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American Water Heater 30 Gallon 30000 BTU UltraLow Nox Natural Gas Water Heater UG6130T303NV user manual

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    							21
    Operating the Temperature 
    Control System
    Figure 19B: Status Codes
    VAC
    List of status codes are shown
    at top of gas control valve/thermostat.
    Water Temperature Adjustment
    The water temperature setting can be adjusted from 55°F 
    to 155°F. Turn the Gas Control/Temperature Knob to the 
    desired setting/temperature.
    NOTE: The temperatures indicated are approximates. The 
    actual temperature of the heated water may vary.  Also, 
    some models are certified for 180°F outlet temperatures. 
    See the Data Plate on the front of the water heater for the 
    maximum outlet temperature.
    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 temperature that 
    prevents the water in the water heater from freezing 
    while still conserving energy.
    Status Light Codes 
    Normal Flashes: 
    •  0 Flashes   Indicates Control Off/Pilot Out.
    •  1 Flash  Indicates Normal Operation.
    •  Continuous Light indicates the gas control 
    valve/thermostat is shutting down.
    Diagnostic Flashes: If the water heater is not working, look 
    for the following diagnostic flashes after lighting the pilot.
    2 Flashes   Indicates thermopile voltage is low.
    4 Flashes  Indicates overheat failure.         
    5 Flashes   Indicates water temperature sensor failure.
    7 Flashes   Indicates electronic control failure.
    8 Flashes   See “Status Light Code Troubleshooting Chart.”
    9 Flashes   Indicates chamber temperature sensor circuit    
        is open or shorted.
    10 Flashes  Indicates an LDO occurrence was detected in 
        the combustion chamber (contaminants).
    Operational Conditions
    Condensation
    Moisture from the products of combustion condenses on 
    the tank surface and the outside jacket of the water heater 
    and forms drops of water which may fall onto the burner or 
    other hot surfaces. This will produce a “sizzling” or “frying” 
    noise. NOTE: This condensation is normal and should 
    not be confused with a leaking tank. Condensation may 
    increase or decrease at different times of the year.
    High efficient energy saver water heaters will produce 
    larger amounts of condensation on initial start-up or when 
    a large amount of hot water is being used. NOTE: Do not 
    confuse this with a “tank leak”. Once the water reaches a 
    temperature of 120°F and the tank warms up (usually 1-2 
    hours), the condensation will stop.
    IMPORTANT: It is always recommended that a suitable 
    metal drain pan be installed under the water heater 
    to protect the area from water damage resulting from 
    normal condensation production, a leaking tank or piping 
    connections. Refer to “Location Requirements” on page 
    4. Under no circumstances is the manufacturer to be held 
    responsible for any water damage in connection with this 
    water heater.
    Water Heater Sounds
    During the normal operation of the water heater, sounds or 
    noises may be heard. These noises are common and may 
    result from the following:
    1.  Normal expansion and contraction of metal parts during 
    periods of heat-up and cool-down.
    2.  Condensation causes sizzling and popping within the 
    burner area and should be considered normal.
    3.  Sediment buildup in the tank bottom will create varying 
    amounts of noise and may cause premature tank fail-
    ure. Drain and flush the tank as directed under “Drain-
    ing and Flushing”.
    Smoke/Odor
    The water heater may give off a small amount of smoke 
    and odor during the initial start-up of the unit. This is due to 
    the burning off of oil from metal parts of a new unit and will 
    disappear after a few minutes of operation. 
    Safety Shut-off
    This water heater is designed to automatically shut-off in 
    the event of the following:
    1.  The pilot flame is extinguished for any reason.
    2.  The water temperature exceeds 189°F (87°C).
    3.  Excessive contaminants in the combustion chamber.
    4.  The ignition of flammable vapors.
    A thermopile is used to determine if a pilot flame is present 
    and will shut off the gas supply to the main burner and pilot 
    if the flame is absent.  This unit is also equipped with a 
    combustion chamber temperature sensor that will shut off  
    						
