AO Smith Water Heater 185874 001 User Guide
Instruction Manual  
resIdentIal Gas water heaters  
FOR USE ONLY IN MANUFACTURED HOMES  
GAMA certification applies  
to all residential gas water  
heaters with capacities of 20  
to 100 gallons with input rating  
of 75,000 BTU/Hr. or less.  
C3 Technology® Gas Water Heaters meet the new ANSI Z21.10.1  
standard that deals with the accidental or unintended ignition of  
flammable vapors, such as those emitted by gasoline.  
• for Your safety •  
AN ODORANT IS ADDED TO THE GAS USED  
BY THIS WATER HEATER.  
all technIcaland warrantY questIons: SHOULD BE DIRECTED TO THE LOCALDEALER FROM WHOM THE WATER HEATER WAS  
PURCHASED. IF YOUARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.  
Keep thIs Manual In the pocKet on heater for future reference  
whenever MaIntenance adjustMent or servIce Is requIred.  
PRINTED 0807  
185874-001  
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safe InstallatIon, use and servIce  
Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.  
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and  
others of a potential injury hazard. read and obey all safety messages and instructions throughout this manual. It is very important  
that the meaning of each safety message is understood by you and others who install, use or service this water heater.  
this is the safety alert symbol. It is used to alert you  
to potential personal injury hazards. obey all safety  
messages that follow this symbol to avoid possible  
injury or death.  
danGerindicatesanimminentlyhazardous  
situation which, if not avoided, could result  
in death or injury.  
danGer  
warnInG indicates a potentially hazardous  
situation which, if not avoided, could result  
in death or injury.  
warnInG  
cautIon indicates a potentially hazardous  
situation which, if not avoided, may result  
in minor or moderate injury.  
cautIon  
cautIon used without the safety alert  
symbol indicates a potentially hazardous  
situation which, if not avoided, could result  
cautIon  
in property damage.  
all safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and  
how to avoid the risk of injury.  
the california safe drinking water and toxic enforcement act requires the Governor of california to publish a list of substances  
known to the state of california to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of  
potential exposure to such substances.  
this product contains a chemical known to the state of california to cause cancer, birth defects, or other reproductive harm. this  
appliance can cause low level exposure to some of the substances listed, including formaldehyde, carbon monoxide and soot.  
IMportant defInItIons  
•
•
Qualified Installer: Aqualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing,  
air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas  
Code as it relates to the installation of gas fired water heaters. The qualified installer must also be familiar with the  
design features and have a thorough understanding of this instruction manual.  
service agency: Aservice agency also must have ability equivalent to a licensed tradesman in the fields of plumbing,  
air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas  
Code as it relates to the installation of gas fired water heaters. The service agency must also have a thorough  
understanding of this instruction manual, and be able to perform repairs strictly in accordance with the service guidelines  
provided by the manufacturer.  
•
Gas supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning  
appliances within this application. The gas supplier typically has responsibility for the inspection and code approval of  
gas piping up to and including the Natural Gas meter or Propane storage tank of a building. Many gas suppliers also  
offer service and inspection of appliances within the building.  
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General safetY  
3
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taBle of contents  
SAFE INSTALLATION, USE AND SERVICE............................2  
GENERAL SAFETY..................................................................3  
TABLE OF CONTENTS............................................................4  
INTRODUCTION......................................................................4  
Preparing for the New Installation.....................................4  
TYPICAL INSTALLATIONS .................................................. 5-6  
LOCATING THE NEW WATER HEATER.................................7  
Facts to Consider About Location................................. 7-8  
Insulation Blankets............................................................8  
INSTALLING THE NEW WATER HEATER ........................ 9-18  
Securing Water Heater to Floor and Wall .........................9  
T & P Valve and Pipe Insulation........................................9  
Water Piping ............................................................... 9-10  
Water Piping Pressure Test.............................................10  
Temperature Pressure Relief Valve ...........................10-11  
Filling the Water Heater .............................................11-12  
Venting...................................................................... 12-13  
Gas Piping ................................................................ 13-14  
Sediment Traps...............................................................14  
White-Rodgers Fuel Conversion Instructions  
RobertShaw Fuel Conversion Instructions  
from Propane (L.P.) to Natural Gas........................... 16-18  
RobertShaw Fuel Conversion Instructions  
from Natural Gas to Propane (L.P.) Gas.........................18  
WHITE-RODGERS GAS VALVE............................................19  
ROBERTSHAW GAS VALVE .................................................20  
INSTATLLATION CHECKLIST ...............................................21  
TEMPERATURE REGULATION ............................................22  
FOR YOUR INFORMATION............................................. 23-24  
Start Up Conditions.........................................................23  
Operational Conditions ............................................. 23-24  
PERIODIC MAINTENANCE............................................. 25-27  
Venting System Inspection..............................................25  
Burner Inspection............................................................25  
Burner Cleaning..............................................................25  
Housekeeping.................................................................25  
Anode Rod Inspection.....................................................26  
Temperature-Pressure Relief Valve Operation ...............26  
Draining..................................................................... 26-27  
Drain Valve Washer Replacement..................................27  
Service............................................................................27  
LEAKAGE CHECKPOINTS....................................................28  
REPAIR PARTS................................................................ 29-30  
TROUBLESHOOTING GUIDELINES.....................................31  
WARRANTY......................................................................Insert  
from Natural Gas to Propane (L.P.) Gas................... 14-16  
White Rodgers Fuel Conversion Instructions  
from Propane (L.P.) to Natural Gas.................................16  
IntroductIon  
thank You for purchasing this water heater. Properly installed and  
Instruction for replacement installation:  
maintained, it should give you years of trouble free service.  
The installation must conform with these instructions and the local  
code authority having jurisdiction. In the absence of local codes,  
installations shall comply with the National Fuel Gas Code ANSI  
Z223.1/NFPA54, current edition. This publication is available from  
theCanadianStandardsAssociation,8501EastPleasantValleyRd.,  
Cleveland Ohio 44131, orThe National Fire ProtectionAssociation,  
1 Batterymarch Park, Quincy, MA 02269.  
Abbreviations Found In This Instruction Manual:  
•
•
•
•
•
CSA - Canadian Standards Association  
ANSI - American National Standards Institute  
NFPA - National Fire Protection Association  
ASME - American Society of Mechanical Engineers  
GAMA - Gas Appliance Manufacturer’s Association  
3. If after reading this manual you have any questions or do not  
understand any portion of the instructions, call the local gas utility  
or the manufacturer whose name appears on the rating plate.  
Thisgas-firedwaterheaterisdesigncertifiedbyCSAINTERNATIONAL  
under American National Standard/CSA Standard for Gas Water  
Heaters for Manufactured Home Installation, ANSI Z21.10.1 • CSA  
4.1 (current edition).  
4. Carefully plan the place where you are going to put the water  
heater. Correct combustion, vent action, and vent pipe installation  
are very important in preventing death from possible carbon  
monoxide poisoning and fires, see Figures 1 and 2.  
preparInG for the InstallatIon  
1. Read the “General Safety” section, page 3 of this manual first and  
then the entire manual carefully. If you don’t follow the safety rules,  
the water heater will not operate properly. It could cause DEATH,  
SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.  
Examine the location to ensure the water heater complies with  
the “Locating the New Water Heater” section in this manual.  
5. For California installation this water heater must be braced,  
anchored, or strapped to avoid falling or moving during an  
earthquake. See instructions for correct installation procedures.  
Instructions may be obtained from California Office of the State  
Architect, 400 P Street, Sacramento, CA 95814.  
This manual contains instructions for the installation, operation, and  
maintenance of the gas-fired water heater. It also contains warnings  
throughoutthemanualthatyoumustreadandbeawareof.Allwarnings  
and all instructions are essential to the proper operation of the water  
heater and your safety. Since we cannot put everything on the first  
few pages, read the entIre Manual BeforeatteMptInG  
to Install or operate the water heater.  
