American Water Heater 74 Gallon 75100 BTU UltraLow Nox High Recovery Natural Gas Water Heater UBG6275T75S4NV user manual

							11 FIGURE 6. WIRING DIAGRAM AND SCHEMATIC
HEATER WIRING
All electrical work must be installed in the United States in accordance with the current edition of the National Electrical Code ANSI/NFPA  No. 
70, in Canada, must conform to all local code authority having jurisdiction.  AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF 
ELECTRICAL SHOCK OR POSSIBLE ELECTROCUTION.
If any of the original wire as supplied with the appliance must be replaced, use only type 105°C thermoplastic or equivalent, 250°C type F must 
be used for the fl ame sensor leads and the spark ignition cable must be high voltage 250°C.
 CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.  WIRING ERRORS CAN CAUSE IMPROPER AND 
DANGEROUS OPERATION.  VERIFY PROPER OPERATION AFTER SERVICING. 
						

							125. Wait fi ve (5) minutes                   to clear out any gas.  
If you then smell gas,           STOP!  Follow B in 
the safety information                above on this label.
  If you dont smell gas, go to next step.
6.  Turn on all electrical power to the appliance.
7.  Set thermostat to desired setting by fi rst pressing the 
COOLER 
  and HOTTER   buttons together and 
holding for 1 second. Then press the HOTTER 
   
button.
8.  If the appliance will not operate, follow the 
instructions TO TURN OFF GAS TO APPLIANCE 
and call your technician or gas supplier.
9. WATER TEMPERATURE ADJUSTMENT
    is approximately 120°F (49°C).
   
   
 
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fi re or explosion 
may result causing property damage, personal injury or loss of life.
•  If you cannot reach your gas supplier, call the fi re 
department.
C.  Use only your hand to push in the control buttons. 
Never use tools. If the control buttons will not push 
in, don’t try to repair them, call a qualifi ed  service 
technician. Force or attempted repair may result in a 
fi re or explosion.
D.  Do not use this appliance if any part has been under 
water. Immediately call a qualifi ed service technician 
to inspect the appliance and to replace any part of the 
control system and any gas control which has been 
under water.
OPERATING INSTRUCTIONS
A.  Set thermostat to the lowest setting.
B.  Turn off all the electric power to the appliance 
  if service is to be performed. 
TO TURN OFF GAS TO APPLIANCE
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.
1.    STOP!   Read the safety information above  
  on this label.
2.  Set the thermostat to the lowest setting by fi rst pressing 
the COOLER 
 and HOTTER  buttons together 
and holding for 1 second. Then press the COOLER 
  button until the WARM indicator light appears.  
3.  Turn the ON/OFF swich on the blower control to the 
OFF position.
4.  This appliance is equipped with a device which 
automatically lights the burner.
  DO NOT TRY TO LIGHT THE BURNER BY HAND. A.  This appliance does not have a pilot.  It is equipped with 
an ignition device which automatically lights the burner.  
 Do not try to light the burner by hand.
B. BEFORE OPERATING smell all around the appliance 
area for gas. Be sure to smell next to the fl oor because 
some gas is heavier than air and will settle on the fl oor.
WHAT TO DO IF YOU SMELL GAS:
•  Do not try to light any appliance.
•  Do not touch any electric switch;
  do not use any phone in your building.
•  Immediately call your gas supplier from a neighbor’s 
phone. Follow the gas supplier’s instructions.
CAUTION:  Hotter water increases the risk 
of scald injury.  Consult the instruction 
manual before changing temperatures.
WARNING:  TURN OFF ALL ELECTRIC
POWER BEFORE SERVICING
HOTTER
COOLER
VERY
HOT WARM VACATION VACATION
ABC
WARNING! 
						

