American Water Heater Commercial Gas NonDampered Water Heater CG3275T75 CG32100T77 User Manual

							21
checKInG Gas Input
With	this	heater	 in	operation,	 determine	whether	it	is	 receiving	 the	
full	 rated	 input	of	gas.	 This	 may	be	done	 by	timing	 the	gas	 meter	
and	 measuring	 gas	pressure	 with	a	gauge	 or	manometer.	 When	the	
heater	 is	operating	 at	full	 capacity	 (full	gas	 input)	 it	should	 consume	
approximately	1	cubic	foot	of	gas	in	the	time	shown	in	 Table	5.
table 5. Input checK tIMe requIred 
to consuMe 1 cu. ft . of Gas
Modeltype of Gas btu per 
cu. ft. approx. t
ime required t o 
consume 1 cu. ft. of Gas
75 Natural 
Propane 1050 
2500 50.3	sec.	119.
	8 	sec.
100 Natural 
Propane 1050  
2500 50.3	sec.	119.8
	sec.
Use	 this	formula	 to	“clock”	 the	meter.	 	 Be	sure	 that	other	 gas	
consuming	appliances	are	not	operating	during	this	interval.
  3,600		X		H		=		Btu/Hr
     T
	 T 		=		Time	in	seconds	needed	to	burn	one	cubic	foot	of	gas.
	 H		=		Heating	value	of	gas	in	Btu’s	per	cubic	foot	of	gas.
	 Btu/Hr		=		 Actual	heater	input	rate.
	 Example:
	 T 		=		50.3	seconds/ft
3
	 H		=		1,050	Btu/ft3	(natural	gas)
	 Btu/Hr		=		?
  3,600		X		1,050		=		75,100	Btu/Hr	(22.0	kW)
 50.3
Compare	 the	actual	 input	rate	to	that	 given	 on	the	 heater’s	 rating	
plate.	 In	the	 example,	 the	full	input	 rate	should	 be	75,100	 Btu/Hr	
for	natural	gas.
Because	 of	the	 suddenness 	and	 amount 	of 	water, 	condensation 	
water	 may	be	diagnosed	 as	a	“tank	 leak”.	 After	the	water	 in	the	 tank	
warms	up	(about	1-2	hours),	the	condition	should	disappear.
Do	 not	 assume	 the	water	 heater	 is	leaking	 until	there	 has	been 	
enough	time	for	the	water	in	the	tank	to	warm	up.
An	 undersized	 water	heater	 will	cause	 more	condensation.	 The	water 	
heater	 must	be	sized	 properly	 to	meet	 the	family’s	 demands	 for	hot	
water	 including	 dishwashers,	 washing	machines	 and	shower	 heads.
Excessive	 condensation	 may	be	noticed	 during	the	winter	 and	early	
spring	 months	 when	incoming	 water	temperatures	 are	at	their	 lowest.
Good	 venting	 is	essential	 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.
stranGe sounds
Possible	 noises	due	to	expansion 	and	 contraction	 of	some	 metal	
parts	 during	 periods	 of	heat-up	 and	cool-down	 do	not	 necessarily	
represent	harmful	or	dangerous	conditions.
Condensation	 causes	sizzling	 and	popping	 within	the	burner	 area	
during	 heating	 and	cooling	 periods	 and	should	 be	considered	 normal.		
See	“Condensation”	in	this	section.
operatIonal condItIons
sMell Y w ater
In	each	 water	 heater	 there	is	installed	 at	least	 one	anode	 rod	(see	
parts	 section)	 for	corrosion	 protection	 of	the	 tank.	 Certain	 water	
conditions	 will	cause	 a	reaction	 between	 this	rod	and	 the	water.	
The	 most	 common	 complaint	 associated	 with	the	anode	 rod	is	one	
of	 a	“rotten	 egg	smell”	 in	the	 hot	water.	 This	odor	 is	derived	 from	
hydrogen	 sulfide	gas	dissolved	 in	the	water.	The	smell	is	the	result	
of	four	factors	which	must	all	be	present	for	the	odor	to	develop:
a.		A 	concentration	of	sulfate	in	the	supply	water.
b.		Little	or	no	dissolved	oxygen	in	the	water.
c.		 A 	sulfate	 reducing	 bacteria	which	has	accumulated	 within	the	
water	heater	(this	harmless	bacteria	is	nontoxic	to	humans).
d.		An	 excess	 of	active	 hydrogen	 in	the	 tank.		 This	is	caused	 by	the	
corrosion	protective	action	of	the	anode.
Smelly	 water	may	be	eliminated	 or	reduced	 in	some	 water	 heater 	
models	 by	replacing	 the	anode(s)	 with	one	of	less	 active 	material, 	
and	 then	 chlorinating	 the	water	 heater	 tank	and	all	hot	 water 	
lines.	 Contact	 the	local	 water	 heater	 supplier	 or	service	 agency	
for	 further	 information	 concerning	an	Anode	 Replacement 	Kit 	and 	
this	chlorination	treatment.