6. 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.  
2. Instructions to Manufactured Home Manufacturers:  
The installation must conform with the Manufactured Home  
Construction and Safety Standards Title 24 CFR, Part 3280.  
7. Complies with SCAQMD rule #1121 and districts having equivalent  
NOx requirements.  
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tYpIcal InstallatIons  
Get to Know Your water heater - Gas Models  
a
B
c
d
e
f
G
h
I
vent pipe  
drafthood  
anode  
hot water outlet  
outlet  
j
K
l
M
n
o
p
drip leg (sediment trap)  
Inner door  
S
t
Flue Baffle  
thermostat  
drain valve  
pilot and Main Burner  
flue  
drain pan  
outer door  
union  
u
v
w
X
Y
Z
Inlet water shut-off valve  
cold water Inlet  
Inlet dip tube/nipple  
temperature-pressure relief valve  
rating plate  
roof jack  
Gas supply  
thermostat shield (optional)  
air Intake screen  
Manual Gas shut-off valve  
Ground joint union  
q
r
whIte-rodGers  
roBertshaw  
* InstallInaccordance  
wIth local codes.  
* drIp leG as requIred  
BY local codes.  
ve
o
Y
vacuuM  
relIef  
valve  
TherMostat  
shIeld  
(optIonal)  
Install per  
local codes  
Install therMal eXpansIon  
tanK or devIce If water  
heater Is Installed In  
closed water sYsteM.  
a
(v) pIlot & MaIn Burner  
* all pIpInG MaterIals to Be  
supplIed BY custoMers.  
* 50 gallon unit has top connections and  
no side connection as shown here.  
fIGure 1.  
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tYpIcal InstallatIons  
InstallatIon In enclosure of Manufactured  
hoMe wIth solId eXterIor door  
InstallatIon In enclosure of Manufactured  
hoMe wIth louvered eXterIor door  
* MIXInG valve usaGe  
fIGure 2.  
This appliance has been design certified as complying withAmerican  
National Standard/CSAStandard for water heaters and is considered  
suitable for:  
HOTTER WATER CAN SCALD:  
Water heaters are intended to produce hot water. Water heated to  
a temperature which will satisfy space heating, clothes washing,  
dish washing, and other sanitizing needs can scald and permanently  
injure you upon contact. Some people are more likely to be  
permanently injured by hot water than others. These include the  
elderly, children, the infirm, or physically/mentally handicapped. If  
anyone using hot water in your home fits into one of these groups or  
if there is a local code or state law requiring 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 Qualified Installer or Service Agency.  
Follow mixing valve manufacturer’s instructions for installation of  
the valves. Before changing the factory setting on the thermostat,  
read the “Temperature Regulation” section in this manual, see  
Figures 29 and 30.  
water (potable) heating: All models are considered suitable for  
water (potable) heating.  
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locatInG the new water heater  
such locations cannot be avoided, a suitable drain pan should be  
facts to consIder aBout the locatIon  
installed under the water heater. Drain pans are available at your  
local hardware store. Such a drain pan must have a minimum length  
and width of at least 2 inches (51 mm) greater that the water heater  
dimensions and must be piped to an adequate drain. The pan must  
not restrict combustion air flow.  
This manufactured home gas-fired water heater is for use in a  
manufactured home. You should carefully choose an indoor location  
for the new water heater, because the placement is a very important  
consideration for the safety of the occupants in the building and for  
the most economical use of the appliance. this water heater is  
for use only in manufactured homes and is not intended for  
outdoor installation.  
Water heater life depends upon 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 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 drain pan. These devices are available from some plumbing  
supply wholesalers and retailers, and detect and react to leakage  
in various ways:  
the installation of this water heater must be within an enclosure  
so as to separate the appliance combustion system and venting  
system from the interior atmosphere of the manufactured home.  
there shall not be any door, removable access panel, or other  
opening into the enclosure from the inside of the manufactured  
home.  
•
•
•
Sensorsmountedinthedrainpanthattriggeranalarmorturnoffthe  
incoming water to the water heater when leakage is detected.  
Whether replacing an old water heater or putting the water heater in  
a new location, the following critical points must be observed.  
Sensors mounted in the drain pan that turn off the water supply  
to the entire home when water is detected in the drain pan.  
1. An enclosure with an exterior access door incorporating a single  
opening positioned a maximum of 6 inches above the lower edge  
of the access door and which may incorporate either 1/4 inch wire  
mesh or louvers. When 1/4 inch wire mesh is used, the size of  
the opening must be a minimum of 20 square inches. When the  
louvers are used, the free area must be a minimum of 20 square  
inches, see Figure 2 page 6.  
Water supply shut-off devices that activate based on the water  
pressure differential between the cold water and hot water pipes  
connected to the water heater.  
•
Devices that will turn off the gas supply to a gas water heater  
while at the same time shutting off its water supply.  
2. An optional enclosure incorporating a solid exterior access door,  
when a 5 inch or 8 inch diameter, or 20 square inch minimum  
equivalent free air opening is located in the floor of the enclosure.  
The opening must be covered by a 1/4 inch wire mesh, see Figure  
2 page 6.  
Install water heater into closet so as to have 0 inches minimum  
clearance at sides and back. Clearance of 4 inches is needed to  
front to accommodate the gas control valve, see Figure 3. Be sure  
to allow adequate clearance for servicing the water heater and for  
access to the piping and temperature-pressure relief valve.  
The water heater should be secured to the floor and to the wall of the  
enclosure with the mounting brackets provided. For bracket location  
refer to “Securing Water Heater to Floor and Wall” in the “Installing  
the New Water Heater” section.  
When a manufactured home is skirted, an air intake opening with a  
minimum free area of 32 square inches must be provided in the skirt.  
Other gas fired appliances in the home will require additional free air  
openings; consult these manufacturers for correct sizing.  
If the opening is covered by louvers or screen, the total free area  
must be 32 square inches.  
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS  
(VAPORS) ARE LIKELY TO BE PRESENT OR STORED  
(GARAGES, STORAGE AND UTILITY AREAS, ETC.): Flammable  
liquids (such as gasoline, solvents, propane [LP or butane, etc.] and  
other substances such as adhesives, etc.) emit flammable vapors  
which can be ignited by a gas water heater’s pilot light or main burner.  
The resulting flashback and fire can cause death or serious burns to  
anyone in the area. Even though this water heater is a flammable  
vapors ignition resistant water heater and is designed to reduce  
the chances of flammable vapors being ignited, gasoline and other  
flammable substances should never be stored or used in the same  
vicinity or area containing a gas water heater or other open flame  
or spark producing appliance.  
Installation of the water heater must be accomplished in such a  
manner that if the tank or any connections should leak, the flow  
will not cause damage to the structure. For this reason, it is not  
advisable to install the water heater in an attic or upper floor. When  
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Also, the water heater must be located and/or protected so it is not  
subject to physical damage by a moving vehicle.  
A gas water heater cannot operate properly without the correct  
amount of air for combustion. Do not install in a confined area  
such as a closet, unless you provide air as shown in the Typical  
Installations, see Figure 2 page 6. Never obstruct the flow of  
ventilation air. If you have any doubts or questions at all, call your  
gas supplier. Failure to provide the proper amount of combustion  
air can result in a fire or explosion and cause death, serious bodily  
injury, or property damage.  
If this water heater will be used in beauty shops, barber shops,  
cleaning establishments, or self-service laundries with dry cleaning  
equipment, it is imperative that the water heater or water heaters  
be installed so that combustion and ventilation air be taken from  
outside these areas.  
Propellants of aerosol sprays and volatile compounds, (cleaners,  
chlorine based chemicals, refrigerants, etc.) in addition to being  
highly flammable in many cases, will also change to corrosive  
hydrochloric acid when exposed to the combustion products of  
the water heater. The results can be hazardous, and also cause  
product failure.  
This water heater must not be installed directly on carpeting.  