							13.                             
SETTING THE WATER HEATER TEMPERATURE AT 120°F (49°C) 
(APPROX.  MARK ON FACE OF THE TEMPERATURE ADJUSTING 
DIAL) WILL REDUCE THE RISK OF SCALDS. Some States or Provinces 
require settings at specifi c lower temperatures.
Figure 6 shows the approximate water temperatures produced at various 
thermostat settings. 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 20°F (11°C). If you experience this type of 
use you should consider using lower temperature settings to reduce 
scald hazards.
Valves for reducing point of use temperature by mixing cold and hot 
water are available.  Also available are inexpensive devices that attach 
to faucets to limit hot water temperatures. Contact a licensed plumber 
or the local plumbing authority.
To avoid any unintentional changes in water temperature settings, the 
control has a tamper resistant feature for changing the temperature 
setting.  To change the temperature setting follow these instructions:
1.  Wake Up the temperature indicators by holding down both the 
COOLER and HOTTER temperature adjustment buttons at 
the same time for one second (see Figure 6).  One or two of the 
temperature indicators will light up.  These indicators will only remain 
on for 30 seconds if no further buttons are pressed.  After 30 seconds 
the control will go back to Sleep mode.
2.  Release both of the temperature adjustment buttons.
  A.  To decrease the temperature press and release the COOLER 
button until desired setting is reached.
  B.  To increase the temperature press and release the HOTTER 
button until the desired setting is reached.
NOTE: Holding down the button will not continue to lower or raise the 
temperature setting.  The button must be pressed and released for each 
temperature change desired.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO 
SHUT OFF, TURN OFF THE MAIN MANUAL GAS SHUTOFF VALVE 
TO THE APPLIANCE. SEE FIGURE 1 (G).
TEMPERATURE REGULATION
   DANGER
THIS WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE 
THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT WATER 
TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHING AND 
LAUNDRY USE CAN CAUSE PAINFUL SCALDING WITH POSSIBLE 
SERIOUS AND PERMANENT INJURY. THE TEMPERATURE AT WHICH 
INJURY OCCURS VARIES WITH THE PERSON’S AGE AND THE TIME 
OF THE  EXPOSURE. THE SLOWER RESPONSE TIME OF CHILDREN, 
AGED OR DISABLED PERSONS INCREASES THE HAZARDS TO 
THEM. NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER TAP, 
OR TO DRAW THEIR OWN BATH WATER. NEVER LEAVE A CHILD 
OR DISABLED PERSON UNATTENDED IN A BATHTUB OR SHOWER.
THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE 
THE GENERAL PUBLIC DOES NOT HAVE ACCESS. IF A SUITABLE 
AREA IS NOT AVAILABLE, A COVER SHOULD BE INSTALLED OVER 
THE THERMOSTAT TO PREVENT TAMPERING. Suitable covers 
are available through Water Heater Parts Fulfi llment, 125 Southeast 
Parkway, Franklin, TN 37068. 
It is recommended that lower water temperatures be used to avoid the 
risk of scalding. It is further recommended, in all cases, that the water 
temperature setting be set for the lowest temperature that satisfi es 
your hot water needs. This will also provide the most energy effi cient 
operation of the water heater. The water temperature adjustment was 
factory set at the lowest temperature. Pressing the COOLER 
 button 
decreases temperature and pressing the HOTTER 
 button increases 
the temperature
Temperature Setting
     Display 
      
 A B  C
  C-Flashing = approx. 160°F (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)
  WARM = approx. 80°F (27°C)
FIGURE 7.
Water 
Temperature 
°F (°C)Time for 1st 
Degree Burn 
(Less Severe Burns)Time for Permanent Burns 
2nd & 3rd Degree 
(Most Severe Burns)
  110 (43.3)   (normal shower temp.)
116 ( 46.6)  (pain threshold)
116 ( 46.6)  35 minutes    45 minutes
122 (50)    1 minute 5 minutes
131 (55)    5 seconds 25 seconds
140 (60)  2 seconds 5 seconds
149 (65)   1 second  2 seconds
154 (67.7)  instantaneous 1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978) 
						