If	 the	 smelly	 water	persists	 after	the	anode	 replacement	 and	chlorination 	
treatment,	 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. 
						

							22
(generally	two	weeks	 or	more).	 Hydrogen	 gas	is	extremely 	
flammable	 and	explosive.	 	 To	prevent	 the	possibility	 of	injury 	
under	 these	conditions,	 we	recommend	 the	hot	water	 faucet, 	
located 	farthest 	away, 	be 	opened 	for 	several 	minutes 	before 	
any 	electrical 	appliances 	which	are	connected 	to	the 	hot	water 	
system	 are	used	 (such	 as	a	dishwasher	 or	washing	 machine).	 If	
hydrogen	 gas	is	present,	 there	will	probably	 be	an	unusual	 sound	
similar 	to	air 	escaping 	through	the	pipe 	as	the 	hot	water 	faucet 	
is	 opened.	 There	must	be	no	smoking	 or	open	 flame	 near	the	
faucet	at	the	time	it	is	open.
h IG h water te Mperature shut off s Yste M
This	 water	 heater	 is	equipped	 with	an	automatic	 gas	Shut-off 	
system. 		This	system 	works	when	high	water 	temperatures 	are	
p r e s e n t . 	T h e	h i g h 	t e m p e r a t u r e 	S h u t - o f f	i s	b u i l t 	i n t o	t h e	g a s 	c o n t r o l 	
valve. 		It	is 	non-resettable. 		If	the 	high 	temperature 	Shut-off	
activates,	 the	gas	 control	 valve	must	be	replaced.	 Contact	your	
gas	 supplier	 or	service	 agency.	 Turn	“OFF”	 the	entire	 gas	supply 	
to	the	water	heater. 		
“a Ir ” I n 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 	
perIodIc MaIntenance
ventInG sYsteM InspectIon
At	least	 once	a	 year	 a	visual	 inspection	 should	be 	made 	of	 the	 venting 	
system.	 You	should	look	for:
1. 		 Obstructions	 which	could	cause	 improper	 venting.	The 
	 combustion	and	ventilation	air	flow	must	not	be	obstructed.
2.		 Damage	 or	deterioration	 which	could	 cause	 improper	 venting 
	 or	leakage	of	combustion	products.
3.		 Rusted	flakes	around	top	of	water	heater.
Be	 sure	 the	vent	 piping	 is	properly	 connected	 to	prevent	 escape	
of	dangerous	flue	gases	which	could	cause	deadly	asphyxiation.
Obstructions	 and	deteriorated	 vent	systems	 may	present	 serious	
health	risk	or	asphyxiation.
Chemical	 vapor	corrosion	 of	the	 flue	 and	 vent	 system	 may	occur	
if	 air	 for	 combustion	 contains	certain	chemical	 vapors.	Spray	can	
propellants, 	cleaning	 solvents,	refrigerator	 and	air	conditioner 	
refrigerants,	 swimming	pool	chemicals,	 calcium	and	sodium	 chloride, 	
waxes, 	bleach	 and	process	 chemicals	 are	typical	 compounds	 which	
are	potentially	corrosive.
If	 after	 inspection	 of	vent	 system	 you	found	 sooting	 or	deterioration,	
something	 is	wrong.	 Call	the	local	 gas	utility	 to	correct	 problem	 and	
clean	 or	replace	 the	flue	 and	 venting	 before	resuming	 operation	 of	
water	heater.
burner InspectIon
Flood	 damage	 to	a	water	 heater	 may	not	be	readily	 visible	or	
immediately	 detectable.	However,	over	a	period	 of	time	 a	flooded	
water	 heater	 will	create	 dangerous	 conditions	which	can	cause 	
DEATH, SERIOUS BODIl Y INjURY, OR PROPERTY DAMAGE. 
Contact	 a	qualified	 installer	or	service	 agency	 to	replace	 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	pilot	burner,	see	Figure	19.
You	 should	 check	for	sooting.	 Soot	is	not	 normal	 and	will	impair	
proper	combustion.
Soot	 build-up	 indicates	 a	problem	 that	requires	 correction	 before	
further	 use.		Turn	 “OFF”	 gas	to	water	 heater	 and	leave	 off	until	 repairs 	
are	 made,	 because	 failure	to	correct	 the	cause	 of	the	 sooting	 can	
result	in	a	fire	causing	death,	serious	injury,	or	property	damage.
natural
propane
fIGure 19.
burner cleanInG
If	inspection	 of	the	 burner	 shows	that	cleaning	 is	required,	 turn	
the	 gas	 control	 knob	clockwise	 (		)	 to 	the 	“OFF” 	position, 	
depressing 	slightly.
note:  the knob cannot be turned from “ pIlot ” to “ off” 
unless knob is depressed slightly.  do not force .