Carpeting must be protected by metal or wood panel beneath the  
appliance extending beyond the full width and depth of the appliance  
by at least 3 inches (76.2 mm) in any direction, or if the appliance is  
installed in an alcove or closet, the entire floor must be covered by  
the panel. Failure to heed this warning may result in a fire hazard.  
InsulatIon BlanKets  
Insulation blankets are available to the general public for external  
use on gas water heaters but are not necessary with these products.  
The purpose of an insulation blanket is to reduce the standby heat  
loss encountered with storage tank heaters. Your water heater  
meets or exceeds the National Appliance Energy Conservation Act  
standards with respect to insulation and standby loss requirements,  
making an insulation blanket unnecessary.  
fIGure 3.  
Minimum clearances between the water heater and combustible and  
noncombustible construction are 0” at the sides and rear, 4” at the  
front, and 6” from the vent pipe. Clearance from the top of the draft  
hood is 12”. Refer to the label on the water heater located adjacent  
to the gas control valve for all clearances.  
Should you choose to apply an insulation blanket to this heater, you  
should follow these instructions (For identification of components  
mentioned below, see Figure 1). Failure to follow these instructions  
can restrict the air flow required for proper combustion, potentially  
resulting in fire, asphyxiation, serious personal injury or death.  
•
•
•
•
•
•
Do not apply insulation to the top of the water heater, as this will  
interfere with safe operation of the draft hood.  
Do not cover the outer door, thermostat or temperature & pressure  
relief valve.  
Do not allow insulation to come within 2” (50.8 mm) of the floor to  
prevent blockage of combustion air flow to the burner.  
Do not cover the instruction manual. Keep it on the side of the  
water heater or nearby for future reference.  
Doobtainnewwarningandinstructionlabelsfromthemanufacturer  
for placement on the blanket directly over the existing labels.  
Do inspect the insulation blanket frequently to make certain it  
does not sag, thereby obstructing combustion air flow.  
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InstallInG the new water heater  
securInG water heater to floor and wall  
water pIpInG  
The water heater must be secured to the floor and to the wall of the  
enclosure with the three mounting brackets and screws packaged  
in the carton with the water heater. The two small brackets stamped  
#0110064 are used to attach the water heater to the floor and the  
one large bracket #0110063 is used to secure the top of the water  
heater to the wall.  
Because of installation variances these brackets can be located at  
any points around the circumference of the jacket. When the bracket  
locations are determined using the 1/8 inch drill bit for a pattern, drill  
only through the outer jacket of the water heater. Then using the  
screws provided, secure the bracket to the water heater, floor and  
wall, see Figure 4. If the heater is installed in a drain pan, seal the  
drilled holes and screws with a heavy bead of silicone sealant to  
prevent any potential water damage.  
HOTTER WATER CAN SCALD:  
Water heaters are intended to produce hot water. Water heated to  
a temperature which will satisfy space heating, clothes washing,  
dish washing, cleaning and other sanitizing needs can scald and  
permanently injure you upon contact. Some people are more likely  
to be permanently injured by hot water than others. These include  
the elderly, children, the infirm, or physically/mentally handicapped.  
If anyone using hot water in your home fits into one of these groups  
or if there is a local code or state law requiring 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, see Figure 2. Valves for reducing point of use temperature  
by mixing cold and hot water are also available:  
ConsultaQualifiedInstallerorServiceAgency. Follow manufacturer’s  
instructions for installation of the valves. Before changing the factory  
setting on the thermostat, read the “Temperature Regulation” section  
in this manual.  
fIGure 4.  
t&p valve and pIpe InsulatIon  
Remove insulation for T&P Valve and pipe connections from carton.  
Fit pipe insulation over the hot water line. Make sure that the  
insulation is against the top cover of the heater.  
Fit T&P Valve insulation over valve. Make sure that the insulation  
does not interfere with the lever of the T&P valve.  
This water heater shall not be connected to any heating systems or  
component(s) used with a non-potable water heating appliance.  
Secure all insulation using tape.  
Toxic chemicals, such as those used for boiler treatment shall not  
be introduced into this system.  
Water supply systems may, because of such events as high line  
pressure, frequent cut-offs, the effects of water hammer among  
others, have installed devices such as pressure reducing valves,  
check valves, back flow preventers, etc. to control these types of  
problems. When these devices are not equipped with an internal  
by-pass, and no other measures are taken, the devices cause the  
water system to be closed. As water is heated, it expands (thermal  
expansion) and closed systems do not allow for the expansion of  
heated water.  
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The water within the water heater tank expands as it is heated and  
increases the pressure of the water system. If the relieving point of the  
water heater’s temperature-pressure relief valve is reached, the valve  
will relieve the excess pressure. the temperature-pressure relief  
valve is not intended for the constant relief of thermal expansion.  
This is an unacceptable condition and must be corrected.  
water pIpInG pressure test  
It is recommended that any devices installed which could create a  
closed system have a by-pass and/or the system have an expansion  
tank to relieve the pressure built by thermal expansion in the water  
system. Expansion tanks are available for ordering through a local  
plumbing contractor. Contact the local water supplier and/or a service  
agency for assistance in controlling these situations.  
note: to protect against untimely corrosion of hot and cold  
water fittings, it is strongly recommended that di-electric unions  
or couplings be installed on this water heater when connected  
to copper pipe.  
This section is only for the manufacturer installing the water heater  
when the installation is to comply with H.U.D. Standards.  
When testing the water ways, H.U.D. Standards state:  
“Water distribution system. All water piping in the water distribution  
system shall be subjected to a pressure test. The test shall be made by  
subjecting the system to air or water at 100 psi for 15 minutes without  
loss of pressure. when air pressure is used, the water heater shall  
not be connected during the test”.  
note: If water piping system is to be air pressure tested, the water  
heater must be disconnected from the water piping system. Failure  
to disconnect the water heater during air pressure testing of water  
piping system could result In death, serIous BodIlY InjurY,  
or propertY daMaGe.  
fIGure 6.  
teMperature-pressure relIef valve  
fIGure 5.  
Figure 5 shows the typical attachment of the water piping to the  
water heater. The water heater is equipped with 3/4 inch NPT water  
connections.  
note: If using copper tubing, solder tubing to an adapter before  
attaching the adapter to the cold water inlet connection. do not  
solder the cold water supply line directly to the cold water inlet.  
It will harm the dip tube and damage the tank.  
10  
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This heater is provided with a properly certified combination  
temperature - pressure relief valve by the manufacturer.  
The valve is certified by a nationally recognized testing laboratory  
that maintains periodic inspection of production of listed equipment of  
materials as meeting the requirements for Relief Valves for Hot Water  
Supply Systems, ANSI Z21.22 • CSA 4.4, and the code requirements  
of ASME.  
If replaced, the valve must meet the requirements of local codes, but  
not less than a combination temperature and pressure relief valve  
certified as indicated in the above paragraph.  
The valve must be marked with a maximum set pressure not to  
exceed the marked hydrostatic working pressure of the water heater  
(150 psi = 1,035 kPa) and a discharge capacity not less than the water  
heater input rate as shown on the model rating plate.  
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 replace the  
temperature-pressure relief valve with a new one.  
For safe operation of the water heater, the relief valve must not be  
removed from its designated opening nor plugged.  
The temperature-pressure relief valve must be installed directly into  
the fitting of the water heater designed for the relief valve. Position  
the valve downward and provide tubing so that any discharge will exit  
only at any distance below the structural floor. Be certain that no  
contact is made with any live electrical part. The discharge opening  
must not be blocked or reduced in size under any circumstances.  
Excessive length, over 30 feet (9.14 m), or use of more than four  
elbows can cause restriction and reduce the discharge capacity of  
the valve, see Figure 7.  
No valve or other obstruction is to be placed between the relief valve  
and the tank. Do not connect tubing directly to discharge drain unless  
a 6 inch air gap is provided. To prevent bodily injury, hazard to life, or  
property damage, the relief valve must be allowed to discharge water  
in quantities should circumstances demand. If the discharge pipe is  
not connected to a drain or other suitable means, the water flow may  
cause property damage.  