    							22NOTE: This rod may reduce but not eliminate water odor 
    problems. The water supply system may require special 
    filtration equipment from a 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 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”.
    •  Significant sections of the support wire (approx. 1/3 or 
    more of the anode rod’s length) are visible.
    If the anode rod show signs of either or both it should be 
    replaced. NOTE: Whether re-installing or replacing the 
    anode rod, check for any leaks and immediately correct if 
    found.
    In replacing the anode:
    1.  Turn off gas supply to the water heater.
    2.  Shut off the water supply and open a nearby hot water 
    faucet to depressurize the water 
    tank.
    3.  Drain approximately 5 gallons 
    of water from tank. (Refer to 
    “Draining and Flushing” for proper 
    procedures). Close drain valve.
    4.  Remove old anode rod.
    5.  Use Teflon® tape or approved pipe 
    sealant on threads and install new 
    anode rod.
    6.  Turn on water supply and open a 
    nearby hot water faucet to purge air 
    from water system.
    7.  Check for any leaks and 
    immediately correct any if found.
    8.  Restart the water heater as directed in this manual. 
    See the Repair Parts Illustration for anode rod location.
    TEFLON ® is a registered trademark of E.I. Du Pont De Nemours and Company.
    the gas supply to the burner if poor combustion is sensed 
    (caused by a blocked vent or insufficient combustion air).  If 
    the gas control valve/thermostat shuts off the gas supply, 
    check the diagnostic flash code and refer to the “Status 
    Light Code Troubleshooting Chart.”  If necessary, also refer 
    to the “Troubleshooting Chart.”
    IMPORTANT: Correct any issues prior to resetting the gas 
    control valve/thermostat.  Reference the telephone number 
    on the cover of this manual for service information. 
      
    Reset the system by following these steps:  1.) Turn the 
    temperature adjustment knob to OFF.  2.) Unplug the 
    thermopile plug from the gas control valve/thermostat.  
    3.) Wait for about three minutes.  4.) Plug the thermopile 
    plug back into the gas control valve/thermostat.  5.) Turn 
    the temperature adjustment knob to PILOT and restart the 
    water heater as directed in this manual.
      
    A temperature limit switch or ECO (Energy Cut Off)  sensor  
    located in the gas control valve	hermostat is used to shut 
    off the water heater if the water temperature exceeds 
    189°F (87°C).
    The Diagnostic Status Light will flash a code indicating 
    an “Overheat Failure” (4 Flashes).  See “Operating the 
    Temperature Control System.”  If the ECO has functioned 
    the gas control valve/thermostat should be replaced by 
    a qualified person. Contact your local dealer for service 
    information.
    Anode Rod/Water Odor
    Each water heater contains at least one anode rod, 
    which will slowly deplete (due to electrolysis) prolonging 
    the life of the water heater by protecting the glass-lined 
    tank from corrosion. Adverse water quality, hotter water 
    temperatures, high hot water usage, hydronic heating 
    devices, and water softening methods can increase 
    the rate of anode rod depletion. Once the anode rod 
    is depleted, the tank will start to corrode, eventually 
    developing a leak.
    Certain water conditions will cause a reaction between the 
    anode rod and the water. The most common complaint 
    associated with the anode rod is a “rotten egg smell” 
    produced from the presence of hydrogen sulfide gas 
    dissolved in the water. 
    IMPORTANT: Do not remove this rod permanently as it will 
    void any warranties. A special anode rod may be available 
    if water odor or discoloration occurs. 
    						
    							23
    MAINTENANCE OF YOUR WATER HEATER
    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.  Open a nearby hot water faucet until the water is no 
    longer hot.
    3.  Close the cold water inlet valve.
    4.  Connect a hose to the drain valve and terminate it to an 
    adequate drain or external to the building.
    5.  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.
    6.  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: 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.
    •  After servicing this water heater, check to make sure it 
    is working properly. (See Operating Your Water Heater 
    section of this manual.)
    IMPORTANT: If you lack the necessary skills required to 
    properly perform this visual inspection, you should not 
    proceed, but get help from a qualified person.
    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 control valve and the 
    cold water inlet valve and call a qualified person.Figure 21
    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 
    person replace it.
    Examples of a qualified person include:
    licensed plumbers, authorized gas company 
    personnel, and authorized service 
    personnel.
    Do not plug valve.
    Do not remove valve.
    Failure to follow these instructions can 
    result in death, or explosion.
    WARNING 
    						