Loose	 deposits	 on	or	around	 the	burner	 can	be	removed	 by	carefully 	
using	 the	hose	 of	a	vacuum	 cleaner	inserted	 through	the	access	 door	
of	 the	 water	 heater.	 If	the	 burner	 needs	to	be	 removed	 for	additional	
cleaning,	 call	a	service	 agency	 to	remove	 and	clean	 the	burner	 and	
correct	the	problem	that	required	the	burner	to	be	cleaned. 
						

							23
It	is	 recommended	 that	the	Temperature-Pressure	 Relief	Valve	should 	
be	 checked	 to	ensure	 that	it	is	 in	 operating	 condition	every	6	months.
When	 checking	 the	Temperature-Pressure	 Relief	Valve	operation, 	
make	 sure	that	(1)	no	one	 is	in	 front	 of	or	 around	 the	outlet	 of	the 	
Temperature-Pressure	 Relief	Valve	discharge	 line,	and	(2)	that	 the	
water	 discharge	 will	not	 cause	 any	property	 damage,	 as	the	 water 	
may	 be	extremely	 hot.	Use	 care	 when	 operating	 valve	as	the	 valve 	
may	be	hot.
To	 check	 the	relief	 valve,	 lift	the	 lever	 at	the	 end	 of	the	 valve	 several 	
times, 	see	 Figure	 20.	The	 valve	 should	 seat	properly	 and	operate	 freely.
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	 and	drain	 the	water	 heater,	 see	
Draining	 And	Flushing	 on	page	 25.	Replace	 the	Temperature-
Pressure	 Relief	Valve	with	a	properly	 rated/sized	 new	one,	 see	
Temperature-Pressure	 Relief	Valve	on	page	 11	for	 instructions 	
on	replacement.
DISCHARGE PIPE
TEMPERA TURE-PRESSURERELIEF VA LVE
fIGure 20.
If	the 	Temperature-Pressure 	Relief 	Valve 	on 	the 	water 	heater 	
weeps	 or	discharges	 periodically,	 this	may	 be	due	 to	thermal 	
expansion.
note:	 Excessive	 water	pressure 	is	 the	 most	 common	 cause	of	
Temperature-Pressure	 Relief	Valve	leakage.	 Excessive	 water	
system	 pressure	 is	most	 often	 caused	 by	“thermal	 expansion”	
in	 a	“closed	 system.”	 See	Closed	 Water	Systems	 and	Thermal	
Expansion	 on	page	 10.	The	 Temperature-Pressure	 Relief	Valve	is	
not	intended	for	the	constant	relief	of	thermal	expansion.
Temperature-Pressure	 Relief	Valve	leakage	 due	to	pressure	 build	
up	 in	a	closed	 system	 that	does	 not	have	 a	thermal	 expansion	
tank	 installed	 is	not	 covered	 under	the	limited	 warranty.	 Thermal	
expansion	tanks	must	be	installed	on	all	closed	water	systems.
do not pluG the teMperature-pressure relIef 
v alve openInG. thIs can cause propertY  daMaGe,  
serIous Injur Y or death.
Explosion Hazard
Te mperature-Pressure Relief  Valve
must comply with  ANSI Z21.22-
CSA 4.4 and  ASME code.
Properly sized temperature-
pressure relief valve must be
installed in opening provided .
Can result in overheating and
excessive tank pressure .
Can cause serious injury or death.
recoMMended procedure for perIodIc  
reMoval  of lIMe deposIts froM tanK tYpe  
coMMercIal  water heaters
The	amount	 of	calcium	 carbonate	 (lime)	released	 from	water	 is	in	
direct	 proportion	 to	water	 temperature	 and	usage,	 see	chart.	 The	
higher	 the	water	 temperature	 or	water	 usage,	 the	more	 lime	deposits 	
are	dropped	out	of	the	water.	 This	is	the	lime	scale	which	forms	in 	
pipes,	heaters	and	on	cooking	utensils.
houseKeepInG
Fire and Explosion Hazard
Do  not  obstruct combustion air 
openings at the bottom of the 
water heater .
Do not use or store flammable vapor
products such as gasoline, solvents
or adhesives in the same room or area  
near water heater or other appliance.
C an cause serious injury or death.
Vacuum	 around	base	of	water	 heater	 for	dust,	 dirt,	and	 lint	on	a	
regular	basis.
INSTALLED	 IN	SUITABLE	 AREA:	To	insure	 sufficient	 ventilation 	
and	 combustion	 air	supply,	 proper	clearances	 from	the	water	 heater	
must	 be	maintained.	 See	“Locating	 the	New	 Water	 Heater”	 section.	
Combustible	 materials	such	as	clothing, 	cleaning	 materials, 	or 	
flammable	 liquids,	etc.	must	 not	be	placed	 against	 or	adjacent	 to	
the	water	heater	which	can	cause	a	fire.
anode rod InspectIon
Property Damage Hazard
• Av oid water heater damage.
• Inspection and replacement of anode rod required .
