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8

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. NOTE: The pan must not 

restrict combustion air flow. 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. 

 

METAL
DRAIN
PAN

AT LEAST 2” GREATER  THAN THE 
DIAMETER OF THE WATER HEATER.

PIPED TO AN 
ADEQUATE DRAIN

FIGURE 1A.

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 drain pan piped to a 

drain. However, unanticipated damage can be reduced 

or prevented by a leak detector or water shut-off device 

used in conjunction with a piped drain pan. These devices 

are available from some plumbing supply wholesalers and 

retailers, and detect and react to leakage in various ways:
•   Sensors mounted in the drain pan that trigger an alarm 

or turn off the incoming water to the water heater when 

water is detected.

•   Sensors mounted in the drain pan that turn off the 

water supply to the entire home when water is detected 

in the drain pan.

•   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.

•   Devices that will turn off the gas supply to a gas water 

heater while at the same time shutting off its water 

supply.

REVERSE FLOW
OF GASES 

 

EXHAUST FAN

FIGURE 1B.

Clearances and Accessibility                                    

NOTE: Minimum clearances from combustible surfaces are 

stated on the rating plate 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 three inches (76.2mm) in any direction; or if in 

an alcove or closet installation, the entire floor must be 

covered by the panel. 

• 

Figure 2 may be used as a reference guide to locate 

the specific clearance locations. A minimum of 24 inch-

es of front clearance should be provided for inspection 

and service. 

 

BACK

SIDES

TOP
VIEW

SIDES

VENT

FRONT
24” MINIMUM
FOR SERVICE

TOP

TO 

CEILING

FIGURE 2.

State of California                                                       

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://

www.dsa.dgs.ca.gov,  or call 1-916-445-8100 and request 

instructions.

Summary of Contents for Conservationist XGV Series

Page 1: ...ch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier WARNING If the information in these instructions is not followed exactly ...

Page 2: ...d Pipe Installation 17 Combination Space Heating Potable Water System 17 18 Solar Installation 18 Important Information About this Water Heater 19 Operating Your Water Heater 20 26 Lighting Instructions 20 21 Checking the Draft 22 Burner Flames 22 Emergency Shutdown 22 Water Temperature Regulation 22 23 Operating the Temperature Control System 23 Operational Conditions 23 24 Draining and Flushing ...

Page 3: ...ity 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 servic...

Page 4: ... period of non use Read instruction manual before installing using or servicing water heater Fire or Explosion Harzard Hydrogen gas can be produced in a hot water system after a period of non use generally two or more weeks Hydrogen gas is extremely flammable and can ignite To return hot water system to service open a hot water faucet in kitchen for several minutes before using electrical applianc...

Page 5: ...stat T Drain Valve U Manifold Burner Assembly V Flue W Metal Drain Pan X Piezo Igniter Y Base Ring Filter ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS TO VENT TERMINATION ON ROOF A B D F G H I W V U T S O R J K Q VACUUM RELIEF VALVE INSTALL PER LOCAL CODES INSTALL THERMAL EXPANSION TANK IF WATER HEATER IS INSTALLED IN A CLOSED WATER SYSTEM M N L E P X Y DISCHARGE PIPE DO NOT CAP OR PLUG 6 MAXI...

Page 6: ... 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 fai...

Page 7: ...n 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 Fire or Explosion Hazard WARNING Read instruction manual before installing using or servicing water heater Improper use may result in fire or explosion Maintain required clearances to combustibles Keep comb...

Page 8: ...vice used in conjunction with a piped drain pan These devices are available from some plumbing supply wholesalers and retailers and detect and react to leakage in various ways Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to the water heater when water is detected Sensors mounted in the drain pan that turn off the water supply to the entire home when water i...

Page 9: ...o an L P gas supply 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 Explosion Hazard 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 ...

Page 10: ... in the occurrence of a leak in the system the gas will settle at floor level Basements crawl spaces closets and areas below ground level will serve as pockets for the accumulation of gas Before lighting an L P gas water heater smell all around the appliance at floor level If you smell gas follow the instructions as given in the warning on the front page When your L P tank runs out of fuel turn of...

