and correct.  
4. Thermostat not functioning prop-  
erly.  
4. Replace thermostat.  
5. Heater installed in a confined area. 5. Provide fresh air ventilation.  
6. Burner flame yellow-lazy.  
6. See “Burner Flame Yellow-Lazy”.  
HEATING LIGHTS BUT  
GOES OUT IN 4-5  
SECONDS  
1. Outlet polarity is reversed.  
1. Test polarity and correct.  
1. Thermostat set too high.  
2. Sediment or lime in tank.  
3. Water heater too small for job.  
4. Wrong piping connections.  
5. Leaking faucets.  
1. Set temperature dial to lower setting.  
2. Drain/flush-provide water treatment if needed.  
3. Install adequate heater.  
HIGH OPERATION COSTS  
4. Correct piping-dip tube must be in cold inlet.  
5. Repair faucets.  
6. Gas leaks.  
6. Check with utility-repair at once.  
7. Advise customer.  
7. Wasted hot water.  
8. Long runs of exposed piping.  
9. Hot water piping in exposed wall.  
8. Insulate piping.  
9. Insulate piping.  
THERMOSTAT FAILS TO  
SHUT-OFF  
1. Thermostat not functioning proper- 1. Replace thermostat.  
erly.  
2. Improper calibration.  
2. Replace thermostat.  
CONDENSATION  
1. Thermostat set too high.  
2. Water dripping from draft hood.  
1. See “OPERATIONAL CONDITIONS” section.  
2. Provide drip “TEE” to catch condensation  
from horizontal section of exhaust vent close  
to draft hood.  
1. Excessive water pressure.  
2. Heater stacking.  
1. Use a pressure reducing valve and relief  
valve.  
2. Lower the thermostat setting.  
DRIP FROM RELIEF VALVE  
3. Closed water system.  
3. See “CLOSED SYSTEM/THERMAL EXPAN-  
SION”, section.  
29  
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CONTROL DISPLAY TROUBLESHOOTING  
ELECTRONIC CONTROL DISPLAY  
Please check guidelines below. For your safety, water heater service should be performed only by a qualified service person.  
Read the GENERAL SAFETY INFORMATION supplied by the water heater manufacturer.  
CONTROL DISPLAY STATUS  
“POWER” Flashing  
PROBLEM  
SOLUTION  
1. Check the 5-conductor data cable that  
runs between the upper and lower  
controls. Check that the wiring is not  
broken, and the connectors on both ends  
are properly seated in the mating  
connectors.  
1.  
Communication Error  
The system has detected a  
communication error between the  
upper and lower controls.  
2. Replace the upper control, if the problem  
persists:  
3. Replace the lower control.  
1. Turn the power off for 10 to 20 seconds  
2.  
3.  
“HEATING” and “SHORT” Flashing  
“HEATING” and “OPEN” Flashing  
The self-diagnostic tests have  
found a problem with an internal  
circuit.  
then on again to clear the error code.  
2. If the error code persists or cannot be  
cleared, replace the lower control.  
1. Gas supply is turned off – pressure too  
low. Ensure supply and manifold gas  
pressures are within requirements in the  
installation manual. Manifold gas  
pressure is non-adjustable, if pressure is  
off by more than 0.3” W.C. (75 Pa)  
replace the lower control.  
Ignition/flame failure.  
The water heater has reached the  
maximum number of retries and is  
currently locked out for one hour.  
Cycle the power to the water  
heater off and on to reset.  
2. Low supply voltage – should be 115 –  
125 VAC.  
3. Ensure flame sensor is making good  
contact with the burner flame, ensure  
flame is steady.  
4. Ensure the flame sensor is clean – use  
TM  
ultra fine steel wool or Scotch-Brite pad  
to clean the flame sensor.  
5. Ensure the hot surface ignitor is  
positioned to provide consistent ignition.  
6. Check for any cracks in the ignitor  
assembly ceramic insulators – replace  
ignitor assembly if damaged.  