CAUTION
The	anode	 rod	is	used	 to	protect	 the	tank	 from	 corrosion.	 Most	hot	
water	 tanks	are	equipped	 with	an	anode	 rod.	The	 submerged	 rod	
sacrifices	 itself	to	protect	 the	tank.	 Instead	 of	corroding	 the	tank,	
water	 ions	attack	 and	eat	away	 the	anode	 rod.	This	 does	 not	affect	
water’s	 taste	or	color.	 The	rod	must	 be	maintained	 to	keep	 the	tank	
in	operating	condition.
Anode	 deterioration	 depends	on	water	 conductivity,	 not	necessarily	
water	 condition.	 A	corroded	 or	pitted	 anode	 rod	indicates	 high	water	
conductivity	 and	should	 be	checked	 and/or	replaced	 more	often	than		
an	 anode 	rod	 that	 appears	 to	be	 intact.	 Replacement	 of	a	depleted	
anode	 rod	can	 extend	 the	life	of	your	 water	 heater.	 Inspection	 should	
be	 conducted	 by	a	 qualified	 service	agency, 	and	 at	a	 minimum 	should 	
be	checked	annually	after	the	warranty	period.
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.
teMperature-pressure relIef v alve test
Burn hazard.
Hot water discharge. Keep clear of  Temperature-
Pressure Relief V alve
discharge outlet. 
						

							24
Lime	accumulation	 not	only	 reduces	 the	life	of	the	 equipment	 but	
also	 reduces	 efficiency	 of	the	 heater	 and	increases	 fuel	consumption.
The	 usage	 of	water	 softening	 equipment	 greatly	reduces	 the	
hardness	 of	the	 water.	 However,	 this	equipment	 does	not	always	
remove	 all	of	the	 hardness	 (lime).	For	this	 reason	 it	is	 recommended 	
that	a	regular	schedule	for	deliming	be	maintained.
The	 time	 between	 cleaning	will	vary	 from	 weeks	 to	months	 depending 	
upon	water	conditions	and	usage.
The	 depth	 of	lime	 buildup	 should	be	measured	 periodically.	 Heaters	
equipped	 with	cleanouts	 will	have	 about	 2”	of	lime	 buildup	 when	
the	 level	 of	lime	 has	reached	 the	bottom	 of	the	 cleanout	 opening.	 A	
schedule	 for	deliming	 should	then	be	set	 up,based	 on	the	 amount	
of	 time	 it	would	 take	for	a	1”	 buildup	 of	lime.	 It	is	 recommended	 that	
the	water	heater	initially	be	inspected	after	6	months.
Example	1:
Initial	 inspection	 after	6	months	 shows	1/2”	of	lime	 accumulation.	
Therefore,	the	heater	should	be	delimed	once	a	year.
Example	2:
Initial	inspection	after	6	months	shows	2”	of	lime	accumulation.
Therefore,	the	heater	should	be	delimed	every	3	months.
fIGure 21.
delIMInG solvents
UN•LIME	 is	recommended	 for	deliming.	 UN•LIME	 is	a	patented 	
food	 grade	 acid	which	 is	safe	 to	handle	 and	does	 not	create	 the	
harmful	fumes	which	are	associated	with	other	products.
UN•LIME	 may	be	obtained	 from	your	dealer,	 distributor	 or	water 	
heater	 manufacturer.	 Order	Part	Number	 9005416105,	 1	gallon, 	
packed	 4	gallons	 per	case	 or	Part	 Number	 9005417105,	 5	  
gallon	container.
note:	Un•Lime	is	not	available	for	use	in	Canada.
Hydrochloric	 base	acids	 are	not	recommended	 for	use	 on	glass 	
lined tanks.
Observe	handling	instructions	on	label	of	product	being	used.
tanK cleanout procedure
The	 following	 practices	 will	ensure	 longer	life	and	 enable	 the	unit	 to	
operate	at	its	designed	efficiency:
1.	 Once 	a	 month	 the	heater	 should	 be	flushed.	 Open	the	drain 	valve 	
and	 allow	 two	gallons	 of	water	 to	drain 	from	 the	heater.	 Inlet	water 	
valve	should	remain	open	to	maintain	pressure	in	tank.
2.	 A 	cleanout	 opening	is	provided	 for	periodic	 cleaning	 of	the	 tank.		
Gas	 must	 be	shut	 off	and	 heater	 drained	 before	opening	 cleanout.
To	clean	heater	through	cleanout	opening,	proceed	as	follows:
1.	 Drain	heater.
2.	 Remove	outer	cover	plate	from	lower	side	of	heater	jacket.
3.	 Remove	 six	(6)	hex	 head	 screws	 securing	 tank	cleanout	 plate	
and	remove	plate.
4.	 Remove	 lime,	scale,	 or	sediment	 using	care	not	to	damage	 the	
glass	lining.
5.	 Inspect 	cleanout 	plate	 gasket, 	if 	new	 gasket 	is 	required, 	see 	
replacement	parts	list	for	item	number.
6.	 Install	 cleanout	plate.		Be	 sure	 to	draw	 plate	up	tight 	by	 tightening 	
screws	securely.
