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MAINTENANCE OF YOUR WATER HEATER

Temperature and Pressure 
Relief Valve

Manually operate the temperature and pressure relief 
valve at least once a year to make sure it is working 
properly. To prevent water 
damage, the valve must 
be properly 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. If the valve fails to completely reset and 
continues to release water, immediately shut off the 
manual gas valve and the cold water inlet valve and call 
a qualified service technician.

Figure 20

Temperature and Pressure
Relief Valve

Manual Relief
Valve

Discharge line to drain

Explosion Hazard

If the temperature and pressure relief 
valve is dripping or leaking, have a 
qualified service technician replace it.
      • Do not plug valve.
      • Do not remove valve.
Failure to follow these instructions can 
result in death or explosion.

20

Draining and Flushing

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:

1.

Turn off the gas to the water heater at the Manual 
Gas Shut-off Valve.

2.

Close the cold 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. Flush the tank with 
water as needed to remove sediment.

6.

Close the drain valve, refill the tank, and restart the 
heater as directed under “Operating Your Water 
Heater”.

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 not be confused with a tank leak.

Routine Preventative 
Maintenance

At least annually, a visual inspection should be made of 
the venting and air supply system, piping systems, 
main burner, pilot burner, and Flame-trap. 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. 

!

Build up of soot and carbon on the main burner and 
pilot burner. Check for a soft blue flame.

!

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.

!

Verify proper operation after servicing this water 
heater.

Important:

  If you lack the necessary skills required to 

properly perform this visual inspection, you should not 
proceed, but get help from a qualified service 
technician.

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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