							14
Type of Gas BTU Per Cu. Ft.Time Required To Consume 1 Cu. 
Ft. of Gas
Natural 1050 50.3 Seconds
CHECKING VENTING
The following steps shall be followed with each appliance connected 
to the venting system placed in operation, while any other appliances 
connected to the venting system are not in operation.
1.  Seal any unused openings in the venting system.
2.    Inspect the venting system for proper size and horizontal pitch, as 
required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54  
Installation codes and these instructions.  Determine that there is 
no blockage or restriction, leakage, corrosion and other defi ciencies 
which could cause an unsafe condition.
3.  So far as is practical, close all building doors and windows and all 
doors between the space in which the water heater(s) connected 
to the venting system are located and other spaces of the building.  
Turn on all appliances not connected to the venting system.  Turn 
on all exhaust fans, such as range hoods and bathroom exhausts, 
so they shall operate at maximum speed.  Close fi replace dampers.
4.  Follow the lighting instruction.  Place the water heater being 
inspected in operation. Adjust thermostat so appliance shall operate 
continuously.
5.  Test for vent system leakage after 5 minutes of main burner 
operation.
6.  After it has been determined that each appliance connected to the 
venting system properly vents when tested as outlined above, return 
doors, windows, exhaust fans, fi replace dampers and any other gas 
burning appliance to their previous conditions of use.
7.  If improper venting is observed during any of the above tests, the 
venting system must be corrected.
 WARNINGFAILURE TO CORRECT BACK DRAFTS MAY CAUSE AIR 
CONTAMINATION AND UNSAFE CONDITIONS.
HIGH TEMPERATURE LIMIT SWITCH (ECO)
The water heater is equipped with a manual reset type high limit (Energy 
Cutoff) sensor. The high limit switch interrupts the main burner gas fl ow 
should the water temperature reach 195°F (90°C). The high limit switch 
must be manually reset by turning the power to the water heater off for 
5 seconds then back on and cannot be reset until the water temperature 
drops below 120°F (49°C). It is important that a serviceman be called 
to determine the reason for limit operation and thus avoid repeated 
thermostat resetting.
   WARNINGTHE ON/OFF SWITCH MUST HAVE BEEN IN THE OFF POSITION FOR 
AT LEAST 5 MINUTES.  This waiting period is an important safety step.  
Its purpose is to permit gas that may have accumulated in the combustion 
chamber to clear.  IF YOU DETECT GAS ODOR AT THE END OF THIS 
PERIOD DO NOT PROCEED WITH LIGHTING. RECOGNIZE THAT 
GAS ODOR, EVEN IF IT SEEMS WEAK, MAY INDICATE PRESENCE 
OF ACCUMULATED GAS SOMEPLACE IN THE AREA WITH RISK 
OF FIRE OR EXPLOSION.  SEE THE FRONT PAGE FOR STEPS TO 
BE TAKEN.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO 
SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO 
THE APPLIANCE.
SERVICE INFORMATION
The installer may be able to observe and correct certain problems 
which may arise when the unit is put into operation.  HOWEVER, it is 
recommended that only qualifi ed servicemen, using appropriate test 
equipment, be allowed to service the heater.
FOR YOUR SAFETY AND SATISFACTORY OPERATION, IT IS 
RECOMMENDED THAT THIS HEATER BE CHECKED ONCE A YEAR 
BY A COMPETENT SERVICE PERSON.
USERS OF THIS APPLIANCE SHOULD BE AWARE THAT GAS 
COMPONENTS WEAR OUT OVER A PERIOD OF TIME.  THE GAS 
CARRYING COMPONENTS OF THIS APPLIANCE SHOULD BE 
INSPECTED FOR PROPER OPERATION PERIODICALLY BY A 
QUALIFIED SERVICE TECHNICIAN.
MAIN BURNER AND IGNITER
Check main burner (figure 7) at least every 6 months for proper 
fl ame characteristics.  The main burner should display the following 
characteristics:
BURNER HEAD
ASSEMBLY
BURNER TUBE
ASSEMBLY
H.S.I.
ASSEMBLY
FIGURE 8. MAIN BURNER AND IGNITER ASSEMBLY
1.  Provide complete combustion of gas.
2.  Cause rapid ignition and carryover of fl ame across entire burner.
3.  Give reasonably quiet operation during ignition, burning and extinction.
4.  Cause no excessive lifting of fl ames from burner ports.
If preceding burner characteristics are not evident, check for accumulation 
of lint or other foreign material that restricts or blocks the air openings 
to the heater or burner.
  WARNINGSOOT BUILD-UP INDICATES A PROBLEM THAT REQUIRES 
CORRECTION BEFORE FURTHER USE. CONSULT WITH A 
QUALIFIED SERVICE TECHNICIAN.
Should the main burner or burner air openings require cleaning, remove 
the burner and clean with a soft brush. Clean main burner orifi ce  with 
a suitable soft material.  
CHECK FOR GOOD FLOW OF COMBUSTION AND VENTILATING 
AIR TO THE UNIT. MAINTAIN A CLEAR OPEN AREA AROUND THE 
HEATER AT ALL TIMES. DO NOT STORE COMBUSTIBLES OR 
FLAMMABLE LIQUIDS NEAR OR AROUND AN APPLIANCE.
CHECKING GAS INPUT
For appliance installation locations with elevation above 2000  ft.(610m) 
refer to HIGH ALTITUDE INSTALLATIONS section of this manual for 
input reduction procedure.
With this heater in operation, determine whether it is receiving the full 
rated input of gas.  This may be done by timing the gas meter and 
measuring gas pressure with a gauge or manometer.  When the heater is 
operating at full capacity (full gas input) it should consume approximately 
1 cubic foot of gas in the time shown in table 6.
 TABLE 7 
 INPUT CHECK TIME REQUIRED TO CONSUME 1 CU. FT. OF GAS 
						