7.	 Replace	outer	jacket	cover	plate.
fIGure 22.
9.	 In	 some	 water	 areas	 the	sediment	 might	not	be	removed 	
by	 this	 method	 and	may	 result	 in	the	 water	 heater	 making	
rumbling	 or	boiling	 noises. 	To	 dissolve	 and	remove	 these	more	
stubborn	 mineral	deposits,	 UN•LIME	 Professional	 Delimer	
should	be	used.
delIMInG usInG flo-juG Method
UN•LIME	 in	the	 5	gallon	 size	is	recommended	 for	deliming	 of	the	
BT-75	 and	100	models.	 UN•LIME	 with	the	necessary	 hoses	and	
fittings	 to	delime	 your	heater	 is	also	 available	 as	a	kit:	 Up-N-Down	
Transfer	 Kit.	Contact	 your	local	 dealer,	 distributor	 or	water	 heater	
manufacturer.
prepare the w ater heater
To	delime	 the	water	 heater	 using	the	Flo-Jug	 method,	 first	prepare	
the	heater	for	deliming.
prepare the up-n-down transfer KIt
The	 next	 step	is	the	 preparation	 on	the	 Up-N-Down	 Transfer	Kit,	if	
you	have	not	already	done	so:
1.	 With	 the	5	gallon	 Up-N-Down	 container	in	the	 vertical	 position,	
unscrew	 the	plastic	 vent	cap	in	the	 handle	 and	pierce	 the	
plastic	 membrane	 over	the	vent	 boss	 under	 the	cap	 to	allow	 the	
container	to	vent.
  note:	 	 If	your	 container	 does	not	have	 the	vent	 cap	and	 vent	
boss,	 drill	a	3/16”	 (4.76mm)	 hole	in	the	 handle.		 When	you	have	
finished	 deliming	 you	will	be	able	 to	plug	 this	drilled	 vent	with	the	
stainless	steel	screw	that	is	supplied	with	the	kit.
2.	 Remove	 the	container’s	 cap	and	 cut	plastic	 membrane	 located	in	
the	 3/4”	 IPT	opening	 in	cap.		 Take	 care	to	not	 damage	 the	threads.
3.	 Find	 the	3/4”	 male	 adapter,	 apply	teflon	 tape	to	the	 threaded	 end	
and	screw	it	into	the	3/4”	IPT 	opening	in	the	cap. 
						

							25
4.	 Put	cap	with	 male	 adapter	 back	on	the	 container	 and	slide	 3/4”	
hose	 over	end	of	male	 adapter	 and	fasten	 in	place	 using	hose	
clamp	provided.
delIMe usInG flo-juG Method
5.	 Slide	 the	hose	 clamp	 over	end	of	hose	 and	slide	 hose	 over	the	
male	 adapter	 in	the	 water	 heater	 drain	opening	 and	secure	 in	
place	using	hose	clamp.
6.	 Lift	 container	 to	the	 “Pour”	 Position	 being	careful	 to	keep	 the	vent	
in	 the	 handle	 above	the	liquid	 level	and	pour	 the	UN•LIME	 into	
the	heater.
7.	 Lower	 container,	 you	may	 have	 to	place	 the	container	 on	its	empty 	
carton	 to	prevent 	the	 UN•LIME	 from	flowing	 back	into	the	container.
8.	 Let	 UN•LIME	 remain	in	the	 heater	 for	5	minutes	 and	then	 lower	
the	container	to	the	“Drain”	Position.
9.	 Deliming	 activity	is	indicated	 by	foaming	 on	the	 surface	 of	the	
UN•LIME.		If	there	is	deliming	activity,	repeat	steps	6	thru	8.
Normally,	 lime	removal	 will	be	completed	 within	one	hour.	 Severe	
build-up	 of	lime	 may	 take	longer	 than	an	hour	 to	complete	 descaling.
Note:	 To	check	 UN•LIME	 for	continued	 use,	place	 some	 scale	or	white 	
chalk	 in	a	glass	 with	a	small	 amount	 of	UN•LIME.	 If	the	 material	 is	
vigorously	 dissolved	by	the	 UN•LIME,	 it	can	 be	reused;	 if	not,	 the	
UN•LIME	should	be	replaced.
If	 the	 temperature-pressure	 relief	valve	 on	the	 appliance	 weeps	
or	 discharges	 periodically,	 this	may	 be	due	 to	thermal	 expansion. 	
You	 may	 have	 a	check	 valve	installed	 in	the	 water	 line	or	a	water 	
meter 	with	 a	check 	valve. 	Consult 	your 	local	 water	supplier 	or 	
service 	agency	 for		further	 information.	 Do	not	 plug	 the	temperature-
pressure	relief	valve.
draInInG and  flushInG
It	is	 recommended	 that	the	water	 heater	 storage	 tank	be	
drained	 and	flushed	 every	6	months	 to	reduce	 sediment	
buildup.	 The	water	 heater	 should	 be	drained	 if	being	 shut	down	
during	 freezing	 temperatures.	 See	Features	 And	Components	
in	 this	 manual	 for	the	 location	 of	the	 water	 heater	 components	
described	below.