7. Check resistance of the ignitor at room  
temperature (77°F – 25°C) at the plug  
end. Replace ignitor if the resistance is  
not within 1.38 to 2.31 ohms at room  
temperature.  
1. Ensure flame sensor is making good  
contact with the burner flame, ensure  
flame is steady.  
4.  
5.  
“HEATING”, “OPEN”, and “SHORT” Flashing  
“ECO” and “OPEN” Flashing  
Weak flame sensor current.  
2. Ensure the flame sensor is clean – use  
TM  
ultra fine steel wool or Scotch-Brite pad  
to clean the flame sensor.  
1. Turn the power off for 10 – 20 seconds  
Water temperature in the tank has  
exceeded 185°F (85°C) and has  
activated the ECO.  
then on again to clear this error code.  
2. Replace the lower control if the error  
code persists.  
30  
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cont.  
CONTROL DISPLAY STATUS  
PROBLEM  
SOLUTION  
1. Clean the screen on the combustion air  
intake tube. Retest, if the problem  
persists:  
6.  
“P-SW”, “OPEN”, and “CLEAN SCREEN” Flashing  
The air pressure switch contacts  
remain open longer than 5  
seconds after the combustion fan  
is energized.  
2. Ensure the pressure switch sensing tube  
is in good condition and securely  
connected at both ends.  
3. Ensure the inner door to the combustion  
chamber is secure and the gasket is  
properly sealing.  
4. Take a pressure reading from the  
pressure switch’s sensing point on the  
inner door with a digital manometer.  
A. If actual pressure reaches design  
“make-point” for the switch check  
pressure switch contacts continuity  
with the combustion fan running. If  
switch contacts remain open replace  
switch.  
B. If pressure does not reach “make-  
point” check system for restrictions  
and cleanliness.  
1. Turn off power to the water hater.  
7.  
“P-SW” and “SHORT” Flashing  
The air pressure switch contacts  
remain closed for more than 5  
seconds when they should be  
open.  
2. Locate the pressure switch wiring –  
ensure pressure switch wiring is correct  
and not jumped.  
3. Remove wires to both terminals on  
pressure switch.  
4. Check pressure switch contacts with an  
ohmmeter for continuity.  
A. If pressure switch contacts show  
continuity (closed circuit) replace  
the pressure switch.  
B. If pressure switch contacts show  
open circuit and all wiring is correct  
– replace the lower control.  
1. Check all wiring to the hot surface ignitor.  
8.  
“IGN” Flashing  
Open ignitor circuit  
2. Check the 3 pin Molex ignitor assembly  
plug and receptacle on the lower control  
for a good connection. Repair or replace  
parts if necessary.  
3. Check resistance of the ignitor with an  
ohmmeter on the ignitor assembly plug.  
Replace ignitor if resistance is not within  
1.38 and 2.31 ohms.  
4. If above checks are good – turn off  
power for 10 seconds and then back on.  
If this error code will not clear and the  
ignitor resistance is within specifications  
– replace the lower control.  
Flammable Vapor Sensor has  
detected the presence of  
flammable vapors and is in lockout  
1. Contact a service agency to determine  
the cause.  
9.  
“FV-SENSE” Flashing  
The air pressure switch contacts  
remain open longer than 5  
seconds after the combustion fan  
is energized.  
1. Clean the screen on the combustion air  
intake tube. Retest, if the problem  
persists:  
10.  
“LDO-SW”, “OPEN”, and “CLEAN SCREEN”  
Flashing  
31  
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cont.  
CONTROL DISPLAY STATUS  
“FV-SENSE” and “OPEN” Flashing  
PROBLEM  
SOLUTION  
1. Check all wiring to the flammable vapor  
sensor.  
11.  
Flammable Vapor Sensor is open  
2. Remove the connectors from the  
flammable vapor sensor and measure  
the resistance of the sensor with an  
ohmmeter.  
A. If the reading taken is more than  
1.7 million ohms, replace the  
flammable vapor sensor.  
B. If the reading taken is less than 1.7  
million ohms, and the wiring from  
the control to the sensor is good,  
replace the lower control.  
