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Water System Piping

Piping Installation

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.

Water supply pressure should not exceed 80% of the 
working pressure of the water heater. The working 
pressure is stated on the water heater’s data plate. If 
this occurs, a pressure limiting 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.

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.

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 fitting marked “C”. Connect the hot 
water supply (3/4” NPT) to the fitting marked “H”.

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.

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.

3.

The manufacturer of this water heater recommends 
installing a tempering 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. 

4.

If installing the water heater in a closed water 
system, install a relief valve or expansion tank in 
the cold water line as specified under “Closed 
System/Thermal Expansion” (Page 13).

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.

Install a temperature and pressure relief valve in 
the opening marked “Temperature and Pressure 
(T & P) Relief Valve” on the water heater. Add a 
discharge line to the opening of the T & P relief 
valve. Follow the instructions under “Temperature 
and Pressure Relief Valve" (Page 14).

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.

Figure 14
Typical Tempering
Valve Installation

Follow the tempering
valve manufacturer’s
instructions.

Cold

Water

Inlet

Hot

Water
Outlet

Tempered water
to fixtures

Tempering valve
(Set to 120°F)

12

In a closed system use a
thermal expansion tank

Figure 13
Water Piping Installation

Main

Water

Supply

Cold Water

Inlet Valve

Cold Water

Supply to Fixtures

Hot Water
Outlet

Union

Temperature and
Pressure Relief Valve

Discharge line
6” maximum
above drain

Drain line
3/4” ID
minimum

Drain

Metal
Drain Pan
1 3/4” depth max.

1” min.

Massachusetts: 
Install a vacuum relief 
in cold water line per 
section 19 MGL 142.

Pressure reducing
valve with bypass

Summary of Contents for Flame Guard Safety System

Page 1: ...ctly a fire or explosion may result causing property damage personal injury or death Gas Water Heater with the Flame Guard Safety System Installation Instructions and Use Care Guide Table of Contents 2 To obtain technical warranty or service assistance during or after the installation of this water heater visit our website at or call toll free 1 800 999 9515 When calling for assistance please have...

Page 2: ...h as air escaping through the faucet as water begins to flow Do not smoke or have any open flame near the faucet at the time it is open 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 ...

Page 3: ...to properly install this water heater or you have difficulty following the instructions you should not proceed but have a qualified service 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 data plate identifying your water heater can be f...

Page 4: ...sources have been extinguished Site Location 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 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 m...

Page 5: ...an 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 Under no circumstances will the manufacturer or seller of this water heater be held liable for any water damage which is caused by your failure to foll...

Page 6: ...lution bubbles forming indicate a leak or other approved method Gas Pressure Important The gas supply pressure must not exceed the maximum supply pressure as stated on the water heater s data plate The minimum supply pressure is for the purpose of input adjustment Gas Pressure Testing Important This water heater and its gas connection must be leak tested before placing the appliance in operation I...

Page 7: ... the water heater data plate The heating value of the gas BTU FT may be determined by consulting the local natural gas utility Cu Ft Per Hr Required Nominal Iron Pipe Size in Length of Pipe Feet 3 4 1 2 1 1 1 4 275 576 1071 2205 189 393 732 1496 152 315 590 1212 129 267 504 1039 114 237 448 913 103 217 409 834 96 196 378 771 89 185 346 724 83 173 322 677 78 162 307 630 69 146 275 567 63 132 252 51...

Page 8: ...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 data plate Additional air can be provided by two methods Figure 4 Opening Locations Confined Spaces 12 maximum Permanent openings to the outside or additional r...

Page 9: ...ipment so that they are opened automatically during equipment operation Keep louvers and grilles clean and free of debris or other obstructions Direct to outdoors Vertical ducts Horizontal ducts Figure 6 Figure 7 Figure 8 Table 4 Minimum Free Area of Permanent Openings for Ventilation and Combustion Air Supply All Air from Outdoors Only Based on the total BTUH input rating for all gas utilizing eq...

Page 10: ... Screws four provided Drafthood Jacket top Install the drafthood with the four screws provided 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 drafthood outlet Vent Connectors 1 Type B Doublewall U L Listed Vent Pipe 2 Singlewall Ven...

Page 11: ...anufacturer 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 An unused chimney flue or masonry enclosure may be used as a passageway for the installation of a gas vent Figure 12 Common combined...

Page 12: ...s 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 4 If installing the water heater in a closed water system install a relief valve or expansion tank in the cold water line as specified under Closed System Thermal Expansion Page 13 5 Install a shut off valve in the cold water inlet line It should be loca...

Page 13: ...s DO NOT add any chemicals to the system piping which will contaminate the potable water supply Closed System Thermal Expansion Periodic discharge of the temperature and pressure relief valve may be due to thermal expansion in a closed water supply system The water utility supply meter may contain a check valve backflow preventer or water pressure reducing valve This will create a closed water sys...

Page 14: ...erature 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 The Temperature Pressure Relief Valve Must not be in contact with any electrical part Must be connected to an adequate discharge line Must not be...

Page 15: ...piping and fittings must be compatible with potable water 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 The ...

Page 16: ...gs Installation Checklist Vent Pipe System Drafthood properly installed Vent connectors securely fastened with screws and supported properly to maintain six inch clearance Vent connector made of approved material and sized correctly Vent pipe system 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 NFPA54 late...