    							24
    Replacement Parts
    IMPORTANT: The following maintenance procedures are 
    for the Flame Guard™ Safety System components and 
    should be performed by a qualified person.
    Replacement parts may be ordered through your plumber 
    or the local distributor. Parts will be shipped at prevailing 
    prices and 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 pages 31-32 for a list of available repair parts.
    Removing the Burner Door Assembly
    1.  Turn off the gas to the water heater at the manual 
    shut-off valve (Figure 3).
    2.  Before performing any maintenance, it is important to 
    turn off the gas supply to the 
    water heater at the manual 
    gas shut-off valve. This valve 
    is typically located beside 
    the water heater. Note the 
    position of the shut-off valve 
    in the open/on position, then 
    proceed to turn it off (Figure 
    3).
    3.  Remove the outer door.
    4.  Remove the two screws 
    (1/4” nut driver) securing 
    the burner door assembly 
    to the combustion chamber 
    (Figure 23).
    5.  Disconnect the pilot tube 
    (7/16” wrench), the igniter wire from the igniter lead 
    wire, and manifold tube  (3/4” wrench) at the gas 
    control valve/thermostat.  Disconnect the sensor wires 
    (lift white lever outward, then gently pull the plug 
    downward). Also, use needle nose pliers to disconnect 
    the red (+) and white (-) thermopile wires from the gas 
    control valve/thermostat. See Figures 22 & 23.   
    Figure 23
    Burner Assembly
    Removal
    Burner Door Screws (2)
    Manifold Component BlockBurner DoorTemperature
    SensorManifold Tube
    Pilot Tube
    ViewportThermopile 
    Wire
    Connections
    Piezo Igniter ButtonGas Control Valve/
    ThermostatTemperature Sensor
    Wire Connection
    Outer Door
    Not Shown
    VAC
    Igniter
    WireRed
    Wire
    (Left 
     Side) Pilot 
    Tube
    Manifold 
    Tube Igniter
    Button Figure 22
    Gas Control Valve/
    Thermostat
    Igniter
    Lead
    Wire
    White
    Wire
    (Right
     Side)
    VACSensor 
    Wires
    6.  Grasp the manifold tube and push down slightly to free 
    the manifold, pilot tube, and thermopile.
    7.  Carefully remove the burner door assembly from the 
    burner compartment.  
     NOTE: Be sure not to damage internal parts.
    Figure24A
    NaturalGas(Low Nox)
    Burner Door Assembly
    Burner
    Use brush on this surface.Pilot Assembly
    Figure24B
    NaturalGas(Low Nox)
    Burner Door Assembly
    50K Models
    Burner
    Use brush on this surface.Pilot Assembly
    Natural Gas Burner (Ultra Low Nox)
    Check the burner to see if it is dirty or clogged. The burner 
    may be cleaned with soft paint brush (Figure 24). Do not 
    use a wire brush or any tool that may damage the burner 
    screen. Important: Do not use the burner if the burner screen 
    is damaged. NOTE: Damage may be rips or holes in the 
    burner screen. Discoloration is normal. 
    						
    							25
    Replacing the Pilot/Thermopile Assembly
    1.  Remove the burner assembly. See Removing the Burner 
    Door Assembly  Section.
    2.  Lift the retainer clip straight up from the back of 
    the manifold component block (using a flat-blade 
    screwdriver), then remove the manifold component 
    block from the burner door (Figure 25). IMPORTANT: 
    Be careful not to bend or alter the position of the pilot 
    tube. Note the placement/order of the wires in the 
    manifold component block.
    Figure 25 
    Manifold Component
    Block Assembly
    Thermopile
    Connectors
    Manifold 
    Component
    Block Pilot TubeIgniter
    Wire
    Burner Door Opening
    Retainer
    Clip
    3.  Turn the burner door assembly over till the pilot/
    thermopile assembly is easily accessible.
    4.  Use a 7/16” wrench to loosen the nut securing the pilot 
    tube to the pilot (right-hand threads). IMPORTANT: 
    Be careful not to bend or alter the position of the pilot/
    thermopile assembly components during the following 
    steps. To prevent any bending, use a pair of pliers to 
    steady the pilot/thermopile assembly bracket.
      
