4
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE ...................................................................................................................... 2
SAFETY PRECAUTIONS ........................................................................................................................... 2-3
TABLE OF CONTENTS ................................................................................................................................. 4
WARRANTY................................................................................................................................................................................... 5
CUSTOMER RESPONSIBILITIES ......................................................................................................................................... 6
PRODUCT SPECIFICATIONS ................................................................................................................................................ 6
MATERIALS AND BASIC TOOLS NEEDED ....................................................................................................................... 7
Materials Needed .....................................................................................................................................................7
Basic Tools................................................................................................................................................................7
TYPICAL INSTALLATION.......................................................................................................................................................... 8
INSTALLATION INSTRUCTIONS ..................................................................................................................................... 9-18
Removing the Old Water Heater ...............................................................................................................................9
Facts to Consider About the Location ................................................................................................................10-11
Insulation Blankets ............................................................................................................................................11-12
Combustion Air and Ventilation Appliances in Unconfi ned Spaces ........................................................................12
Combustion Air and Ventilation Appliances in Confi ned Spaces .......................................................................12-13
Water Piping ......................................................................................................................................................13-14
T & P Valve and Pipe Insulation .............................................................................................................................14
Temperature Pressure Relief Valve ...................................................................................................................15,16
Filling the Water Heater ..........................................................................................................................................16
Venting ...............................................................................................................................................................16-17
Gas Piping .........................................................................................................................................................17,18
Sediment Trap ........................................................................................................................................................18
OPERATING INSTRUCTIONS ........................................................................................................................................ 19-21
Lighting & Operating Label .....................................................................................................................................19
Temperature Regulation .........................................................................................................................................20
Operating the Temperature Control System ...........................................................................................................21
SERVICE AND ADJUSTMENT ....................................................................................................................................... 22-27
Venting System Inspection .....................................................................................................................................22
Burner Inspection ...................................................................................................................................................22
Removing the Burner Door Assembly ....................................................................................................................23
Ultra Low NOx Natural Gas Burner ........................................................................................................................23
Replacing the Pilot/Thermopile Assembly ..............................................................................................................23
External Inspection & Cleaning of the Flame Trap .................................................................................................24
Cleaning the Combustion Chamber and Flame Trap .............................................................................................24
Replacing the Burner Door Assembly .....................................................................................................................25
Piezoelectric Igniter System ...................................................................................................................................25
Testing the Igniter System ......................................................................................................................................25
Removing and Replacing the Gas Control Valve/Thermostat ................................................................................26
Housekeeping .........................................................................................................................................................26
Anode Rod Inspection .......................................................................................................................................26-27
Temperature-Pressure Relief Valve Operation .......................................................................................................27
Draining ..................................................................................................................................................................27
Drain Valve Washer Replacement ..........................................................................................................................27
Service ....................................................................................................................................................................27
TROUBLESHOOTING GUIDE ........................................................................................................................................ 28-34
Start Up Conditions ................................................................................................................................................28
Thermal Expansion ...........................................................................................................................................28
Strange Sounds ................................................................................................................................................28
Draft Hood Operation ........................................................................................................................................28
Condensation ....................................................................................................................................................29
Smoke/Odor ......................................................................................................................................................29
Operational Conditions ......................................................................................................................................29-30
Smelly Odor ......................................................................................................................................................29
Water Temperature Stacking .............................................................................................................................29
Air in Hot Water Faucets ...................................................................................................................................29
Safety Shut-Off .............................................................................................................................................29,30
Troubleshooting Items .......................................................................................................................................30-34
PARTS ORDER LIST ................................................................................................................................................................ 35