US CRAFTMASTER 100263116 Installation And Operation Manual

Residenial atmospheric gas water heater with the flame guard safety system

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Installa on Instruc ons and
Use & Care Guide
Read this manual and the labels on the water heater before you install,
operate, or service it. If you have diffi culty following the direc ons, or
aren't sure you can safely and properly do any of this work yourself:
• Call our Technical Assistance Hotline at 1-800-999-9515 . We can help you with in-
stalla on, opera ons, troubleshoo ng, or maintenance. Before you call, write down
the model and serial number from the water heater's data plate.
Incorrect installa on, opera on, or service can damage the water heater, your house
and other property, and present risks including fi re, scalding, electric shock, and
explosion, causing serious injury or death.
Table of Contents Page
IMPORTANT SAFETY INFORMATION ............................................. 3
GETTING STARTED ........................................................................ 7
INSTALLATION ............................................................................. 14
OPERATION ................................................................................. 23
TROUBLESHOOTING ................................................................... 25
MAINTENANCE ........................................................................... 28
NOTES ......................................................................................... 31
REPAIR PARTS ............................................................................. 35
Keep this manual in the pocket on heater for future reference whenever maintenance, adjustment or service is required.

Residential Gas

Water Heater
Residen al Atmospheric Gas Water Heater
with the Flame Guard Safety System
Retain your original receipt as proof of purchase.
WARNING: If the informa on in
these instruc ons is not followed
exactly, a fi re or explosion may
result causing property damage,
personal injury or death.
Do not store or use gasoline or other
fl ammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch;
do not use any phone in your build-
ing.
• Immediately call your gas supplier
from a neighbor's phone. Follow the
gas supplier's instruc ons.
• If you cannot reach your gas sup-
plier, call the fi re department.
Installa on and service must be per-
formed by a qualifi ed installer, service
agency or the gas supplier.
LOW LEAD
CONTENT
100263116
January 2015

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Summary of Contents for US CRAFTMASTER 100263116

  • Page 1: Table Of Contents

    MAINTENANCE ................28 NOTES ..................31 LOW LEAD CONTENT REPAIR PARTS ................35 Keep this manual in the pocket on heater for future reference whenever maintenance, adjustment or service is required. Retain your original receipt as proof of purchase. 100263116 January 2015...
  • Page 2: Completed Installation Typical

    COMPLETED INSTALLATION TYPICAL Vent pipe Cold water shut off Expansion tank (Connect to cold water water supply) line Cold water line Dra hood T&P relief valve T&P discharge pipe Gas supply shut off Drain valve Gas supply Drain pan discharge pipe Gas control valve/thermostat...
  • Page 3: Important Safety Information

    IMPORTANT SAFETY INFORMATION Read and follow all safety messages and instruc ons in Important informa on to keep this manual. Fill out this sec on and keep this manual in the pocket of the water This is the safety alert symbol. It is used to alert you to heater for reference.
  • Page 4 IMPORTANT SAFETY INFORMATION o reduce the risk of property Gas Pressure Table 1 damage, serious injury or death, WARNING! The gas supply pressure Time to Produce read and follow the precau ons below, must not exceed the maximum supply Temperature a Serious Burn all labels on the water heater, and pressure as stated on the water...
  • Page 5 IMPORTANT SAFETY INFORMATION • If the water supplied to the water Fire Risk • Keep the water heater from becom- heater is pre-heated (for example, ing wet. Immediately shut the water This water heater is by a solar system) the temperature heater off...
  • Page 6 IMPORTANT SAFETY INFORMATION if the T&P Relief Valve or discharge instruc ons. When the installa on is Installa on Accessories pipe is blocked. Do not cap or plug the complete, check the vent’s dra using T&P Relief Valve or discharge pipe. the instruc ons on pages 23-24.
  • Page 7: Getting Started