    5.  Locate and remove the screw attaching the pilot/
    thermopile assembly to the burner and keep it for reuse 
    later. 
    IMPORTANT: Be careful not to bend or alter the 
    position of the pilot/thermopile assembly components.
    Figure 26
    Pilot/Thermopile Assembly
    Pilot/Thermopile
    Assembly Igniter Connector
    PilotThermopile
    Thermopile
    Connectors
    Pilot Tube
    (Ferrule Nut 
    Not Shown)
    6.  Install the new pilot/thermopile assembly by routing the 
    new igniter wire and new thermopile wire through the 
    opening in the burner door (See Figure 25).7.  Use the screw removed earlier to attach the new pilot/
    thermopile assembly to the burner door assembly. 
    NOTE: Remove the pilot nut included with the new 
    pilot/thermopile. IMPORTANT: Once the pilot nut is 
    removed the pilot orifice MUST be kept in the pilot.
    8.  Connect the pilot tube to the new pilot and tighten the 
    nut securely. To prevent any bending, use a pair of pli-
    ers to steady the pilot bracket. IMPORTANT: Keep the 
    pilot orifice in the pilot when making the connection. 
    DO NOT operate the water heater without the pilot ori-
    fice installed.
    9.  Reinstall the manifold component block in the burner 
    door. (See Figures 25). Be sure that the thermopile 
    wires are positioned through the top opening of the 
    manifold component block. The igniter wire should be 
    positioned through the middle opening and the pilot 
    tube through the bottom opening.
    10.  Follow the “Replacing the Burner Door Assembly” 
    instructions to replace the burner door assembly.
    Replacing the Pilot/Thermopile 
    Assembly (50K Models)
    1.  Remove the burner assembly as directed previously.
    2.  Lift the retainer clip straight up from the back of 
    the manifold component block (using a flat-blade 
    screwdriver), then remove the manifold component 
    block from the burner door assembly
     (Figure 27).
    Figure 27 
    Manifold Component
    Block Assembly (50K Models)
    Thermopile
    Connectors
    Manifold 
    Component
    Block Pilot TubeIgniter
    Wire
    Burner Door Opening
    Retainer
    Clip
    3.  Locate and remove the screw attaching the pilot/
    thermopile assembly to the burner and keep it for reuse 
    later. 
    IMPORTANT: Be careful not to bend or alter the 
    position of the pilot/thermopile assembly components.    
    4.  Pull the pilot/thermopile assembly from the burner door 
    assembly. IMPORTANT: Be careful not to bend or alter 
    the position of the pilot assembly components.
    5.  Use the old pilot tube as a guide and bend the new 
    pilot tube to match the old one. Make only the bends 
    closest to the pilot before going to the next step. 
    						
    							26
    Pilot Thermopile Pilot/Thermopile
    AssemblyPilot Tube
    (Ferrule Nut 
    Not Shown) Igniter 
    Connector
    Thermopile
    Connectors Figure 28
    Pilot/Thermopile Assembly
    (50K Models)
    6.  Push the new pilot/thermopile assembly connectors 
    through the opening in the burner door (See Figure 27). 
    Do not to scrape or nick the wires during installation. 
    IMPORTANT: DO NOT USE PILOT/THERMOPILES 
    WITH FIBERGLASS SLEEVES. The replacement kit 
    does not contain a fiberglass sleeve over the pilot/
    thermopile wires.
    7.  Attach the pilot assembly to the Burner Door Assembly.
    8.  Position the new thermopile wires through the top 
    opening of the manifold component block (Figure 27). 
    Be sure that the igniter wire is positioned through the 
    middle opening of the manifold component block.  
    Position the pilot tube through the bottom opening of 
    the manifold component block.
    9.  See “Replacing the Burner Door Assembly” section. 
    NOTE: Use the ferrule nut supplied with the new pilot/
    thermopile assembly when connecting the pilot tube to 
    the gas control valve/thermostat.
    External Inspection & Cleaning of the 
    Flame-trap
    Although not likely to occur, if debris collects on the flame-
    trap, use a vacuum, compressed air, or a soft bristle brush 
    to remove it.  
    NOTE: If unable to inspect or clean the flame trap from 
    underneath, follow the “Cleaning the Combustion Chamber 
    and Flame-trap” section instructions.
    Figure 29
    Flame-trap visual inspection 
    Mirror Flashlight
    Cleaning the Combustion Chamber and 
    Flame-trap
    1.  Follow procedure outlined in “Removing the Burner 
    Door Assembly”.
    2.  Use a vacuum cleaner/shop vac to remove all loose 
    debris in the combustion chamber (Figure 30A). Use 
    compressed air to clear any dust or debris that may 
    have accumulated in the flame-trap.
    3.  Reassemble following the procedure under “Replacing 
    the Burner Door Assembly”.
    Replacing the Burner Door Assembly
    result in death, explosion, or fire.
     