Page 17: ...for about 1 minute after the pilot is lit Release the reset button and it will pop back up Pilot should remain lit If the pilot light goes out repeat steps2 6 TO TURN OFF GAS TO APPLIANCE 2 Turn the gas control knob clockwise to the OFF position OPERATING YOUR WATER HEATER Lighting Instructions Read and understand these directions thoroughly before attempting to light or re light the pilot Make su...

Page 18: ... WAR M H O T 120 F Bar 130 F Bar Index Bars Gas Control Knob Figure 19 Robertshaw Gas Valve Thermostat Settings W ARNIN G Dial Stop 130 F Bar Reset Button Note During low demand periods when hot water is not being used a lower thermostat setting will reduce energy 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 ...

Page 19: ...n burner and pilot light in the event a flammable vapor incident occurs or due to poor combustion caused by a blocked vent or insufficient combustion air If the fuse opens the water heater cannot be used unless the thermocouple is replaced by a qualified service technician Contact the Product Service and Support Department for service information at A high temperature limit switch or ECO Energy Cu...

Page 20: ...old water inlet valve 3 Open a nearby hot water faucet 4 Connect a hose to the drain valve and terminate it to an adequate drain Note The drain hose should be rated for at least 200 F If the drain hose does not have this rating open the cold water inlet valve and a nearby hot faucet until the water is no longer hot 5 Open the water heater drain valve and allow all the water to drain from the tank ...

Page 21: ... is dirty or clogged The burner may be cleaned with soap and hot water Figure 23A L P Gas Burner 1 Separate the pilot bracket from the L P burner by removing screw 2 Loosen set screw located on top of the L P burner near the manifold door Carefully pull the burner away from the manifold door assembly 3 Check the burner to see if it is dirty or clogged The burner may be cleaned with soap and hot wa...

Page 22: ...e Thermocouple contains a thermal fuse Do not bend in the location shown below Figure 25 Be sure igniter wire is positioned through the small opening of the two piece wire connector 6 See Replacing Manifold Assembly Page 23 Notice The thermocouple contains a thermal fuse which is used as a safety device Notice Thermocouple must not be bent in this location Figure 24 Two Piece Wire Connector Assemb...

Page 23: ...flame trap 3 Reassemble following the procedure under Replacing the Manifold Assembly Replacing the Manifold Assembly 1 Check the door gasket for damage or imbedded debris prior to installation 2 Inspect the viewport for damage and replace as required 3 Insert the manifold assembly into the burner compartment making sure that the tab of the manifold tube engages in the slot of the bracket inside t...

Page 24: ...ipe joint compound on the gas piping connections and fitting on the back of the gas valve that screws into tank Be sure to remove the pilot ferrule nut from the new gas control valve thermostat Turn gas supply on and check for leaks Use a chloride free soap and water solution bubbles forming indicate a leak or other approved method Be sure tank is completely filled with water before lighting and a...

Page 25: ...ecessary skills to perform the adjustment properly you should not proceed but get help from a qualified service technician 1 Remove the manifold assembly using the instructions on page 21 2 Remove the two screws securing the burner to the manifold assembly then separate the burner from the manifold assembly see figure 29 3 While holding the burner loosen the air shutter set screw and rotate the ai...

Page 26: ...rmocouple 7 Locate source and correct 8 Replace thermostat 9 Call 1 800 999 9515 10 Replace igniter pilot assembly 11 Replace water heater eliminate flammable vapors source Call 1 800 999 9515 12 Check with gas utility company 13 See maintenance section for inspection and cleaning of flame trap HIGH OPERATION COSTS 1 Thermostat set too high 2 Sediment or lime in tank 3 Water heater too small for j...

Page 27: ...4 Defective thermostat 5 Heater installed in a confined area 6 Burner flame yellow lazy 1 Insufficient secondary air 2 Flue clogged 3 Heater installed in a confined area 1 Provide ventilation to water heater Check flue way flue baffle and burner 2 Clean locate source and correct 3 Provide fresh air ventilation 1 Temperature setting too low 1 Increase the temperature setting 1 Replace thermostat 2 ...

Page 28: ...AFTHOOD 2 REDUCER RING SOME MODELS 3 FLUE BAFFLE 4 HEAT TRAP COLD SOME MODELS 5 HEAT TRAP HOT SOME MODELS 6 COLD WATER DIPTUBE 7 ANODE ROD 8 TEMPERATURE PRESSURE RELIEF VALVE LOCATED TOP OR SIDE 9 DRAIN VALVE 10 GAS VALVE THERMOSTAT 11 PILOT ASSEMBLY THERMOCOUPLE KIT Natural Gas 12 PILOT ASSEMBLY THERMOCOUPLE KIT L P Gas 13 OUTER DOOR 14 15 MANIFOLD DOOR ASSEMBLY Natural Gas Low Nox BURNER Natural...

Page 29: ...sembly which contains the manifold tube gasket door pilot tube thermocouple two piece wire connector with retainer clip and pilot assembly Natural Gas Low Nox Item 17 Manifold door assembly which contains the manifold tube gasket door pilot tube thermocouple two piece wire connector with retainer clip and pilot assembly L P Gas Item 18 Contains two piece wire connector with retainer clip and pilot...

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