Page 11: ...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 exclu...

Page 12: ...e typical examples of each method 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 t...

Page 13: ...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 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 IMPORTANT If you lack the necessary skills required to properly...

Page 14: ...ay 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 The connector must be installed above the extreme bottom of the chimney to prevent po...

Page 15: ...Closed System Thermal Expansion 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 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 mus...

Page 16: ...ay cause excessive restriction to water flow is not recommended Use only 95 5 tin antimony or other equivalent solder Any lead based solder must not be used Piping that has been treated with chromates boiler seal or other chemicals must not be used Chemicals that may contaminate the potable water supply must not be added to the piping system Closed System Thermal Expansion As water is heated it ex...

Page 17: ...ations If this water heater is to be used to supply both space heating and domestic potable drinking water the instructions listed below must be followed Be sure to follow the manual s shipped with the air handler system Temperature and Pressure Relief Valve Explosion Harzard Temperature pressure relief valve must comply with ANSI Z21 22 CSA 4 4 and ASME code Properly sized temperature pressure re...

Page 18: ... water heating appliances when used to supply potable water 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 A diaphragm type expansion tank suitable for potable water will normally eliminate this weeping condition Please read and...

Page 19: ...at contain negative pressure producing devices such as exhaust fans fireplaces etc 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 HVA...

Page 20: ...he outer door If the Pilot Does Not Light 1 Wait 10 minutes before another lighting attempt If the pilot does not light the Igniter may not be sparking or the unit may not be getting gas or for a new installation there may still be air in the gas line Each time you click the igniter button you should be able to see the spark by looking through the view port See Figure 23 You may have to darken the...

Page 21: ...chnician or your gas supplier DANGER Hotter water increases the risk of scald injury Consult the instruction manual before changing temperature Refer to the Lighting Instructions in the Installation Manual for more detailed troubleshooting information 1 Turn the gas control temperature knob counterclockwise to the OFF setting The status light will stop blinking and stay on for a short time after t...

Page 22: ... 49 C 60 C is recommended by most dishwasher manufacturers The thermostat is adjusted to the pilot position when it is shipped from the factory Water temperature can be regulated by moving the temperature dial to the preferred setting The preferred starting point is 120 F at the HOT setting Align the knob with the desired water temperature as shown in Figure 19A There is a hot water scald potentia...

Page 23: ...f the heated water may vary Operating Modes and Settings Standard Mode The controller adjusts the water heater to maintain the temperature set by the user Vacation Setting The Vacation setting VAC sets the controller at approximately 55 F This setting is recommended when the water heater is not in use for a long period of time This effectively turns the controller temperature setting down to a tem...

Page 24: ...water conditioning company to successfully eliminate all water odor problems Artificially softened water is exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions The use of a water softener may decrease the life of the water heater tank The anode rod should be removed from the water heater tank every 3 years for inspection NOTE Artificially softened water...

Page 25: ...e water heater drain valve and allow all of the water to drain from the tank Flush the tank with water as needed to remove sediment 6 Close the drain valve refill the tank and restart the water 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 IMPORTANT Condensation may occur when refilling the tank and should ...

Page 26: ...nd 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 Removing the Manifold Burner Assembly 1 Turn the gas control temperature knob to the OFF position Figure 22 2 Before performing any maintenance it is importan...

Page 27: ...PILOT THERMOPILE ASSEMBLY PILOT THERMOPILE ASSEMBLY IGNITER CONNECTOR THERMAL SWITCH CONNECTORS PILOT THERMOPILE THERMOPILE CONNECTOR WHITE WIRE RED WIRE PILOT TUBE NOT SHOWN FOR CLARITY FIGURE 26 7 Route the new pilot tube igniter wire and thermopile wire through the opening in the manifold door See Figure 25 8 Using the pilot screw removed earlier attach the new pilot thermopile assembly Reattac...

Page 28: ...port if glass is missing or damaged removed Replace door gasket if damaged 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 Figure 28 2 Inspect the viewport for damage and replace as required Figure 23 3 Insert the new manifold burner assembly into the burner compartment making sure that the tab o...