     
    WARNING
    Replace manifold component block if missing
    or removed.
    Replace door gasket if damaged.
    Failure to follow these instructions can Replace viewport if glass is missing or
    damaged.Tighten both burner door screws
    securely.Explosion Hazard
    Remove any fiberglass between gasket
    and combustion chamber.
    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 burner assembly into the burner 
    compartment, making sure that the burner assembly 
    sits firmly against the burner bracket inside the 
    combustion chamber (Figure 30B). 
    IMPORTANT: 
    Do not to scrape or nick the wires during 
    installation.
     
    4.  Inspect the door gasket and make sure there is no 
    fiberglass insulation between the gasket and the 
    combustion chamber.
    5.  Replace the two screws which secure the burner 
    assembly to the combustion chamber and tighten 
    securely. There should be no space between the 
    gasket part of the burner door and combustion 
    chamber. IMPORTANT: Do not operate the water heater  
    						
    							27 if the door gasket does not create a seal between the 
    burner door and the combustion chamber.
    6.  Reconnect the manifold tubing (3/4” wrench), pilot 
    tubing (7/16” wrench), temperature sensor wires, and 
    thermopile wires to the gas control valve/thermostat. 
    (See Figure 22 for the correct position of the thermopile 
    wires.)  Do not cross-thread or apply any thread sealant 
    to the fittings. NOTE: If installing a new pilot tube 
    install the provided ferrule nut in the gas control valve/
    thermostat at the pilot location, hand tight only. Next, 
    insert the pilot tube into the ferrule nut until it bottoms 
    out. Hold the tube in this position. Tighten the ferrule 
    nut with a 7/16” wrench until the crimp connection seals 
    to the pilot tube. Continue to tighten until the nut is tight 
    in the gas control valve/thermostat.     
    7.  Reconnect the igniter wire.
    8.  Turn the main gas supply on and check the gas supply 
    connections for leaks. Use an approved noncorrosive 
    leak detection solution. If such a solution is 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. Correct any 
    leak found. 
    9.  Follow the “Lighting Instructions” on page 17.
    10.  With the pilot and main burner lit, check the manifold 
    tube and pilot tube connections for leaks. Correct 
    any leak found. Use an approved noncorrosive leak 
    detection solution. IMPORTANT: All leaks must be fixed 
    immediately.
    11.  Replace the outer door
    Figure 30A
    Combustion Chamber
    Door GasketBracketFlame-trap
    Figure 30B
    Close-up inside view of the combustion chamber
    Bracket
    Piezoelectric Igniter System
    The piezoelectric igniter system consists of the igniter 
    button, electrode, and wire.  The pilot is ignited by an 
    electric spark generated when the igniter button is pressed.  
    (See Figure 31). Use only factory authorized piezoelectric 
    igniter parts for replacement.
    VAC
    Pilot/Thermopile Bracket
    (Opposite Side)Electrode Thermopile
    Pilot
    Igniter ButtonWire to Electrode Figure 31
    Gas Igniter Assembly
    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 visible spark should jump from the electrode. To avoid 
    shock, do not touch the burner or any metal part on the 
    pilot or pilot assembly. If no spark is visible, check the wire 
    connections and make sure the electrode is not broken. 
    Replace the igniter if defective. Dirt and rust on the pilot or 
    electrode tip can prevent the igniter spark. Wipe clean with 
    a damp cloth and dry completely. Rust can be removed 
    from the electrode tip and metal surfaces by lightly sanding 
    with an emery cloth or fine grit sandpaper. 
    						