1. Check all wiring to the flammable vapor  
12.  
“FV-SENSE” and “SHORT” Flashing  
Flammable Vapor Sensor is  
shorted  
sensor.  
2. Remove the connectors from the  
flammable vapor sensor and measure  
the resistance of the sensor with an  
ohmmeter.  
A. If the reading taken is less than  
2000 ohms, replace the flammable  
vapor sensor.  
B. If the reading taken is more than  
2000 ohms, and the wiring from the  
control to the sensor is good,  
replace the lower control.  
1. Turn power off for 10 to 20 seconds then  
13.  
14.  
15.  
“THMSTR” and “OPEN” Flashing  
“THMSTR” and “SHORT” Flashing  
All Segments Flashing  
The self-diagnostic test has  
detected the temperature sensor  
(thermistor) inside the immersion  
probe is open.  
on again to clear this error code.  
2. This part of the control cannot be  
replaced or serviced. If the error code  
cannot be cleared, the lower control must  
be replaced.  
1. Turn power off for 10 to 20 seconds then  
The self-diagnostic test has  
detected the temperature sensor  
(thermistor) inside the immersion  
probe is shorted.  
on again to clear this error code.  
2. This part of the control cannot be  
replaced or serviced. If the error code  
cannot be cleared, the lower control must  
be replaced.  
1. Press and release each of the  
The self-diagnostic check has  
detected one or both of the  
temperature adjustment buttons  
are stuck.  
temperature adjustment buttons. If the  
above action does not clear the error, the  
control will continue to regulate the water  
temperature at the last setting. However,  
settings will no longer be adjustable – the  
upper control should be replaced.  
1. Check the wire that runs from the power  
anode to the upper control. Check the  
wire for damage, and to ensure that the  
connectors are fully seated into the  
mating connectors on both ends.  
16.  
“P-ANODE” and “OPEN” Flashing  
No current to Power Anode.  
2. Check that the tank is full of water. 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.  
1. Turn the power off for 10 to 20 seconds  
17.  
“P-ANODE” Flashing  
Power Anode circuit failure.  
then on again to clear the error code.  
2. If the error code persists or cannot be  
cleared, replace the upper control.  
32  
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TROUBLESHOOTING FLOWCHART  
APPLY POWER TO  
APPLIANCE  
NO  
REQUEST  
FOR HEAT  
PRESENT?  
3 MINUTE  
AUTOMATIC RESET  
TIME DELAY  
YES  
WAIT FOR PRESSURE  
SWITCH TO OPEN  
DISPLAY ERROR  
IS  
NO  
PRESSURE SWITCH  
PROVEN OPEN WITHIN  
NUMBER  
7
5
SECONDS?  
YES  
COMBUSTION  
FAN ON  
IS  
WAIT FOR PRESSURE  
SWITCH TO OPEN  
DISPLAY ERROR  
NO  
PRESSURE SWITCH  
PROVEN OPEN WITHIN  
5
SECONDS?  
NUMBER  
7
IS  
WAIT FOR PRESSURE  
SWITCH TO CLOSE  
DISPLAY ERROR  
YES  
NO  
PRESSURE SWITCH  
PROVEN CLOSED  
WITHIN  
5
NUMBER  
6
SECONDS?  
ONE HOUR  
AUTOMATIC RESTART  
TIME DELAY  
YES  
PREPURGE  
COMBUSTION FAN  
OFF  
TURN OFF  
COMBUSTION FAN,  
DISPLAY ERROR CODE  
NO  
IS  
IGNITOR  
OKAY?  
NUMBER  
8
YES  
IGNITOR ON FOR  
WARM-UP TIME  
TURN OFF  
COMBUSTION FAN  
AFTER POST-PURGE  
COMBUSTION  
FAN OFF  
DISPLAY ERROR  
3
GAS VALVE OPENS  
YES  
IS  
NO  
WAIT FOR PRESSURE  
SWITCH TO CLOSE  
DISPLAY ERROR  
PRESSURE SWITCH  
PROVEN CLOSED  
COMBUSTION FAN  
ON  
WITHIN  
5
NUMBER  
6
SECONDS?  