    GETTING STARTED Review all of the instruc ons codes applicable to the installa on of Combus on and before you begin work. this water heater. Ven la on Air Supply Improper installa on can Before you start, be sure you damage the water heater, your home Before installing the water heater, you have the following tools and...
  • Page 8 GETTING STARTED Example: Op on A: Installa on without Check for Chemicals: outside ven la on (not recom- Installa ons where corrosive chemi- Gas Burning Appliance BTU/HR Ra ng mended) cals may be present require outside Gas Water Heater 40,000 Ven la on with outside air is recom- air.
  • Page 9 GETTING STARTED A2: Calculate required air volume mum free area is sized according to Table may be adequate). 3. Two openings must be used when B3: Determine minimum free A water heater installed in an unconfi ned ven la ng with air from another room. area required for each vent a c or garage requires that the space opening...
  • Page 10 GETTING STARTED covering (in decimals – e.g., 60% = .6) B5: Check that air source is clean and free of chemicals For example, an installa on area that requires openings with 100 square Air for combus on and ven la on inches of free area would need 134 must be clean and free of corrosive square inch openings if using metal...
  • Page 11 GETTING STARTED Ven ng Installing a New Vent System upward slope of at least ¼ inch per foot. Install pipe avoiding unnecessary WARNING! Carbon Monoxide The vent pipe must meet the following bends. Pipe joints must be fastened by Hazard. This water heater must be specifi...
  • Page 12 GETTING STARTED • The vent pipe must be fi rmly at- Install a readily accessible manual tached and sealed to prevent it shut-off valve in the gas supply line from falling out. as recommended by the local u l- ity. Know the loca on of this valve •...
  • Page 13 GETTING STARTED Space Hea ng con nuous fl ow of water through the air handler circuit during the off cycle. TYPICAL MIXING VALVE INSTALLATION • The domes c hot water line from the COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM water heater should be ver cal past EXPANSION TANK COLD WATER INLET...
  • Page 14: Installation

    INSTALLATION ✓ gauge to an outside faucet and mea- Water pressure Step 1: sure the maximum water pressure increase caused experienced throughout a 24-hour ✓ by thermal expansion Verify that your period (highest water pressures o en Verify that you have a properly sized occur at night).
  • Page 15 INSTALLATION increases in water pressure (despite • Install an automa c leak detec- the use of a Pressure Reducing Valve on and shutoff device (available at in the home’s main water supply line). your local plumbing supplier ). These The Safe Drinking Water Act of 1974 devices can detect water leaks and requires the use of backfl...
  • Page 16 INSTALLATION or oily vapors, at least annually • Avoid loca ons such as a cs, up- Step 2: check and clean the air fi lter. See per fl oors, or where a leak might Verify that the loca on Maintenance sec on for steps on damage the structure or furnish- cleaning the air fi...
  • Page 17 INSTALLATION On the old water heater, turn drain, outside, or in buckets. (Sedi- the control knob on the gas ment in the bo om of the tank may control valve to the clog the valve and prevent it from OFF posi on. draining.
  • Page 18: Installing The New Water Heater

    INSTALLATION line is turned off . Disconnect the gas base that extends beyond the dimen- Installation: Wrap the filter around the base of the water line from the water heater’s gas sions of the water heater (width and heater. Cut to fit around a control valve and cap it.
  • Page 19 INSTALLATION Check the filter at least every came with your water heater. Do not T&P Relief Valve. Do not cap, three months and clean as reuse an old T&P Relief Valve. block, plug, or insert any valve necessary. After installation, •...
  • Page 20 INSTALLATION Step 7: IF YOU HAVE COPPER PIPES: connec ons contain non-metallic parts which could be damaged. The proper Install Shutoff and Ther- If your home has copper water pipes, way to connect the water heater to you can solder the water pipe connec- copper water pipes is as follows: mosta c Mixing Valves ons or use compression fi...
  • Page 21 INSTALLATION NOTICE: Most water heater models Connect the cold water supply contain energy saving heat traps in the using 3/4 inch Na onal Pipe inlet and outlet connec ons. Do not Thread “NPT” to the fi ng marked “C” remove the heat traps. (COLD).
  • Page 22 INSTALLATION surfaces maintained and suffi cient Check inlet and outlet Step 11: room to service the water heater. connec ons and water pipes ✓ for leaks. Dry pipes connec- Not installed directly on a carpeted Make Gas Connec ons ons so that any drips or leaks will be fl...
  • Page 23: Operation