    							28
    Flame Guard™ Safety System Operational Checklist
    TROUBLESHOOTING CHART
    4.  Manifold component block properly installed.
    5.  No leaks at pilot and manifold connection.
    6.  Burner door screws securely tightened.  1.  Burner door gasket properly sealed.
    2.  Viewport not damaged or cracked.
    3.  Flame-trap free of debris and undamaged.
    PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION
    BURNER WILL NOT IGNITE 1.  Pilot not lit
    2.  Thermostat set too low
    3. No gas
    4.  Dirt in the gas lines
    5.  Pilot line clogged
    6.  Main burner line clogged
    7. Non-functioning thermopile
    8. Non-functioning thermostat
    9.  Heater installed in a confined area1. Light pilot
    2.  Turn temp. dial to desired temperature
    3.  Check with gas utility company
    4.  Notify utility-install trap in gas line
    5.  Clean, locate source and correct
    6.  Clean, locate source and correct
    7. Replace thermopile
    8. Replace thermostat
    9.  Provide fresh air ventilation
    SMELLY WATER 1.  Sulfides in the water 1.  Replace the anode with a special anode
    BURNER FLAME YELLOW-
    LAZY1.  Insufficient secondary air
    2.  Low gas pressure
    3. Flue clogged
    4.  Main burner line clogged
    5.  Heater installed in a confined area
    6.  Obstruction in main burner orifice1.  Provide ventilation to water heater
    2.  Check with gas utility company
    3.  Clean, locate source and correct
    4.  Clean, locate source and correct
    5.  Proper fresh air ventilation
    6.  Clean or replace orifice
    PILOT WILL NOT LIGHT OR 
    REMAIN LIT1. Non-functioning igniter
    2.  Thermopile connection loose
    3.  Air in gas line
    4.  Proper Lighting Sequence not followed.  
    Gas Control / Temperature Knob was not 
    held in for sufficient time.
    5.  Low gas pressure
    6. No gas
    7.  Dirt in gas lines
    8. Cold drafts1.  Replace igniter pilot assembly
    2.  Seat connector firmly in socket
    3.  Bleed the air from the gas line
    4.  Do not attempt to relight if the red light is lit 
    and the pilot flame is not visible through the 
    view port.  Wait until the red light is no longer 
    lit, then follow lighting instructions on the water 
    heater.
    5.  Check with gas utility company
    6.  Check with gas utility company
    7.  Notify utility-install dirt trap in gas line
    8.  Locate source and correct
    Removing and Replacing the Gas 
    Control Valve/Thermostat
    Removing the Gas Control Valve/Thermostat:
    1.  Turn the gas control/temperature knob  to the “OFF” 
    position (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 on “Draining 
    and Flushing” and follow the procedure.
    4.  Disconnect the igniter wire from the igniter lead wire. 
    Disconnect the temperature sensor wire, then 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 
    control valve/thermostat  (Figure 22). Refer to “Gas 
    Piping” (Figure 3) and disconnect the ground joint union 
    in the gas piping. Disconnect the remaining pipe from 
    the gas control valve/thermostat.
    5.  To remove the gas control valve/thermostat, thread a 4”  
    section of gas pipe into the inlet and use it to turn the 
    gas control valve/thermostat (counterclockwise.) Do not 
    use a pipe wrench or equivalent to grip body.  Damage 
    may result.  Do not insert any sharp objects into the 
    inlet or outlet connections. Damage to the gas control 
    valve/thermostat may result.Gas Control Valve/Thermostat:
    To replace the gas control valve/thermostat, reassemble 
    in reverse order. When replacing the gas control valve/
    thermostat, thread a 4” section of gas pipe into the inlet and 
    use it to turn the gas control valve/thermostat (clockwise.) 
    DO NOT OVER TIGHTEN, damage may result. 
    •  Be sure to use approved Teflon® tape or pipe joint 
    compound on the gas piping connections and fitting on 
    the back of the gas control valve that screws into the 
    tank.
    •  Be sure to remove the pilot ferrule nut from the new gas 
    control valve/thermostat.
    •  Turn the main gas supply on and check the gas supply 
    connections for leaks. Use an approved noncorrosive 
    leak detection solution. If such a solution is 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. Correct any 
    leak found. 
    •  Be sure tank is completely filled with water before 
    lighting and activating the water heater. Follow the 
    “Lighting Instructions” on page 17.
    •  With the pilot and main burner lit, check the manifold 
    tube and pilot tube connections for leaks. Correct any 
    leak found. 
    •  If additional information is required, reference the 
    number on the cover of this manual for service 
    information.
    TEFLON® is a registered trademark of E.I. Du Pont De Nemours and Company. 
    						