MAIN  
BURNER LIGHTS  
AND IS SENSED  
DURING TRIAL  
FOR  
YES  
NO  
LESS  
GAS VALVE CLOSES  
INTERPURGE  
THAN  
3
TRIES  
FOR IGNITION?  
IGNITION  
NO  
YES  
IGNITOR TURNS OFF  
YES  
LOST  
IS  
YES  
GAS VALVE CLOSES  
FLAME SENSE  
LOST?  
LESS THAN  
TIMES?  
4
NO  
NO  
IS  
WAIT FOR PRESSURE  
SWITCH TO CLOSE  
DISPLAY ERROR  
NO  
PRESSURE SWITCH  
PROVEN CLOSED  
WITHIN  
SECONDS?  
5
NUMBER  
6
Please Note:  
The control continually monitors  
YES  
internal circuits and external sensors.  
Error codes noted above, and those for  
self-diagnostic faults can be found on  
pages 30 through 32.  
YES  
IS  
COMBUSTION FAN  
OFF AFTER POST-  
PURGE DELAY  
REQUEST FOR HEAT  
SATISFIED?  
GAS VALVE OFF  
NO  
33  
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REPAIR PARTS ILLUSTRATION  
3
1
2
4
When ordering repair parts always give  
the following information:  
1. Model, serial, and product number  
2. Type of gas  
3. Item number  
5
8
4. Parts description  
6
9
7
10  
18  
20  
19  
21  
11  
12  
14  
Repair Parts List  
Item  
No.  
Parts Description  
1
Draft Hood  
2
Flue Baffle  
3
Nipple (Hot)  
4
Nipple (Cold)  
5
Anode Rod  
6
Cold Water Inlet Tube  
Temperature and Pressure Valve  
Control Display  
7
8
9
Air Intake Chamber  
Gas Control Valve/Thermostat  
Drain Valve  
10  
11  
12* Natural Gas Burner  
13* Hot Surface Igniter (HSI)  
14* Manifold Door Assembly - Natural Gas  
15* Manifold Component Block w/Retainer Clip  
16* Manifold Door Gasket  
LEGEND  
Special anode rod (see Anode Rod/Water Odor  
17* Viewport Assembly  
section)  
18  
19  
20  
21  
FV Sensor  
Temperature and Pressure Relief Valve is required,  
but may not be factory installed  
Outer Door  
Electrical Transformer  
Pressure Switch  
*Pictured on next page.  
Unique: FVIR System parts  
34  
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Listed Parts Kits and Illustrations  
Item 12A: Burner (Natural Gas)  
Item 13:  
Item 14:  
Flame Sense/Hot Surface Igniter Assembly.  
Manifold door assembly which contains the manifold tube, gasket, manifold door, manifold component block  
with retainer clip, and flame sense/hot surface igniter assembly. (Natural Gas)  
Item 15:  
Item 16:  
Item 17:  
Contains manifold component block with retainer clip.  
Contains manifold door gasket.  
Contains viewport.  
ITEM 13  
ITEM 12  
ITEM 14  
ITEM 15  
ITEM 17  
ITEM 16  
35  
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NOTES  
36  
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NOTES  
37  
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NOTES  
38  
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LIMITED RESIDENTIAL GAS WARRANTY  
THIS WARRANTY IS APPLICABLE TO THE ORIGINAL  
OWNER ONLY in accordance with the warranty terms and  
conditions specied below.  
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;  
The warrantor will furnish the ORIGINAL OWNER, 1) a  
replacement 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.  
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;  
red with the fuel for which it was factory built;  
red at the factory rated input;  
operated with the inner and outer combustion chamber  
doors in place and all factory seals to combustion  
chamber intact.  
installed with no attempted, nor actual modication or  
alteration of the water heater’s design in any way,  
including but not limited to, the attachment of non-  
company approved appliances or equipment, including  
any additional aftermarket equipment introduced into  
the sealed system.  