The Discharge Pipe:  
fIGure 7.  
• Shall not be smaller in size than the outlet pipe size of the valve, or  
have any reducing couplings or other restrictions.  
fIllInG the water heater  
• Shall not be plugged or blocked.  
• Shall be of material listed for hot water distribution.  
• Shall be installed so as to allow complete drainage of both the  
temperature-pressure relief valve, and the discharge pipe.  
• Shall terminate at an adequate drain.  
• Shall not have any valve between the relief valve and tank.  
The temperature-pressure relief valve must be manually operated at  
least once a year. Caution should be taken to ensure that (1) no one  
is in front of or around the outlet of the temperature-pressure relief  
valve discharge line, and (2) the water manually discharged will not  
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  
cause any bodily injury or property damage because the water may must flow from the hot water faucet before turning “ON” gas to the  
be extremely hot. water heater.  
11  
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To fill the water heater with water:  
temperature. Such temperatures may not be high enough to properly  
open thermally operated vent dampers. This would cause spillage of  
the flue gases and may cause carbon monoxide poisoning.  
1. Close the water heater drain valve by turning the handle to the right  
(clockwise). The drain valve is on the lower front of the water heater.  
Vent dampers must bear evidence of certification as complying with  
the current edition of the American National Standard ANSI Z21.68  
(ANSI Z21.66 & 67, respectively, cover electrically and mechanically  
actuated vent dampers). Before installation of any vent damper,  
consult the local gas utility for further information.  
2. Open the cold water supply valve to the water heater.  
note: the cold water supply valve must be left open when  
the water heater is in use.  
3. To insure complete filling of the tank, allow air to exit by opening the  
nearest hot water faucet. Allow water to run until a constant flow is  
obtained. This will let air out of the water heater and the piping.  
To insure proper venting of this gas-fired water heater, the correct  
vent pipe diameter must be utilized. Any additions or deletions of  
other gas appliances on a common vent with this water heater may  
adversely affect the operation of the water heater. Consult your gas  
supplier if any such changes are planned.  
4. Check all water piping and connections for leaks. Repair as needed.  
ventInG  
Periodically check the venting system for signs of obstruction or  
deterioration and replace if needed.  
Place the draft hood legs in the receiving holes on the top of the water  
heater. The legs will snap in the holes to give a tight fit.  
The combustion and ventilation air flow must not be obstructed.  
Place the vent pipe over the draft hood. With the vent pipe in position,  
drill a small hole through both the vent pipe and draft hood. Secure  
them together with a sheet metal screw.  
The water heater with draft hood installed must be connected to a  
roof jack, which terminates to the outdoors. Never operate the water  
heater unless it is vented to the outdoors and has adequate air supply  
to avoid risks of improper operation, explosion or asphyxiation.  
draft hood InstallatIon  
Obstructed or deteriorated vent systems may present serious health  
risk or asphyxiation.  
The vent pipe from the water heater must be no less than the  
diameter of the draft hood outlet on the water heater.  
All vent gases must be completely vented to the outdoors of the  
structure (dwelling). Install only the draft hood provided with the new  
water heater and no other draft hood.  
Vent pipes must be secured at each joint with sheet metal screws.  
There must be a minimum of 6 inches (153 mm) clearance between  
singlewallventpipeandanycombustiblematerial.Forotherthansingle  
wall, follow vent pipe manufacturer’s clearance specifications.  
fIGure 8.  
Failure to have required clearances between vent piping and  
combustible material will result in a fire hazard.  
The water heater must be connected to a roof jack:The vent pipe from  
the water heater to the roof jack must be no less than the diameter  
of the draft hood outlet (min. 3” [76 mm]) on the water heater.  
This water heater may be installed with single wall or Type B vent  
pipe connection to the draft hood and the following U.L. listed roof  
jacks not furnished.  
•
•
•
Van Dyke Ind. No. 987  
Vent Line No. 2073  
White Metal Products 3RJ  
There must be a minimum clearance of 12” (305 mm) between the  
top of the draft hood and the top of the enclosure.  
The draft hood and combustion air inlet to the water heater must be  
in the same atmospheric pressure zone. Do not separate by a wall,  
shelf, ceiling, partition, or any other means.  
There must be a minimum of 6 inch clearance between single wall  
vent pipe and any combustible material. Fill and seal any clearance  
between single wall vent pipe and combustible material with mortar  
mix, cement or other noncombustible substance. For other than single  
wall, follow vent pipe manufacturer’s clearance specifications.  
VENT DAMPERS -Any vent damper, whether it is operated thermally  
or otherwise must be removed if its use inhibits proper drafting of  
the water heater.  
Be sure vent pipe is properly connected to prevent escape of  
dangerous flue gases which could cause deadly asphyxiation.  
Thermally Operated Vent Dampers: Gas-fired water heaters having  
thermalefficiencyinexcessof80%mayproducearelativelylowfluegas  
12  
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•
•
A drip leg (sediment trap) ahead of the gas control valve to help  
prevent dirt and foreign materials from entering the gas control  
valve.  
Aflexible gas connector or a ground joint union between the shut  
off valve and control valve to permit servicing of the unit.  
Be sure 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.  
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.  
Water heaters covered in this manual have been tested and approved  
for installation at elevations up to 7,700 feet (2,347 m) above sea  
level. For installation above 7,700 feet (2,347 m), the water heater’s  
Btu input should be reduced at the rate of 4 percent for each 1,000  
feet (305 m) above sea level which requires replacement of the burner  
orifice in accordance with the National Fuel Gas CodeANSI Z223.1/  
NFPA 54. Contact your local gas supplier for further information.  
Gas pIpInG  
Failure to replace the standard orifice with the proper high altitude  
orifice when installed at elevations above 7,700 feet (2,347 m)  
could result in improper and inefficient operation of the appliance,  
producing carbon monoxide gas in excess of the safe limits. This  
could result in serious injury or death. Contact your local gas supplier  
for any specific changes that may be required in your area.  
Make sure the gas supplied is the same type listed on the model  
rating plate. The inlet gas pressure must not exceed 10.5” W.C.  
for natural gas and 13” W.C. for propane (L.P.) gas. The minimum  
inlet gas pressure shown on the rating plate is that which will permit  
firing at rated input.  
If the gas control valve is subjected to pressures exceeding 1/2 pound  
per square inch (3.5 kPa), the damage to the gas control valve could  
result in a fire or explosion from leaking gas.  
Use pipe joint compound or Teflon tape marked as being resistant  
to the action of petroleum [Propane (L.P.)] gases.  
If the main gas line Shut-off serving all gas appliances is used, also  
turn “off” the gas at each appliance. Leave all gas appliances shut  
“off” until the water heater installation is complete.  
The appliance and its gas connection must be leak tested before  
placing the appliance in operation.  
A gas line of sufficient size must be run to the water heater. Consult  
the current edition of National Fuel Gas Code ANSI Z223.1/NFPA  
54 and your gas supplier concerning pipe size.  
The appliance and its individual Shut-off valve shall be disconnected  
from the gas supply piping system during any pressure testing of  
that system at test pressures in excess of 1/2 pound per square inch  
(3.5 kPa). It shall be isolated from the gas supply piping system  
by closing its individual manual Shut-off valve during any pressure  
testing of the gas supply piping system at test pressures equal to  
or less than 1/2 pound per square inch (3.5 kPa).  
There must be:  
•
A readily accessible manual shut off valve in the gas supply line  
serving the water heater, and  
13  
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Connecting the gas piping to the gas control valve of the water  
heater can be accomplished by either of the two methods shown in  
Figures 9 and 10.  