Page 29: ...n Figure 19A 2 Turn off the gas at the manual shut off valve on the gas supply pipe Figure 3 3 Drain the water heater Refer to the section of Draining and Flushing and follow the procedure 4 Disconnect the igniter wire from the igniter lead wire Use needle nose pliers to disconnect the red and white thermopile wires Disconnect the pilot tube 7 16 wrench and manifold tube 3 4 wrench at the gas cont...

Page 30: ...mostat temperature limit was ex ceeded Status light will blink 4 flashes 11 Pilot line or orifice clogged 12 Non functioning thermopile 13 Air for combustion obstructed 14 FVIR Flame Arrestor blocked with lint dust 15 Flammable vapors incident FVIR function actuated 16 Base Ring Filter blocked with lint dust 1 Replace igniter pilot assembly 2 See Pilot Light Troubleshooting Flowchart section 3 Rem...

Page 31: ... section 5 Clean filter See Cleaning the Combustion Chamber and Flame Arrestor section SMOKING AND CARBON FORMATION SOOTING 1 Insufficient combustion air 2 Low gas pressure 3 Water heater flue or vent system blocked 4 Thermostat not functioning prop erly 5 Heater installed in a confined area 6 Burner flame yellow lazy 7 Base Ring Filter blocked with lint dust 8 FVIR Flame Arrestor blocked with lin...

Page 32: ... on if the return air duct is in the same location Correct size of openings to allow sufficient air NO YES YES NO Section C Pilot light will not remain lit Complete this section after completing Section B YES Set thermostat to desired temperature Section B Pilot light repeatedly goes out Check the Base Ring Filter and Flame Arrestor for blockage due to lint or dust Are both the Air Filter and Flam...

Page 33: ...e water heater has been operating but has stopped and will not re light check the flame arrestor for signs of high temperature blue or black discoloration indicating a flammable vapor incident If you suspect a flammable vapor incident has occurred do not use this appliance Immediately call a qualified technician to inspect the appliance Water heaters subjected to a flammable vapors ignition will r...

Page 34: ...rmostat 8 FLASHES This condition only appears if the gas control temperature knob has been turned off and the thermopile continued to produce electric power This condition can occur if the thermopile does not cool down as quickly as expected when the unit is shut off This condition can also occur if the gas control temperature knob has been turned off and the pilot continues to operate because the...

Page 35: ...35 NOTES ...

Page 36: ...n 1 DRAFT HOOD 2 HEAT TRAP COLD SOME MODELS 3 HEAT TRAP HOT SOME MODELS 4 COLD WATER DIP TUBE 5 ANODE ROD 6 TEMPERATURE PRESSURE RELIEF VALVE LOCATED TOP OR SIDE 7 DRAIN VALVE 8 GAS CONTROL VALVE THERMOSTAT with thermal switch wire lead 9 OUTER DOOR 10 BASE RING FILTER 11A PILOT THERMOPILEASSEMBLY KIT Natural Gas 11B PILOT THERMOPILEASSEMBLY KIT L P Gas 12A BURNER Natural Gas 12B BURNER L P Gas 13...

Page 37: ...m 12B Burner L P Gas Item 13A Manifold Burner Assembly contains the door gasket manifold tube pilot thermopile assembly manifold component block thermal switch and burner Natural Gas Low Nox Item 13B Manifold Burner Assembly contains the door gasket manifold tube pilot thermopile assembly manifold component block thermal switch and burner L P Gas Item 14 Contains manifold component block Item 15 C...

Page 38: ...ion location in the United States its territories or possessions and Canada sized in accordance with proper sizing techniques for residential water heaters bearing a rating plate which has not been altered defaced or removed except as required by the warrantor used in an open system or in a closed system with a properly sized and installed thermal expansion tank operated with properly installed dr...

Page 39: ...RM DOES NOT CONSTITUTE PROOF OF PURCHASE OR PROOF OF INSTALLATION 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 NOT BE RESPONSIBLE FOR WATER DAMAGE LOSS OF USE OF THE UNIT INCONVENIENCE LOSS OR DAMAGE TO PERSONALPRO...

Page 40: ...40 Copyright 2010 A O Smith Corporation All rights reserved ...

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