Burn harzard.
Hot water discharge.
Keep  hands   clear  of  drain
valve  discharge.
t o draIn the water heater storaGe tanK:
1.  Turn	off	the	electrical	supply	to	the	water	heater.
2.  Turn	 off	the	 gas	 supply	 at	the	 Main	 Gas	Shutoff	 Valve	if	the 	
water	 heater	 is	going	 to	be	 shut	 down	 for	an	extended	 period.	
3.  Ensure	the	cold	water	inlet	valve	is	open.
4.  Open	 a	nearby	 hot	water	 faucet	 and	let	the	 water	 run	until	
the	water	is	no	longer	hot.
5.  Close	the	cold	water	inlet	valve	to	the	water	heater.
6. Connect	 a	hose	 to	the	 water	 heater	 drain	valve	 and	
terminate	it	to	an	adequate	drain.
7.  Open	 the	water	 heater	 drain	valve	 and	allow	 all	the	 water	 to	
drain	from	the	storage	tank.
8.  Close	 the	water	 heater	 drain	valve	 when	 all	water	 in	the	
storage	tank	has	drained.
9.  Close	the	hot	water	faucet	opened	in	Step	4.
10.  If	the	 water	 heater	 is	going	 to	be	 shut	 down	 for	an	extended	
period,	the	drain	valve	should	be	left	open.
t o flush the w ater heater storaGe t anK:
1.  Turn	off	the	electrical	supply	to	the	water	heater.
2.  Ensure	the	cold	water	inlet	valve	is	open.
3.  Open	 a	nearby	 hot	water	 faucet	 and	let	the	 water	 run	until	
the	 water	 is	no	 longer	 hot.	Then	 close	 the	hot	water	 faucet.
4.  Connect	 a	hose	 to	the	 drain	 valve	 and	terminate	 it	to	 an	
adequate drain.
5.  Ensure	 the	drain 	hose	 is	secured	 before	and	during	 the	
entire	 flushing	 procedure.	 Flushing	is	performed	 with	
system	water	pressure	applied	to	the	water	heater.	
6.  Open	 the	water	 heater	 drain	valve	 to	flush	 the	storage	 tank.	
7.  Flush	 the	water	 heater	 storage	 tank	to	remove	 sediment	
and	allow	the	water	to	flow	until	it	runs	clean.
8.  Close	 the	water	 heater	 drain	valve	 when	 flushing	 is	
completed.
9.  Remove	the	drain	hose.
10.  Fill	the	 water	 heater	 -	see	 Filling	 The	Water	 Heater	 in	this	 manual.
11.  Turn	 on	the	 electrical	 supply	to	place	 the	water	 heater	 back	
in operation.
12.  Turn	 on	the	 gas	 supply	 to	the	 water	 heater	 at	the	 Main	 Gas	
Shutoff	Valve.
13.  Allow	 the	water	 heater	 to	complete	 several	heating	 cycles	
to	ensure	it	is	operating	properly.
servIce
Before	 calling	for	repair	 service,	 read	the	“Start	 Up	Conditions”	 and	
“Operational	 Conditions”	found	in	the	 “For	 Your	 Information”	 section	
of	this	manual.
If	 a	 condition	 persists	or	you	 are	uncertain	 about	the	operation	 of	the 	
water	 heater	 contact 	a	 service	 agency. 	If 	you	 are	not	thoroughly 	familiar 	
with	 gas	codes,	 your	water	 heater,	 and	safety	 practices,	 contact	your	
gas	supplier	or	qualified	installer	to	check	the	water	heater.
Use	 the	”Leakage	 Checkpoints”	 guide	to	check	 a	“Leaking” 	  
water	 heater.		 Many	suspected	 “Leakers”	are	not	leaking	 tanks.		Often	
the	source	of	the	water	can	be	found	and	corrected.
Read	 this	manual	 first.	Then	 before	 checking	 the	water	 heater	 make	
sure	 the	gas	 supply	 has	been	 turned	 “OFF”,	 and	never	 turn	the	gas	
“ON”	before	the	tank	is	completely	full	of	water.
Never	 use	this	water	 heater	 unless	it	 is	 completely	 filled	with	water.		
To	 prevent	 damage	 to	the	 tank,	 the	tank	 must	 be	filled	 with	water.		
Water	 must	flow	from	 the	hot	water	 faucet	 before	 turning	 “ON”	gas	
to	the	water	heater.
Read	 this	manual	 first.	Then	 before	 checking	 the	water	 heater	 make	
sure	 the	gas	 supply	 has	been	 turned	 “OFF”,	 and	never	 turn	the	gas	
“ON”	before	the	tank	is	completely	full	of	water.
Never	 use	this	water	 heater	 unless	it	 is	 completely	 filled	with	water.		