Contaminants in the gas lines may cause improper operation of the  
gas control valve that may result in fire or explosion. Before attaching  
the gas line be sure that all gas pipe is clean on the inside. To trap any  
dirt or foreign material in the gas supply line, a drip leg (sometimes  
called a sediment trap) must be incorporated in the piping. The drip  
leg must be readily accessible. Install in accordance with the “Gas  
Piping” section. Refer to the current edition of the National Fuel Gas  
Code, ANSI Z223.1/NFPA 54.  
sedIMent traps  
whIte-rodGers fuel conversIon  
InstructIons froM natural Gas to  
propane (l.p.) Gas  
A sediment trap shall be installed as close to the inlet of the water  
heater as practical at the time of water heater installation. The  
sediment trap shall be either a tee fitting with a capped nipple in the  
bottom outlet or other device recognized as an effective sediment  
trap. If a tee fitting is used, it shall be installed in conformance with  
one of the methods of installation shown in Figures 9,10 and 11.  
Fuel conversions shall be completed by a qualified service  
agency in accordance with the detailed conversion instructions  
and all applicable codes and requirements of the authority having  
jurisdiction. The information in these instructions must be followed to  
minimize the risk of fire or explosion and to prevent property damage,  
personal injury or death. The qualified service agency is responsible  
for the proper installation of this kit. The installation is not proper and  
complete until the operation of the appliance is checked as specified  
in the manufacturer’s instructions.  
1. Read and follow detailed conversion instructions below and also  
on the heater.  
2. The conversion kit with necessary parts are in a bag attached to  
the side of the water heater.  
fIGure 9. Gas pIpInG wIth fleXIBle connector.  
3. Shut off the gas supply to the water heater.  
4. Remove the outer door.  
5. Rotate the thermostat dial on the water heater control  
counterclockwise ( ) until the main burner ignites and burns  
off all residual gas in the control and supply lines.  
6. Rotate the thermostat dial clockwise ( ) back to the “PILOT  
LIGHTING” position.  
7. Turn the gas control knob “A” to “PILOT”. Depress knob slightly  
fIGure 10. Gas pIpInG wIth all  
BlacK Iron pIpe to Gas control.  
and rotate to “OFF” position, see Figure 12.  
alternatIve sedIMent trap locatIon  
fIGure 12.  
8. Unplug wire from igniter assembly mounted to the top of the gas  
valve.  
fIGure 11.  
14  
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9. Remove flange nuts holding inner door in place with 3/8” nut  
driver, see Figure 13.  
15. Remove the Phillips-head screw holding the pilot bracket to the  
burner head, see Figure 16.  
fIGure 16.  
16. Remove the two Phillips-head screws holding the natural burner  
head to the burner tube assembly, see Figure 17.  
17. Using 3/8” boxed-end wrench remove the natural gas burner  
orifice “O” from the burner tube. Install burner orifice marked  
“LP” and tighten securely, see Figure 17.  
18. Locate and install the propane burner head to the burner tube  
using the two Phillips-head screws, see Figure 17.  
fIGure 13.  
10. Loosen flare nut “T” holding thermocouple to bottom of gas valve  
with 3/8” open-end wrench and pull down to remove, see Figure  
14.  
11. Loosen flare nut “P” holding pilot line to bottom of gas valve  
with 7/16” open-end wrench and pull tube down to remove, see  
Figure 14.  
12. Loosen flange nut “B” holding burner tube to bottom of gas valve  
with 3/4” open-end wrench and pull down to remove, see Figure  
14.  
fIGure 17.  
19. Push the natural gas pilot assembly grommet out of the inner  
door towards the combustion chamber.  
20. To install the propane pilot assembly, put the igniter wire,  
thermostat lead, and pilot tube through the inner door hole.  
Reinstall the Phillips-head screw securing the TCO bracket to  
the burner tube. Reinstall the Phillips-head screw securing the  
pilot assembly to the burner head bracket.  
fIGure 14.  
21. Push the grommet into the inner door hole making sure the door  
13. Grasp burner tube and remove burner assembly through inner  
fits into the groove in the grommet.  
door opening.  
22. Reinstall the burner assembly through the door opening being  
careful not to damage the door gasket on the studs. Position  
end of burner tube inside bracket as shown in Figure 18.  
14. To remove the natural gas pilot assembly, remove the Phillips-  
head screw holding the TCO bracket to the burner tube bracket,  
see Figure 15.  
fIGure 15.  
fIGure 18.  
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23. Place screwdriver in slot “C”, see Figure 19. Depress and turn  
counterclockwise ( ) to stop. Control screw must be in “IN”  
position for propane (LP) gas and in “OUT” position for natural  
gas. STOP! Read label “For Your Safety” located on your water  
heater.  
Maximum Supply Pressure:  
10.5” W.C. for Natural Gas.  
13” W.C. for Propane (L.P.) Gas.  
Minimum Supply Pressure:  
5” W.C. for Natural Gas.  
11” W.C. for Propane (L.P.) Gas.  
roBertshaw fuel conversIon InstructIons  
froM propane (l.p.) Gas to natural Gas  
Fuel conversions shall be completed by a qualified service  
agency in accordance with the detailed conversion instructions  
and all applicable codes and requirements of the authority having  
jurisdiction. The information in these instructions must be followed to  
minimize the risk of fire or explosion and to prevent property damage,  
personal injury or death. The qualified service agency is responsible  
for the proper installation of this kit. The installation is not proper and  
complete until the operation of the appliance is checked as specified  
in the manufacturer’s instructions.  
fIGure 19.  
24. Light pilot following the lighting and operating instructions on the  
front surface of the heater.  
25. Install outer door.  
1. Read and follow the detailed conversion instruction below and also  
on the heater in their entirety before starting the conversion.  
2. The conversion kit with necessary parts are in a bag attached to  
the side of the water heater.  
3. Shut off the gas supply to the water heater.  
4. Remove the outer door.  
5. Rotate the thermostat dial on the water heater control clockwise  
(
) until the main burner ignites and burns off all residual gas  
in the control and supply lines, see Figure 20.  
6. Rotate the thermostat dial counterclockwise ( ) back to the  
“PILOT LIGHTING” position, see Figure 20.  
whIte-rodGers fuel conversIon  
InstructIons froM propane (l.p.) Gas to  
natural Gas  
For conversion of Propane (LP) gas to Natural Gas follow the “White-  
Rodgers Fuel Conversion Instructions From Natural Gas to Propane  
(LP) Gas” section except in:  
1. Step 14, use natural gas pilot assembly.  
2. Step 16, use natural gas burner head.  
3. Step 17, use burner orifice “O” marked “N”.  
fIGure 20.  
4. Step 23, turn control screw in slot “C” in Figure 19 clockwise to  
7. Turn the gas control knob “A” clockwise to “PILOT”. Depress the  
child safety lever and turn the control knob clockwise to “OFF”  
position, see Figure 21.  
stop. Screw must be in “OUT” position for Natural Gas.  
See “Instruction Label” for orifice sizes.  
16  
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14. To remove the propane (LP) gas pilot assembly, remove the  
Phillips-head screw holding the TCO bracket to the burner tube  
bracket, see Figure 24.  
fIGure 21.  
8. Unplug wire from igniter assembly mounted on the side of the  
gas valve.  
9. Remove flange nuts holding inner door in place with 3/8” nut  
driver, see Figure 22.  
fIGure 24.  
15. Remove the Phillips-head screw holding the pilot bracket to the  
burner head, see Figure 25.  
fIGure 25.  
16. Remove the two Phillips-head screws holding the propane burner  
head to the burner tube assembly, see Figure 26.  
fIGure 22.  
10. Loosen flare nut “T” holding to bottom of gas valve with 3/8”  
open-end wrench and pull down to remove, see Figure 23.  
17. Using 3/8” boxed-end wrench remove the propane gas burner  
orifice “O” from the burner tube. Install the natural gas burner  
orifice and tighten securely, see Figure 26.  
11. Loosen flare nut “P” holding pilot line to bottom of gas valve  
with 7/16” open-end wrench and pull tube down to remove, see  
Figure 23.  
