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TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE

IMPORTANT DEFINITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL SAFETY

TABLE OF CONTENTS

INTRODUCTION 5

Preparing For The Installation . . . . . . . . . . . . . . . . . . . . . . 5

INSTALLATION REQUIREMENTS FOR THE
COMMONWEALTH OF MASSACHUSETTS

TYPICAL INSTALLATION

Get To Know Your Water Heater. . . . . . . . . . . . . . . . . . . . . 7

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Mixing Valve Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

LOCATING THE NEW WATER HEATER

Facts To Consider About The Location. . . . . . . . . . . . . . . . 9

Insulation Blankets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

INSTALLING THE NEW WATER HEATER

Required Ability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Inspect Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Water

Piping

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

T&P Valve And Pipe Insulation (If Supplied). . . . . . . . . . . 12

Temperature-Pressure Relief Valve . . . . . . . . . . . . . . . . . 12

Water (Potable) Heating And Space Heating . . . . . . . . . . 13

Closed Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Sediment Traps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Filling The Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

High Altitude Installations . . . . . . . . . . . . . . . . . . . . . . . . . 16

Combustion Air And Ventilation. . . . . . . . . . . . . . . . . . . . . 16

Vent Terminal Clearances . . . . . . . . . . . . . . . . . . . . . . . . . 16

DV Termination Safety Cover . . . . . . . . . . . . . . . . . . . . . . 16

Vent Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Locating Clearance Hole For Vent . . . . . . . . . . . . . . . . . . 17

High Rise Vent Arrangement . . . . . . . . . . . . . . . . . . . . . . 17

Standard Vent Arrangement . . . . . . . . . . . . . . . . . . . . . . . 18

Vent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Securing Vent Termination Assembly To The
Exterior Wall.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Uncompressing The Corrugated Tubing . . . . . . . . . . . . . . 18

Vent Restricter Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Offset Vent Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . 19

TEMPERATURE REGULATION

Temperature

Regulation

. . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operating The Temperature Control System . . . . . . . . . . 21

FOR YOUR INFORMATION

External Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Start Up Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Operational Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

MAINTENANCE 24

Venting System Inspection . . . . . . . . . . . . . . . . . . . . . . . . 24

Pilot And Main Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Burner Flames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Replacing The Manifold/Burner Assembly . . . . . . . . . . . . 25

Piezoelectric Igniter System . . . . . . . . . . . . . . . . . . . . . . . 25

Testing The Igniter System . . . . . . . . . . . . . . . . . . . . . . . . 25

Removing And Replacing The Gas Control
Valve/Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Removing The Manifold/Burner Assembly . . . . . . . . . . . . 26

Removing

The

Burner

From

The

Manifold/Burner Assembly . . . . . . . . . . . . . . . . . . . . . . . . 27

Replacing The Pilot/Thermopile Assembly . . . . . . . . . . . . 27

Temperature & Pressure Relief Valve. . . . . . . . . . . . . . . . 28

Draining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Cathodic Protection - Anode . . . . . . . . . . . . . . . . . . . . . . . 28

Drain Valve Washer Replacement . . . . . . . . . . . . . . . . . . 28

Anode Rod Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 28

LEAKAGE CHECKPOINTS

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

TROUBLESHOOTING GUIDELINES

NOTES 33
RESIDENTIAL GAS WARRANTY

Содержание GDV

Страница 1: ...USE IN MANUFACTURED MOBILE HOMES RESIDENTIAL GAS WATER HEATERS For Your Safety AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED IF YOU ARE UNSUCCESSFUL PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER 500 Tennessee Waltz Parkway Ashland City TN 3701...

Страница 2: ...ate of California to cause cancer birth defects or other reproductive harm This water heater can cause low level exposure to some of the substances included in the Act Massachusetts Code requires this water heater to be installed In accordance with Massachusetts 248 CMR 2 00 State Plumbing Code and 248 CMR 5 00 This product is certified to comply with a maximum weighted average of 0 25 lead conten...

Страница 3: ...3 GENERAL SAFETY ...

Страница 4: ...Connections 17 Locating Clearance Hole For Vent 17 High Rise Vent Arrangement 17 Standard Vent Arrangement 18 Vent Assembly 18 Securing Vent Termination Assembly To The Exterior Wall 18 Uncompressing The Corrugated Tubing 18 Vent Restricter Plate 18 Offset Vent Arrangement 19 TEMPERATURE REGULATION 21 Temperature Regulation 21 Operating The Temperature Control System 21 FOR YOUR INFORMATION 22 Ext...

Страница 5: ...OPERATE THE WATER HEATER The installation must conform with these instructions and the local code authority having jurisdiction In the absence of lo cal codes installations shall comply with the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA This publi cation is available from the Canadian Standards Association 8501 East Pleasant Valley Road Cleveland OH 44131 If after reading this...

Страница 6: ...terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon mon...