To	 prevent	 damage	 to	the	 tank,	 the	tank	 must	 be	filled	 with	water.		
Water	 must	flow	from	 the	hot	water	 faucet	 before	 turning	 “ON”	gas	
to	the	water	heater. 
						

							26
leaKaGe checKpoInts
A.	 Water	at	the	 draft	 hood	 is	water	 vapor	 which	 has	condensed	 out	
of	 the	 combustion 	products.		 This	is	caused	 by	a	problem	 in	the	
vent.	Contact	the	gas	utility.
B.		*Condensation	 may	be	seen	 on	pipes	 in	humid	 weather	 or	pipe	
connections	may	be	leaking.
C.		*The	anode	rod	fitting	may	be	leaking.
D.		Small	 amounts	of	water	 from	temperature-pressure	 relief	valve	
may	 be	due	 to	thermal	 expansion	 or	high	 water	 pressure	 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	vapor	 which	 can	condense	
on	 the	 cooler	 surfaces	 of	the	 tank.		 Droplets	 form	and	drip	onto	
the	 burner	 or	run	 on	the	 floor.	 	 This	is	common	 at	the	 time	 of	
start-up	after	installation	and	when	incoming	water	is	cold.
I.		 Water	 in	the	 water	 heater	 bottom	 or	on	 the	 floor	 may	be	from	
condensation,	 loose	connections,	 or	the	 relief	 valve.		 DO	NOT 	
replace	 the	water	 heater	 until	a	full	 inspection	 of	all	 possible	 water	
sources	is	made	and	necessary	corrective	steps	taken.
Leakage	 from	other	 appliances, 	water	 lines,	or	 ground	 seepage 	
should	also	be	checked.
*	 To	 check	 where	 threaded	 portion	enters	tank,	insert	 cotton	
swab	 between	 jacket	opening	 and	fitting.		 If	cotton	 is	wet,	 follow	
“Draining” 	instructions 	in	 the	 “Periodic 	Maintenance” 	section	 and	
then	 remove	 fitting.		Put	pipe	 dope	 or	teflon	 tape	on	the	 threads	
and	 replace.		 Then	follow	 “Filling	 the	Water	 Heater”	 instructions	
in	the	“Installing	the	New	Water	Heater”	section. 
						

							27
troubleshootInG GuIdelInes
These	guidelines	should	be	utilized	by	a	qualified	service	agent.
	 Problem cause Solution
WATER lEAkSImproperly	sealed,	hot	or	cold	supply	connection,	relief	
valve,	drain	valve,	or	thermostat	threads.
Tighten	threaded	connections.
Leakage	from	other	appliances	or	water	lines. Inspect	other	appliances	near	water	heater.
Condensation	of	flue	products. Refer	to	CONDENSATION.
lEAkING T&P VAl VEThermal	expansion	in	closed	water	system.
Install	thermal	expansion	tank	(DO	NOT	plug	T&P	valve).
Improperly	seated	valve. Check	relief	valve	for	proper	operation
	
(DO	NOT 	plug	T&P	valve).
SMEll Y WATER High	sulfate	or	mineral	content	in	water	supply.
Drain	and	flush	heater	thoroughly,	then	refill.
Bacteria	in	water	supply. Chlorinate	or	aerate	water	supply.
PIlOT WIll  NOT lIGHT Gas	control	knob	not	positioned	correctly.
Refer	to	LIGHTING	INSTRUCTIONS.
Main	gas	supply	off. Turn	on	main	gas	shutoff	valve.
Thermocouple	malfunction. Replace	pilot	assembly	and/or	thermocouple.
Match	not	close	to	pilot Locate	pilot,	move	match	closer.
BURNER WIll  NOT 
STAY lIT Thermocouple	malfunction.
Replace	pilot	assembly	and/or	thermocouple.
Defective	Gas	Control. Replace	Gas	Control.
PIlOT OUTAGE Dirty	pilot	burner.
Clean	pilot	assembly.
Thermocouple	malfunction. Replace	pilot	assembly	and/or	thermocouple.
Defective	Gas	Control. Replace	Gas	Control.
Thermocouple	tip	is	not	in	contact	with	pilot	flame. Insert	thermocouple	correctly.
NOT ENOUGH   HOT WATER Heater	not	lit	or	thermostat	not	on.
Refer	to	LIGHTING	INSTRUCTIONS.
Thermostat	set	too	low. Refer	to	TEMPERATURE	REGULATION.
Heater	undersized. Reduce	hot	water	use.
Low	gas	pressure. Contact	your	gas	supplier.
Incoming	water	is	unusually	cold. Allow	more	time	for	heater	to	re-heat.
Leaking	hot	water	pipes	or	fixtures. Have	plumber	check	and	repair	leaks.
High	temperature	limit	switch	activated. Contact	a	service	agency	to	determine	cause.
WATER TOO HOT Thermostat	set	too	high. Refer	to	TEMPERATURE	REGULATION.
WATER HEATER SOUNDSCondensation	dripping	on	burner. Refer	to	CONDENSATION.