18. Locate and install the natural gas burner head to the burner tube  
using the two Phillips-head screws, see Figure 26.  
12. Loosen flange nut “B” holding burner tube to bottom of gas valve  
with 3/4” open-end wrench and pull down to remove, see Figure  
23.  
13. Grasp burner tube and remove burner assembly through inner  
door opening.  
fIGure 26.  
fIGure 23.  
17  
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19. Push the propane gas pilot assembly grommet out of the inner  
door towards the combustion chamber.  
20. To install the natural gas pilot assembly, pull the igniter  
wire, thermostat lead, and pilot tube through the inner  
door hole. Reinstall the Phillips-head screw securing the  
TCO bracket too the burner tube. Reinstall the Phillips-  
head screw securing the pilot assembly to the burner head  
bracket.  
21. Push the grommet into the inner door hole making sure the door  
fIGure 28.  
fits into the groove in the grommet.  
25. Light pilot following the lighting and operating instructions on  
the front surface of the heater.  
22. Reinstall the burner assembly through the door opening  
being careful not to damage the door gasket on the studs.  
Position end of burner tube inside bracket as shown in  
Figure 27.  
26. Install the outer door.  
fIGure 27.  
roBertshaw fuel conversIon InstructIons  
froM natural Gas to propane (l.p.) Gas  
23. Reinstall and tighten flange nut “B” on burner tube securely.  
Reinstall and tighten flare nut “P” on pilot line securely.  
Reinstall and tighten flare nut “T” on thermocouple securely.  
Reinstall two flange nuts on inner door. Plug wire from  
combustion chamber into igniter assembly located on the side  
of the gas valve. Make sure burner tube boot is on flange on  
inner door and pilot assembly grommet is secure in the hole  
in the inner door.  
To convert from Natural Gas follow the “RobertShaw Fuel  
Conversion Instructions from Propane (LP) Gas to Natural Gas”  
section except in:  
1. Step 14, use natural gas pilot assembly.  
2. Step 16, use natural gas burner head.  
3. Step 17, use burner orifice “O” marked “N”.  
24. Remove the conversion cap on the control knob, see Figure 28.  
Place screwdriver in slot “C”, depress and turn control screw  
to “LP” position. Control screw must be in “LP” position for  
propane (LP) gas and in “NAT” position for natural gas. Pilot  
screw must be switched to natural position when converting  
to natural gas. STOP! Read label “For Your Safety” located on  
your water heater.  
4. Step 24, turn control screw in slot “C”, depress and turn screw to  
“LP” position. Pilot screw must be switched to LP position when  
converting to LP gas.  
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whIte-rodGers Gas valve  
19  
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roBertshaw Gas valve  
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InstallatIon checKlIst  
Before lIGhtInG the pIlot:  
5. Will a water leak damage anything? See the “Locating the New  
Water Heater” section.  
1. Check the gas lines for leaks.  
6. Is there proper clearance between the water heater and  
anything that might catch fire? See the “Locating the New  
Water Heater” section.  
a. Use a soapy water solution. DO NOT test for gas leaks  
using a match or open flame.  
b. Brush the soapy water solution on all gas pipes, joints and  
fittings.  
7. Do you have adequate ventilation so that the water heater will  
operate properly? See the “Locating the New Water Heater”  
section.  
c. Check for bubbling soap. This means you have leak. Turn  
“OFF” gas and make the necessary repairs.  
8. Is the draft hood vent piping properly secured? See “Venting”  
instructions in the “Installing the New Water Heater” section.  
2. Is the new temperature-pressure relief valve properly installed  
and piped to an adequate drain? See “Temperature-Pressure  
Relief Valve” section.  
9. Is there proper clearance between the vent pipe and anything  
that might catch on fire? See “Venting” Instructions in the  
“Installing the New Water Heater” section.  
3. Are the cold and hot water lines connected to the water heater  
correctly? See “Water Piping” instructions in the “Installing the  
New Water Heater” section.  
10. Is the vent pipe properly sloped and does the vent terminate  
outdoors? See “Venting” instructions in the “Installing the New  
Water Heater” section.  
4. Is the water heater completely filled with water? See “Filling  
the Water Heater” instructions in the “Installing the New Water  
Heater” section.  
11. Do you need to call your gas company to check the gas pipe  
and its hookup?  
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teMperature reGulatIon  
For the RobertShaw control, turn the water temperature dial  
counterclockwise ( ) to decrease the temperature, or clockwise  
) to increase the temperature.  
Short repeated heating cycles caused by small hot water uses can  
cause temperatures at the point of use to exceed the thermostat  
setting by up to 30°F (16.7°C). If you experience this type of use  
you should consider using lower temperature settings to reduce  
scald hazards.  
(
Should overheating occur or the gas supply fail to shut off, turn off  
the manual gas control valve to the appliance.  
fIGure 29.  
HOTTER WATER CAN SCALD: Water heaters are intended to  
produce hot water. Water heated to a temperature which will satisfy  
space heating, clothes washing, dish washing, and other sanitizing  
needs can scald and permanently injure you upon contact. Some  
people are more likely to be permanently injured by hot water than  
others. These include the elderly, children, the infirm, or physically/  
mentally handicapped. If anyone using hot water in your home fits into  
one of these groups or if there is a local code or state law requiring  
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, see Figure 2. Follow manufacturer’s  
instructions for installation of the valves. Before changing the factory  
setting on the thermostat, see Figures 29 and 30. Using the lowest  
hot water temperature that meets your needs will also provide the  
most energy efficient operation of the water heater.  
roBertshaw teMperature adjustMent dIal  
Never allow small children to use a hot water tap, or to draw their own  
bath water. Never leave a child or handicapped person unattended  
in a bathtub or shower.  
NOTE: A water temperature range of 120°F-140°F (49°C-60°C) is  
recommended by most dishwasher manufacturers.  
fIGure 30.  
The thermostat of this water heater has been factory set at its  
lowest position. It is adjustable and must be reset to the desired  
temperature setting to reduce the risk of scald injury. The mark  
Temperature  
Setting  
Time to Produce 2nd and 3rd  
Degree Burns on Adult Skin  
About 1/2 second  
(
) indicative of approximately 120°F (49°C) is the preferred  
starting point for the White-Rodgers control. The 120°F Bar  
indicative of approximately 120°F as shown in Figure 29 is the  
preferred starting point for the Robertshaw control. Some States  
have a requirement for a lower setting.  
VERY HOT = approx. 160° (71°C)  
C = approx. 150°F (66°C)  
B = approx. 140°F (60°C)  
A = approx. 130°F (54°C)  
= approx. 120°F (49°C)  
Lowest Setting = approx. 80°F (27°C)  
About 1-1/2 seconds  
Less than 5 seconds  
About 30 seconds  
For the White-Rodgers control, turn the water temperature dial  
More than 5 minutes  
------------------------  
clockwise (  
) to decrease the temperature, or counterclockwise  
(
) to increase the temperature.  
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for Your InforMatIon  
therMal eXpansIon  
start up condItIons  
draft hood operatIon  
Check draft hood operation by performing a worst case  
depressurization of the building. With all doors and windows closed,  
and with all air handling equipment and exhaust fans operating  
such as furnaces, clothes dryers, range hoods and bathroom fans,  
a match flame should still be drawn into the draft hood of the water  
heater with its burner firing. If the flame is not drawn toward the  
draft hood, shut off water heater and make necessary air supply  
changes to correct.  
Water supply systems may, because of such events as high line  
pressure, frequent cut-offs, the effects of water hammer among others,  
have installed devices such as pressure reducing valves, check  
valves, back flow preventers, etc. to control these types of problems.  