Страница 7: ...LED IN A CLOSED SYSTEM List of status codes are shown at top of gas control valve thermostat FLUE BAFFLE GAS SUPPLY LINE MAIN MANUAL GAS SHUTOFF VALVE GROUND JOINT UNION SEDIMENT TRAP DIRT LEG ANODE HOT WATER OUTLET PIPE UNION INLET DIP TUBE TEMPERATURE AND PRESSURE RELIEF VALVE DISCHARGE PIPE DO NOT CAP OR PLUG GAS CONTROL VALVE THERMOSTAT DRAIN VALVE METAL DRAIN PAN FLOOR DRAIN OUTER DOOR INLET ...

Страница 8: ...ate law requir ing 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 heater Mixing valves are available at plumbing supply or hardware stores Consult a Qualifie...

Страница 9: ...on water quality water pressure and the environment in which the water heater is installed Water heaters are sometimes installed in locations where leakage may result in property damage even with the use of a 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 de...

Страница 10: ...r placement on the blanket directly over the exist ing labels VENT TERMINATION Before installing water heater determine placement of vent ter mination Make certain to observe vent location limitations see Figures 3 15 Minimum clearances between the water heater and combustible and noncombustible construction are 0 in from sides 0 in from back 4 in from front of jacket to closet door and 20 in from...

Страница 11: ...ing systems or component s used with a non potable water heating appli ance All piping components connected to this unit for space heating applications shall be suitable for use with potable water Toxic chemicals such as those used for boiler treatment shall not be introduced into this system When the system requires water for space heating at tempera tures higher than required for domestic water ...

Страница 12: ...ate the slit running the length of a section of pipe insula tion 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 that it is fully seated around the pipe Also ensure that the base of the insulation is flush with the water heater Once seated secure the insulation with duct tape electrical tape or equivalen...

Страница 13: ...ged will not cause any bodily injury or property damage because the water may be extremely hot If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions and re place the temperature pressure relief valve with a new one WATER POTABLE HEATING AND SPACE HEATING All pipin...

Страница 14: ... to check all the gas piping for leaks before lighting the water heater Use a soapy water solution not a match or open flame Rinse off soapy solution and wipe dry When installed at elevations above 7 700 feet input rating should be reduced at the rate of 4 percent for each 1 000 feet above sea level which requires replacement of the burner orifice in accordance with the current edition of the Nati...

Страница 15: ...223 1 NFPA 54 HOT WATER OUTLET COLD WATER INTLET DRAIN VALVE DISCHARGE PIPE DO NOT CAP OR PLUG METAL DRAIN PAN UNION SHUTOFF VALVE FLOOR DRAIN TEMPERATURE AND PRESSURE RELIEF VALVE UNION 6 MAXIMUM AIR GAP FIGURE 9 FILLING THE WATER HEATER Never use this water heater unless it is completely full of water To prevent damage to the tank the tank must be filled with water Water must flow from the hot w...

Страница 16: ...which may be re quired in your area COMBUSTION AIR AND VENTILATION When determining the installation location for a direct vent water heater snow accumulation and drifting should be considered in areas where applicable VENT TERMINAL CLEARANCES The vent system must terminate so that proper clearances are maintained as cited in local codes or the current edition of the National Fuel Gas Code ANSI Z2...

Страница 17: ...utside wall surface is 22 in and the maximum height of H is 12 ft TO BOTTOM OF HEATER WALL THICKNESS 10 in REF D H FIGURE 14 FIGURE 15 Minimum 18 in 12 in above grade or anticipated snow level Minimum 12 in under veranda porch deck or balcony see footnote 1 Minimum 3 ft above if within 10 ft horizontally to a mechanical air supply inlet Minimum 12 in from sides above or below a permanently closed ...

Страница 18: ...e over the outer corrugated tube and fasten the trim plate to the interior wall Caulk the junction of the outer corrugated tube and the trim plate inside with suitable sealant SEALANT TRIM PLATE INSIDE TRIM PLATE OUTSIDE FIGURE 18 UNCOMPRESSING THE CORRUGATED TUBING Pull the inner corrugated tube towards the water heater and leave some length over the water heater s center for bend ing Pull the ou...

Страница 19: ...ube TOP VIEW 90 MAXIMUM BEND FIGURE 24 CONDITION 2 Where floor joists impede venting a rise or drop to complete the vent termination is possible All installations require 1 in clearance to combustibles NOTE A The maximum horizontal vent length of 80 in minus wall thickness should be considered when installing an offset vent arrangement B Do not combine condition 1 Figure 24 with condition 2 Figure...

Страница 20: ... 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 DANGER LIGHTING INSTRUCTIONS FIGURE D MAIN BURNER THERMOPILE PILOT FIGURE A OFF POSITION FIGURE B PILOT POSITION FIGURE C ON POSITION 120 F Mark 120 F Mark CONTROL KNOB 120 F Mark GAS CONTROL Gas C...