    OPERATION Z223.1(NFPA 54)-current edi on. ✓ Check exis ng vent system for rust, restric ons/obstruc ons. Water System Piping ✓ Temperature and pressure relief valve properly installed with a discharge line run to an adequate drain and protected from freezing. ✓...
  • Page 24: Emergency Shut Down

    OPERATION Ligh ng Instruc ons Press the gas control knob in condensa on o en forms inside the fully and hold it in. While water heater. You may hear drips or a WARNING! Explosion Hazard – holding in the gas control sizzling sound when the water heater is Replace viewport if glass is missing or knob, repeatedly click the igniter...
  • Page 25: Troubleshooting

    TROUBLESHOOTING fi replace dampers. Temperature Control • “C” 147°F • “VERY HOT” 160°F System Allow the water heater’s main NOTICE: The temperatures above are burner to operate for fi ve approximates. The actual temperature Adjus ng the Temperature minutes. Pass a newly ex n- of the heated water may vary.
  • Page 26 TROUBLESHOOTING gas build up. See cau on on page 6. Checking the Pilot Light hot water is simply not warm enough, make sure the faucet you are checking No Hot Water Check the spark igniter. Dim doesn’t have a defec ve Thermosta c the room lights and look through the Use the following step-by-step plan Mixing Valve.
  • Page 27 TROUBLESHOOTING Residen al Standard Gas Water Heater Use and Care Guide • 27 Residen al Standard Gas Water Heater Use and Care Guide • 27...
  • Page 28: Maintenance

    MAINTENANCE Rou ne Maintenance Open a hot water faucet and Remove and inspect the let the hot water run un l it is anode rod and replace if Rou ne maintenance will help your cool (This may take 10 min depleted.
  • Page 29 MAINTENANCE Refi ll the tank by opening the discharge pipe, turn the gas control cold water supply valve. Make knob to the OFF posi on and call a sure a hot water faucet is open qualifi ed person to determine the and the drain valve is closed.
  • Page 30 MAINTENANCE Removing and Replacing the gas control valve/thermostat. NOTE: L.P. Gas systems use reverse (le -hand) Gas Control Valve/Thermostat threads on the manifold tube. IMPORTANT: The gas control valve/ thermostat is a standard valve with wire leads that connect to a thermal switch.
  • Page 31: Notes

    NOTES Residen al Standard Gas Water Heater Use and Care Guide • 31...
  • Page 32 NOTES 32 • Residen al Standard Gas Water Heater Use and Care Guide...
  • Page 33 NOTES Residen al Standard Gas Water Heater Use and Care Guide • 33...
  • Page 34 NOTES 34 • Residen al Standard Gas Water Heater Use and Care Guide...
  • Page 35: Repair Parts

    REPAIR PARTS REPAIR PARTS LIST Replacement parts may be ordered through your plumber or the local distributor. Parts will be shipped at prevailing prices Item Parts Description and billed accordingly. DRAFT HOOD NOTICE: When ordering replacement parts, have the following informa on ready: REDUCER RING - SOME MODELS (NOT SHOWN)
  • Page 36: Listed Parts Kits And Illustrations

    REPAIR PARTS Listed Parts Kits and Illustrations Item 12: Pilot assembly kit, which contains the pilot assembly, thermopile, and retainer clip (Natural Gas or L.P.) Item 13: Final burner assembly which contains the burner, orifice, manifold tube, gasket, door, pilot tube, thermopile, manifold component block with retainer clip, thermal switch, and pilot assembly.

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