When these devices are not equipped with an internal by-pass, and  
no other measures are taken, the devices cause the water system to  
be closed. As water is heated, it expands (thermal expansion) and  
closed systems do not allow for the expansion of heated water.  
condensate  
Whenever the water heater is filled with cold water, some condensate  
will form while the burner is on. A water heater may appear to  
be leaking when in fact the water is condensation. This usually  
happens when:  
The water within the water heater tank expands as it is heated and  
increases the pressure of the water system. If the relieving point of the  
water heater’s temperature-pressure relief valve is reached, the valve  
will relieve the excess pressure. the temperature-pressure relief  
valve is not intended for the constant relief of thermal expansion.  
This is an unacceptable condition and must be corrected.  
a. A new water heater is filled with cold water for the first time.  
b. Burning gas produces water vapor in water heaters, particularly  
high efficiency models where flue temperatures are lower.  
c. Large amounts of hot water are used in a short time and the refill  
water in the tank is very cold.  
It is recommended that any devices installed which could create a  
closed system have a by-pass and/or the system have an expansion  
tank or device to relieve the pressure built by thermal expansion in  
the water system. Expansion tanks are available for ordering through  
a local plumbing contractor. Contact the local water heater supplier  
or service agency for assistance in controlling these situations.  
Moisture from the products of combustion condense on the cooler  
tank surfaces and form drops of water which may fall onto the burner  
or other hot surfaces to produce a “sizzling” or “frying” noise.  
stranGe sounds  
Excessive condensation can cause pilot outage due to water  
running down the flue tube onto the main burner and putting out  
the pilot.  
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.  
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.  
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  
Do not assume the water heater is leaking until there has been  
enough time for the water in the tank to warm up.  
sMellY water  
In each water heater there is installed at least one anode rod (see  
parts sections) 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:  
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.  
a. A concentration of sulfate in the supply water.  
b. Little or no dissolved oxygen in the water.  
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.  
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.  
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.  
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  
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the local water heater supplier or service agency for further information  
concerning an Anode Replacement Kit and this chlorination treatment.  
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). 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.  
Ifthesmellywaterpersistsaftertheanodereplacementandchlorination  
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.  
“aIr” In hot water faucets  
hIGh water teMperature shut off sYsteM  
This water heater is equipped with an automatic gas Shut-off  
system. This system works when high water temperatures are  
present. Turn “OFF” the entire gas supply to the water heater.  
The high temperature Shut-off is built into the gas control 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.  
24  
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perIodIc MaIntenance  
You should check for sooting. Soot is not normal and will impair  
ventInG sYsteM InspectIon  
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.  
fIGure 31.  
Burner cleanInG  
At least once a year a visual inspection should be made of the venting  
system. You should look for:  
In the event your burner needs cleaning, follow these instructions:  
1. Obstructions which could cause improper venting.The combustion  
and ventilation air flow must not be obstructed.  
If inspection of the burner shows that cleaning is required, turn the  
gas control knob clockwise (  
) to the “OFF” position, depressing  
slightly.  
2. Damage or deterioration which could cause improper venting or  
leakage of combustion products.  
note: the knob cannot be turned from “pIlot” to “off” unless  
knob is depressed slightly. do not force.  
3. Rusted flakes around top of water heater.  
The burner needs to be removed for cleaning. Call a service agency  
to remove and clean the burner and correct the problem that required  
the burner to be cleaned.  
Be sure the vent piping is properly connected to prevent escape of  
dangerous flue gasses which could cause deadly asphyxiation.  
Obstructions and deteriorated vent systems may present serious  
health risk or asphyxiation.  
houseKeepInG  
Vacuum around base of water heater for dust, dirt, and lint on a  
regular basis.  
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 the vent system you found sooting or  
deterioration, something is wrong. Call the local gas utility to correct  
the problem and clean or replace the flue and venting before  
resuming operation of the 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 BODILY 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 everY sIX Months a vIsual InspectIon  
should Be Made of the aIr IntaKe screen. clean If  
lInt accuMulatIons are notIced.  
At least once a year a visual inspection should be made of the main  
burner and pilot burner, see Figure 31.  
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anode rod InspectIon  
teMperature-pressure  
relIef valve operatIon  
Each water heater contains at least one anode rod, which will slowly  
deplete while protecting the glass-lined tank from corrosion and  
prolonging the life of the water heater. Once the anode is depleted,  
the tank will start to corrode, eventually developing a leak. Certain  
water conditions will cause a reaction between this 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. The parts list includes  
a special anode that can be ordered if water odor or discoloration  
occurs. NOTE: This rod may reduce but not eliminate water odor  
problems. The water supply system may require special aeration  
or chlorination equipment from a water conditioning company to  
successfully eliminate all water odor problems.  
The temperature-pressure relief valve must be manually operated  
at least once a year.  
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, see Figure 32.  
The use of a water softener may decrease the life of the water heater  
tank. The anode rod should be removed from the water heater tank  
every 3 years for inspection. The following are typical (but not all)  
signs of a depleted anode rod:  
•
•
The majority of the rod’s diameter is less than 3/8”.  
fIGure 32.  
Significant sections of the support wire (approx. 1/3 or more of  
the anode rod’s length) are visible.  
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 replace the  
temperature-pressure relief valve with a new one.  
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 situations where  
clearance above the water heater is limited it may be necessary to  
bend the anode rod for removal. Flexible anode rods are available  
for replacement.  
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.  
In replacing the anode:  
1. Turn off gas supply to the water heater.  
draInInG  
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 the  
“Draining and Flushing” section 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 nearby hot water faucet to purge  
air from water system. Check for any leaks and immediately  
correct any if found.  
7. Restart the water heater as directed under the “Operating Your  
Water Heater” section. See the “Repair Parts Illustration” section  
for anode rod location.  
The water heater should be drained if being shut down during  
freezing temperatures. Also periodic draining and cleaning of  
sediment from the tank may be necessary.  
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1. Turn the gas control knob to the “OFF” position.  
4. Screw the handle and cap assembly back into the drain valve  
and retighten using a wrench. DO NOT OVER TIGHTEN.  
2. CLOSE the cold water inlet valve to the water heater.  
5. Follow instructions in the “Filling The Water Heater” section.  
6. Check for leaks.  
3. OPEN a nearby hot water faucet and leave open to allow for  
draining.  
4. Connect a hose to the drain valve and terminate to an adequate  
drain.  
5. OPEN the water heater drain valve to allow for tank draining.  
note: If the water heater is going to be shut down and  
drained for an extended period, the drain valve should be  
left open with hose connected allowing water to terminate  
to an adequate drain.  
6. CLOSE the drain valve.  
7. Follow instructions in the “Filling The Water Heater” section.  
fIGure 33.  
8. Follow the lighting instructions on the label or see page 14 under  
“Lighting Instructions” to restart the water heater.  
servIce  
If a condition persists or you are uncertain about the operation of  
the water heater contact a service agency.  
draIn valve washer replaceMent  
(See Figure 33)  
Use this 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.  
1. Follow “Draining” instructions.  
2. Turning counterclockwise ( ), remove the hex cap below the  
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.  
screw handle.  
3. Remove the washer and put the new one in place.  
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leaKaGe checKpoInts  
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.  
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.  
28  
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30 & 40 Gallon repaIr parts lIst  
Key No.  