SIZZLING	OR 	
RUMBlING Sediment	or	calcium	in	bottom	of	heater	tank.
Clean	sediment	from	tank.		Refer	to	DRAINING
	
instructions	in	Maintenance	section	of	manual.
SOOTING Improper	combustion. No	adjustment	available.	Contact	a	service	agency
	
to	determine	cause.
VENT GAS ODORS Lack	of	supply	air.
Contact	a	service	agency	to	determine	cause.
Improperly	installed	vent	piping.
Downdraft.
Poor	combustion. 
						

							28
water pIpInG dIaGraMs
NOTES:
1.  Preferred piping diagram .
2.  The temperature and pressure relief valve setting shall not exceed press\
ure rating of any component in the system .
3.  Service valves are shown for servicing unit. Howeve r, local codes shall govern their usage.4.  The  Tank  Temperature Control should be wired to and control the pump between the wa\
ter heater(s) and the storage tank(s).SINGLE FL UE - (1 UNIT)
LEGEND
TEMPERA TURE & PRESSURE
RELIEF VA LVEPRESSURE RELIEF VA LVECIRCUL ATING PUMPTANK  TEMPER ATURE CONTRO LDRAIN
FULL PORT BALL  VALV
E
TEMPERA TURE GAGEWATER FLOW SWITCH
CHECK VA
LVE
WA RNING:  THIS DR AWING SHOWS SUGGESTEDPIPING CONFIGURAT ION AND OTHER DEVICES;
CHECK WITH LOCAL CODES  AND ORDINANCES
FOR  ADDITIONAL  REQUIREMENTS.
FINISHED
FLOORHO
C
TO LD
COLD
EXPANSION
TANK
COLD WATER
SUPPLY
PIPE T&P TO
OPEN DRAIN 
						

							29
NOTES:
1 .  Pref erred  piping  diagram.
2 .  The t emperat ure and  pressure  relief valve  setting  shall not exceed  pressure  rating  of  any  component  in the  syst em.
3 .  Servic e v alv es  are s hown f or serv icing  unit. However , local  codes  shall govern t heir usage.
4 .  The  Tank  Temperat ure Cont rol should  be wired t o and  control the pump  between t he wat er heat er(s)  and the storage t ank(s).
5 .  The  wat er heat er’s  operat ing thermost at  should  be set  5 degrees F higher t han the Tank  Temperat ure Cont rol.SINGLE F LUE  - (1 UNIT) WITH VE RTICAL  STORAGE  TANK
LEGEND
TEMPERA TURE & PRESSURE
RELIEF V ALVEPRESSURE RELIEF V ALVECIRCULA TING PUMPTA NK  TEMPER AT URE CO NTR O LDRAIN
FULL  PORT BALL  VAL VETEMPERA TURE GAGEW ATER FLOW SWITCH
CHECK V
ALVE
W ARNING:  THIS DRAW ING SHOWS SUGGESTEDPIPING CONFIGURA TION  AND OTHER DEVICES;
CHECK WITH LOCAL  CODES AND ORDINANCES
FOR  ADDITIONA L REQUIREMENTS.
FINISHED
FLOOR HOT
COLD
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
RETURN FROM 
FIXTURES
HOT WATER
TO FIXTURES
ALT. COLD
WATER CONNECTION
PIPE T&P TO
OPEN DRAIN 
						

							30
NOTES:
1 .  Pref erred  piping  diagram.
2 .  The t emperat ure and  pressure  relief valve  setting  shall not exceed  pressure  rating  of  any  component  in the  syst em.
3 .  Servic e v alv es  are s hown f or serv icing  unit. However , local  codes  shall govern t heir usage.
4 .  The  Tank  Temperat ure Cont rol should  be wired t o and  control the pump  between t he wat er heat er(s)  and the storage t ank(s).
5 .  The  wat er heat er’s  operat ing thermost at  should  be set  5 degrees F higher t han the Tank  Temperat ure Cont rol.SINGLE F LUE  - (1 UNIT) WITH HORIZON TAL  ST ORAGE  TANK
LEGEND
TEMPERA TURE & PRESSURE
RELIEF V ALVEPRESSURE RELIEF V ALVECIRCULA TING PUMPTA NK  TEMPER AT URE CO NTR O LDRAIN
FULL  PORT BALL  VAL VETEMPERA TURE GAGEW ATER FLOW SWITCH
CHECK V
ALVE
W ARNING:  THIS DRAW ING SHOWS SUGGESTEDPIPING CONFIGURA TION  AND OTHER DEVICES;
CHECK WITH LOCAL  CODES AND ORDINANCES
FOR  ADDITIONA L REQUIREMENTS.
FINISHED
FLOOR HOT
COLD
EXPANSION
TANKCOLD WATER
SUPPLYHOT WATER
RETURN FROM 
FIXTURES
HOT WATER
TO FIXTURES
ALTERNATE
LOCATION
PIPE T&P TO
OPEN DRAIN