THE WATER HEATER REPLACEMENT MODEL  
OR 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 transferable and  
applies to models listed below:  
SERIES  
TANK  
PARTS  
6-Year  
6-Year Models  
6-Year  
GP 6  
Any accident to the water heater or any part thereof (including  
freezing, re, oods, or lightning), any misuse, abuse or  
alteration of it, any operation of it in a modied 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 specications of the heating  
component manufacturer.  
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 and to 3 years for 10 year models.  
2. The parts warranty shall be reduced to 1 year for all  
models.  
CONDITIONS AND EXCEPTIONS  
This warranty shall apply only when the water heater is  
installed and operated in accordance with 1) all local re  
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, certied by the  
Canadian GasAssociation must have been properly installed  
and piped to the nearest drain.  
This warranty gives you specic 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.  
SERVICE AND LABOR RESPONSIBILITY  
UNDER THIS LIMITED WARRANTY, THE WARRANTOR  
WILL PROVIDE ONLY A REPLACEMENT WATER HEATER  
OR PART THEREOF. THE OWNER IS RESPONSIBLE FOR  
ALL OTHER COSTS. Such costs may include but are not  
limited to:  
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  
calibrated setting of its thermostat;  
a. Labor charges for service, removal, or reinstallation of  
the water heater or part thereof.  
b. Shipping and delivery charges for forwarding the new water  
heater or replacement part from the nearest distributor  
and returning the claimed defective heater or part to such  
distributor.  
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 at water pressure not exceeding the working  
pressure shown on the heater;  
lled with potable water, free to circulate at all times and  
with the tank free of damaging water sediment or scale  
deposits;  
used in a non-corrosive and non-contaminated  
atmosphere;  
used with factory approved anode(s) installed;  
39  
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LIMITATION ON IMPLIED WARRANTIES  
NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF  
USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE  
TO PERSONALPROPERTY, 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.  
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  
Any claim under this warranty should be initiated with the  
dealer who sold the heater, or with any other dealer handling  
the warrantor’s products. If this is not practical, the owner  
should contact: State Industries, Inc., 500 Tennessee  
Waltz Parkway, Ashland City, Tennessee 37015. Phone:  
Should governmental regulations or industry standards  
prohibit the Manufacturer from furnishing a comparable model  
replacement under this warranty, the Owner will be furnished  
with the closest comparable water heater meeting the then  
current governmental regulations and industry standards. A  
supplementary fee may be assessed to cover the additional  
cost associated with the changes made to meet applicable  
regulations and standards.  
Replacement Parts may be ordered through authorized  
servicers or distributors. Refer to your local Yellow Pages  
for where to call or contact State Industries, Inc., Parts  
Fullllment, 125 Southeast Parkway, Franklin, TN 37068,  
phone: 1.800.821.2017.  
IMPORTANT INFORMATION  
Model Number ________________________________  
Serial Number _________________________________  
INSTALLATION INFORMATION  
The warrantor will only honor replacement with identical or  
similar water heater or parts thereof which are manufactured  
or distributed by the warrantor.  
Dealer replacements are made subject to in-warranty  
validation by warrantor.  
PROOF-OF-PURCHASE AND PROOF-OF-INSTALLATION  
DATE ARE REQUIRED TO SUPPORT WARRANTY CLAIM  
FROM ORIGINAL OWNER. THIS FORM DOES NOT  
CONSTITUTE PROOF-OF-PURCHASE OR PROOF-OF-  
INSTALLATION.  
Date Installed _________________________________  
Company’s Name ______________________________  
Street or P.O. Box ______________________________  
City, State, and Zip Code_________________________  
Phone Number ________________________________  
Plumber’s Name _______________________________  
DISCLAIMERS  
NO EXPRESSED WARRANTY HAS BEEN OR WILL BE  
MADE ON BEHALF OF THE WARRANTOR WITH RESPECT  
TO THE MERCHANTABILITY OF THE HEATER OR THE  
INSTALLATION, OPERATION, REPAIR OR REPLACEMENT  
OF THE HEATER OR PARTS. THE WARRANTOR SHALL  
40  
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