    							29
    PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION
    PILOT WILL NOT LIGHT OR 
    REMAIN LIT (continued)9.  ECO switch open
    10.  Pilot line or orifice clogged
    11. Non-functioning thermopile
    12.  Air for combustion obstructed
    13.  Flammable vapors incident, Flame Guard™ 
    function utilized9.  Replace gas control valve/thermostat
    10.  Clean, locate source and correct
    11. Replace thermopile
    12.  See maintenance section for inspection and   
    cleaning of flame trap 
    13.  Replace water heater, eliminate flammable 
    vapors source. Reference the number on the 
    cover of this manual for service information.
    HIGH OPERATION COSTS 1.  Thermostat set too high
    2.  Sediment or lime in tank
    3.  Water heater too small for job
    4.  Wrong piping connections
    5. Leaking faucets
    6. Gas leaks
    7.  Wasted hot water
    8.  Long runs of exposed piping
    9.  Hot water piping in exposed wall1.  Set temperature dial to lower setting
    2.  Drain/flush-provide water treatment if needed
    3.  Install adequate heater
    4.  Correct piping-dip tube must be in cold inlet
    5. Repair faucets
    6.  Check with utility-repair at once
    7. Advise customer
    8. Insulate piping
    9. Insulate piping
    INSUFFICIENT HOT WATER 1.  Thermostat set too low
    2.  Sediment or lime in tank
    3.  Water heater too small
    4.  Wrong piping connections
    5. Leaking faucets
    6.  Wasted hot water
    7.  Long runs of exposed piping
    8.  Hot water piping in outside wall
    9.  Low gas pressure1.  Turn temperature dial to desired setting
    2.  Drain/flush-provide water treatment if needed
    3.  Install adequate heater
    4.  Correct piping-dip tube must be in cold inlet
    5 Repair faucets
    6. Advise customer
    7. Insulate piping
    8. Insulate piping
    9.  Check with gas utility company
    SLOW HOT WATER 
    RECOVERY1.  Insufficient secondary air
    2. Flue clogged
    3.  Low gas pressure
    4. Improper calibration
    5.  Thermostat set too low
    6.  Water heater too small
    7.  Wrong piping connections
    8.  Wasted hot water1.  Provide ventilation to water heater. Check flue 
    way, flue baffle, and burner
    2.  Clean flue, locate source and correct
    3.  Check with gas utility company
    4. Replace thermostat
    5.  Turn temperature dial to desired setting
    6.  Install adequate heater
    7.  Correct piping-dip tube must be in cold inlet
    8. Advise customer
    DRIP FROM RELIEF VALVE 1.  Excessive water pressure
    2. Heater stacking
    3.  Closed water system1.  Use a pressure reducing valve and relief valve
    2.  Lower the thermostat setting
    3.  See “Closed System/Thermal Expansion”
    THERMOSTAT FAILS TO 
    SHUT-OFF1.  Thermostat not functioning properly
    2. Improper calibration1. Replace thermostat
    2. Replace thermostat
    COMBUSTION ODORS 1.  Insufficient secondary air
    2. Flue clogged
    3.  Heater installed in a confined area1.  Provide ventilation to water heater. Check flue
      way, flue baffle, and burner
    2.  Clean, locate source and correct
    3.  Provide fresh air ventilation
    SMOKING AND  CARBON 
    FORMATION (SOOTING)1.  Insufficient secondary air
    2.  Low gas pressure
    3. Flue clogged
    4.  Thermostat not functioning properly
    5.  Heater installed in a confined area
    6.  Burner flame yellow-lazy1.  Provide ventilation to water heater. Check flue 
    way, flue baffle, burner
    2.  Check with gas utility company
    3.  Clean, locate source and correct
    4. Replace thermostat
    5.  Provide fresh air ventilation
    6.  See “Burner Flame Yellow-Lazy”
    CONDENSATION 1.  Temperature setting too low 1.  Increase the temperature setting
    BURNER FLAME FLOATS 
    AND LIFTS  OFF PORTS1.  Orifice too large
    2.  High gas pressure
    3. Flue clogged
    4. Cold drafts1.  Replace with correct orifice
    2.  Check with gas utility company
    3.  Clean flue and burner-locate source and correct
    4.  Locate source and correct
    BURNER FLAME TOO HIGH 1.  Orifice too large 1.  Replace with correct orifice
    PILOT FLAME
    TOO SMALL1.  Pilot line or orifice clogged
    2.  Low gas pressure1.  Clean, locate source and correct
    2.  Check with gas utility company 
    						