Part Description  
Burner Assembly (White-Rodgers)**  
Burner Assembly (RobertShaw)**  
Burner Head (Natural Gas)  
Burner Head (Propane Gas)  
Burner Orifice (Natural Gas)  
Burner Orifice (Propane Gas)  
Burner Tube (White-Rodgers)**  
Burner Tube (RobertShaw)**  
Pilot Assembly (Natural Gas)  
Pilot Assembly (Propane Gas)  
Inner Door  
*1  
*2  
*3  
4
*5  
*6  
7
Inner Door Gasket  
8
Flue Baffle  
9
Flue Restrictor  
10  
Draft Hood  
Gas Control Valve (White-Rodgers)**  
Gas Control Valve (RobertShaw)**  
Piezo Ignitor Generator (White-Rodgers)**  
Piezo Ignitor Generator (RobertShaw)**  
Piezo Ignitor Bracket (White-Rodgers)**  
Piezo Ignitor Bracket (RobertShaw)**  
Air Intake Screen  
11  
12  
13  
whIte-rodGers  
Burner asseMBlY  
14  
15  
Nipple Inlet Tube  
16  
Heat Trap Nipple  
17  
Viewport Assembly  
18  
Temperature-Pressure Relief Valve  
Drain Valve  
19  
20  
Drain Valve Washer (17/32”x13/64”x1/8” thick)  
Outer Door  
21  
1
22  
Anode Rod  
23  
Angle Brackets  
roBertshaw  
Burner asseMBlY  
24  
White-Rodgers Thermostat Shield (optional)  
Instruction Manual  
***25  
therMostat  
shIeld  
*
door Gasket supplied with these parts  
** white-rodgers & robertshaw parts are not interchangeable.  
*** not shown.  
24  
1
Now that you have purchased this water heater, should a need ever  
exist for repair parts or service, simply contact the company it was  
purchased from or direct from the manufacturer listed on the rating  
plate on the water heater.  
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE  
FOLLOWING INFORMATION:  
•
•
•
•
MODEL NUMBER  
Be sure to provide all pertinent facts when you call or visit.  
TYPE GAS (NATURAL OR PROPANE (L.P.)  
SERIAL NUMBER  
sellingpriceswillbe furnished onrequestorpartswillbe shipped  
at prevailing prices and you will be billed accordingly.  
PART DESCRIPTION  
The model number of your Gas Water Heater will be found on the  
rating place located above the gas control valve.  
thIs Is a repaIr parts lIst, not a pacKInG lIst.  
29  
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50 Gallon repaIr parts lIst  
Key No.  
Part Description  
Burner Assembly (White-Rodgers)**  
Burner Assembly (RobertShaw)**  
Burner Head (Natural Gas)  
Burner Head (Propane Gas)  
Burner Orifice (Natural Gas)  
Burner Orifice (Propane Gas)  
Burner Tube (White-Rodgers)**  
Burner Tube (RobertShaw)**  
Pilot Assembly (Natural Gas)  
Pilot Assembly (Propane Gas)  
Inner Door  
*1  
*2  
*3  
4
*5  
*6  
7
Inner Door Gasket  
8
Flue Baffle  
9
Flue Restrictor  
10  
Draft Hood  
Gas Control Valve (White-Rodgers)**  
Gas Control Valve (RobertShaw)**  
Piezo Ignitor Generator (White-Rodgers)**  
Piezo Ignitor Generator (RobertShaw)**  
Piezo Ignitor Bracket (White-Rodgers)**  
Piezo Ignitor Bracket (RobertShaw)**  
Air Intake Screen  
11  
12  
13  
whIte-rodGers  
Burner asseMBlY  
14  
15  
Inlet Tube  
16  
Heat Trap Nipple  
17  
Viewport Assembly  
18  
Temperature-Pressure Relief Valve  
Drain Valve  
19  
20  
Drain Valve Washer (17/32”x13/64”x1/8” thick)  
Outer Door  
21  
1
22  
Anode Rod  
23  
Angle Brackets  
roBertshaw  
Burner asseMBlY  
24  
White-Rodgers Thermostat Shield (optional)  
Instruction Manual  
***25  
therMostat  
shIeld  
*
door Gasket supplied with these parts  
** white-rodgers & robertshaw parts are not interchangeable.  
*** not shown.  
24  
1
Now that you have purchased this water heater, should a need ever  
exist for repair parts or service, simply contact the company it was  
purchased from or direct from the manufacturer listed on the rating  
plate on the water heater.  
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE  
FOLLOWING INFORMATION:  
•
•
•
•
MODEL NUMBER  
Be sure to provide all pertinent facts when you call or visit.  
TYPE GAS (NATURAL OR PROPANE (L.P.)  
SERIAL NUMBER  
sellingpriceswillbe furnished onrequestorpartswillbe shipped  
at prevailing prices and you will be billed accordingly.  
PART DESCRIPTION  
The model number of your Gas Water Heater will be found on the  
rating place located above the gas control valve.  
thIs Is a repaIr parts lIst, not a pacKInG lIst.  
30  
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trouBleshootInG GuIdelInes  
These guidelines should be utilized by a qualified service agent. When calling for service notify the service agent that this is a  
“Flammable Vapor Ignition Resistant” Product.  
Problem  
Cause  
Solution  
Improperly sealed, hot or cold supply connection, relief valve,  
drain valve, or thermostat threads.  
Tighten threaded connections.  
water leaKs  
Leakage from other appliances or water lines.  
Inspect other appliances near water heater.  
Refer to CONDENSATE.  
Condensation of flue products.  
Install thermal expansion tank (DO NOT plug T&P  
valve).  
Thermal expansion in closed water system.  
leaKInG t&p valve  
sMellY odors  
Check relief valve for proper operation (DO NOT plug  
T&P valve.  
Improperly seated valves.  
High sulfate or mineral content in water supply.  
Bacteria in water supply.  
Drain and flush heater thoroughly, then refill.  
Chlorinate or aerate water supply.  
Refer to LIGHTING INSTRUCTIONS.  
Turn on main gas Shut-off valve.  
Adjust ignitor tip.  
Gas control knob not positioned correctly.  
Main gas supply off.  
Igniter tip more than 1/8” from pilot hood.  
Thermocouple malfunction.  
Replace pilot assembly.  
Thermocouple TCO malfunction.  
Replace pilot assembly.  
pIlot wIll not lIGht  
Melted insulation on ignitor wire or shorting of ignitor wire.  
High ambient room temperature.  
Contact a service agency to determine cause.  
Contact a service agency to determine cause.  
Reconnect wire connector to spark ignitor.  
Replace pilot assembly.  
Wire disconnected from spark ignitor.  
Broken electrode or electrical wire.  
Piezo ignitor generator fails to operate or malfunctions.  
Thermocouple TCO malfunction.  
Replace Piezo ignitor generator.  
Replace pilot assembly.  
High ambient room temperature.  
Contact a service agency to determine cause.  
Clean and reinstall air intake screen.  
Contact a service agency to determine cause.  
Replace gas control.  
Burner wIll not staY lIt Dirty or clogged air intake screen.  
Flame arrestor openings blocked.  
Defective Gas Control.  
Dirty pilot burner.  
Clean pilot assembly.  
Dirty or clogged air intake screen.  
Clean and reinstall air intake screen.  
Insert thermocouple correctly.  
Thermocouple tip is not in contact with pilot flame.  
pIlot outaGe  
Thermocouple malfunction.  
Thermocouple TCO malfunction.  
Defective Gas control.  
Replace pilot assembly.  
Replace pilot assembly.  
Replace Gas Control.  
Heater not lit or thermostat not on.  
Thermostat set too low.  
Refer to LIGHTING INSTRUCTIONS.  
Refer to TEMPERATURE REGULATION.  
Reduce hot water use.  
Heater undersized.  
not enouGh hot water  
Low gas pressure.  
Contact your gas supplier.  
Incoming water is unusually cold.  
Leaking hot water pipes or fixtures.  
High temperature limit switch activated.  
Thermostat set too high.  
Allow more time for heater to re-heat.  
Have plumber check and repair leaks.  
Contact a service agency to determine cause.  
Refer to TEMPERATURE REGULATION.  
Refer to CONDENSATE above.  
water too hot  
water heater sounds  
Condensation dripping on burner.  
Clean sediment from tank. Refer to DRAINING  
instructions in Maintenance section of manual.  
sIZZlInG-ruMBlInG  
sootInG  
Sediment or calcium in bottom of heater tank.  
Improper combustion.  
No adjustment available. Immediately shut down the  
water heater and contact a service agency to determine  
cause.  
Lack of supply air.  
Improperly installed vent piping.  
Downdraft.  
Immediately shut down the water heater and contact a  
service agency to determine cause.  
vent Gas odors  
Poor combustion.  
31  
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