Страница 21: ...shold 116 35 minutes 45 minutes 122 1 minute 5 minutes 131 5 seconds 25 seconds 140 2 seconds 5 seconds 149 1 second 2 seconds 154 instantaneous 1 seconds U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 GAS CONTROL VALVE THERMOSTAT SETTINGS GAS CONTROL TEMPERATURE KNOB STATUS LIGHT IGNITER 120 F MARK 130 F MARK 155 F MARK 150 F MARK 140 F MARK 91 F MARK FIGURE 26 Should overheatin...

Страница 22: ...al for a gas fired water heater to operate properly as well as to carry away products of combustion and water vapor SMOKE ODOR It is not uncommon to experience a small amount of smoke and odor during the initial start up This is due to burning off of oil from metal parts and will disappear in a short while THERMAL EXPANSION Water supply systems may because of such events as high line pressure freq...

Страница 23: ...ent we can only suggest that chlorination or aeration of the water supply be considered to eliminate the water problem Do not remove the anode leaving the tank unprotected By doing so all warranty on the water heater tank is voided AIR IN HOT WATER FAUCETS HYDROGEN GAS Hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hy...

Страница 24: ... qualified installer or service agency to replace 1 2 a flooded water heater Do not attempt to repair the unit It must be replaced At least once a year a visual inspection should be made of the main burner and the pilot assembly for proper flame characteris tics This can be done by removing the Outer Door and viewing the main burner operation through the Viewport on the Inner Door see Figure 1 The...

Страница 25: ...ed See Figure 30 VAC PILOT THERMOPILE BRACKET ELECTRODE THERMOPILE PILOT IGNITER BUTTON WIRE TO ELECTRODE FIGURE 30 TESTING THE IGNITER SYSTEM Turn off the gas to the water heater at the manual gas shut off valve Watch the electrode tip while activating the igniter A vis ible spark should jump from the electrode To avoid shock do not touch the burner or any metal part on the pilot or pilot assembl...

Страница 26: ...not available use a mixture of hand dish washing soap and water one part soap to 15 parts water or childrens soap bubble solution Bubbles forming indicate a leak Be sure tank is completely filled with water before lighting and activating the water heater Follow the Lighting Instructions on page 21 If additional information is required reference the number on the cover of this manual for service in...

Страница 27: ...ENT BLOCK MANIFOLD DOOR BURNER AND OTHER FITTINGS NOT SHOW FOR CLARITY IGNITER WIRE FIGURE 25 6 Read this step carefully before proceeding Using the old pilot pilot tube assembly as a guide bend the new pilot tube to match the old one Make only the bends closest to the pilot before going to the next step 1 2 PILOT THERMOPILE ASSEMBLY WHITE WIRE THERMOPILE CONNECTOR THERMOPILE PILOT IGNITER CONNECT...

Страница 28: ...t to an ad equate drain or external to the building Open the 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 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 IMPORTANT Condens...

Страница 29: ...rease the life of the water heater tank The anode rod should be inspected after a maximum of three years and annually thereafter until the condition of the anode rod dictates its replacement NOTE Artificially softened water requires the anode rod to be inspected annually The following are typical but not all signs of a depleted anode rod The majority of the rods diameter is less than 3 8 in Signif...

Страница 30: ...e plastic plug and isulation D Small amounts of water from temperature pressure relief valve may be due to thermal expansion or high water pres sure in your area E The temperature pressure relief valve may be leaking at the tank fitting F Water from a drain valve may be due to the valve being slightly opened G The drain valve may be leaking at the tank fitting H Combustion products contain water v...

Страница 31: ...ets Gas leaks Wasted hot water Long runs of exposed piping Hot water piping in exposed wall Leaks or cracks in dip tube 1 2 3 4 5 6 7 8 9 10 Set temperature dial to lower setting Drain Flush Provide water treatment if need ed Install adequate size heater Correct piping dip tube must be in cold inlet Repair faucets Check with utility repair at once Advise customer Insulate piping Insulate piping Ch...

Страница 32: ...d Defective gas control thermostat Heater installed in a confined area Burner flame yellow lazy 1 2 3 4 5 6 Provide ventilation to water heater Check flue way flue baffle burner Check with gas utility company Clean locate source and correct Replace gas control thermostat Provide fresh air ventilation See Burner Flame Yellow Lazy 1 2 3 4 5 6 CONDENSATION Temperature setting too low Water heater too...

Страница 33: ...33 NOTES ...

Страница 34: ...mum calibrated setting of its thermostat used at water pressure not exceeding the working pressure shown on the heater filled 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 in its original installation location in the United Sta...

Страница 35: ...ent 125 Southeast Parkway Franklin TN 37068 phone 1 800 433 2545 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 valida tion by warrantor PROOF OF PURCHASE AND PROOF OF INSTALLATION DATE ARE REQUIRED TO SUPPORT WARRANTY CLAIM FROM ORIGINAL OWN...

Страница 36: ...36 500 TENNESSEE WALTZ PARKWAY ASHLAND CITY TN 37015 PHONE 1 800 433 2545 FAX 1 800 433 2515 www aosmithwaterheaters com email parts hotwater com ...

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