    							30
    STATUS LIGHT CODE TROUBLESHOOTING CHART 
    LED STATUS PROBLEM CORRECTIVE ACTION
    0 FLASHES (LED NOT LIT) Pilot light is not lit. Not enough 
    power (millivolts) to keep it lit.Follow the lighting instructions on the front of the 
    water heater and record any diagnostic codes. 
    See Diagnostic Status Light Code section.
    1 FLASH (EVERY 3 SECONDS) Normal operation. No corrective action necessary.
    2 FLASHES Insufficient power (millivolts) to the 
    gas control valve/thermostat.1.  Check all wiring connections. If problem 
    persists proceed to step 2.
    2.  Replace the thermopile. See “Replacing the 
    Pilot/Thermopile Assembly.”
    4 FLASHES High water temperature has 
    activated the over heat sensor.Replace the gas control valve/thermostat. See 
    “Removing and Replacing the Gas Control Valve/
    Thermostat.”
    5 FLASHES Water temperature sensor failure Replace the gas control valve/thermostat. See 
    “Removing and Replacing the Gas Control Valve/
    Thermostat.”
    7 FLASHES Gas Control Valve/Thermostat 
    failure.Replace the gas control valve/thermostat.  See 
    “Removing and Replacing the Gas Control Valve/
    Thermostat.”
    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 pilot valve 
    is stuck in the open position.Make sure that the gas control valve/thermostat 
    knob is set to OFF. Wait one minute. Remove 
    the outer door. Look through the sight glass for 
    a pilot flame. If a pilot flame is observed with the 
    gas control valve/thermostat knob set to the OFF 
    position, the pilot valve is stuck open. Turn the 
    main gas supply OFF. Replace the gas control 
    valve/thermostat. For instructions, see “Removing 
    and Replacing the Gas Control Valve/Thermostat.”
    If the pilot flame is not observed when the gas 
    control valve/thermostat knob is set to the OFF 
    position, wait 10 minutes for the thermopile to cool, 
    then attempt to relight the pilot by following the 
    lighting instructions on the water heater’s label. 
    If this condition returns, replace the gas control 
    valve/thermostat. See “Removing and Replacing 
    the Gas Control Valve/Thermostat” for instructions.
    9 FLASHES Combustion chamber temperature 
    sensor circuit is open or shorted1.  Check all connections. If the problem persists, 
    proceed to step 2.
    2.  Replace the temperature sensor.  
    (Temperature sensor replacement must be 
    performed by a qualified person.)  If the 
    problem persists, proceed to step 3.
    3.  Replace the gas control valve/thermostat.  For 
    instructions, see “Removing and Replacing 
    the Gas Control Valve/Thermostat.”
    10 FLASHES LDO occurrence was detected 
    in the combustion chamber 
    (contaminants)1.  Reset the system by following these steps:  1.) 
    Turn the temperature adjustment knob to OFF.  
    2.) Unplug the thermopile plug from the gas 
    control valve/thermostat.  3.) Wait for about 
    three minutes.  4.) Plug the thermopile plug 
    back into the gas control valve/ thermostat.  
    5.) Turn the temperature adjustment knob to 
    PILOT and restart the water heater as directed 
    in this manual.  If the problem persists, proceed 
    to step 2.
    2.  Follow the procedure outlined in “Cleaning the 
    Combustion Chamber and Flame-Trap.”  
    If the problem persists, proceed to step 3. 
    3.  Shut off the gas supply to the water heater 
    and contact Technical Assistance.  The 
    telephone number is listed on the cover of this 
    manual. 
    						
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