							15  •  To check UN•LIME for continued use or reuse, place some lime 
scale or white chalk into a glass with a small amount of solution.  If 
the material is vigorously dissolved by the solution, the UN•LIME 
can be reused.  If not, the UN•LIME has been weakened and 
should be replaced.
8.  When deliming has been completed, the heater should be fl ushed 
for 3 to 5 minutes with fresh water.
  •  Remove the deliming equipment, install the drain valve, open the 
cold water inlet line and allow water to fl ow through heater and out 
drain valve.  Don’t forget to plug vent and cap opening in Flo-Jug.
9. When fl ushing is completed:
  •  Fill heater being certain to expel air from tank through a nearby 
hot water faucet or, if removed, the relief valve opening.
  •  The heater relief valve can be washed in UN•LIME if it is limed.
  •  Replace relief valve if removed for deliming.
  •  Restore gas, oil or electrical supply to heater.
  •  Check for water leakage.
10. Flo-Jug cleanup:
  •  Allow scale to separate from UN•LIME and settle on bottom of 
Flo-Jug.
 
  •  Pour off UN•LIME into plastic container and check for reuse.
  •  Rinse sediment from Flo-Jug.
DRAINING AND FLUSHING
It is recommended that the tank be drained and fl ushed 
every 6 months to remove sediment which may build up 
during operation. The water heater should be drained if 
being shut down during freezing temperatures. To drain the 
tank, perform the following steps:
1.  Turn off the gas to the water heater at the manual gas 
shut off valve.
2.  Open a nearby hot water faucet until the water is no 
longer hot.
3.  Close the cold water inlet valve.
4.  Connect a hose to the drain valve and terminate it to an 
adequate drain or external to the building.
5.  Open the water heater drain valve and allow all of the 
water to drain from the tank. Flush the tank with water 
as needed to remove sediment.
6.  Close the drain valve, refi ll the tank, and restart the 
heater as directed in this manual.
If the water heater heater is going to be shut down for an 
extended period, the drain valve should be left open.
iMPORTANT: ccondensation may occur when refi lling the 
tank and should not be confused with a tank leak.
Use this formula to “clock” the meter.  Be sure that other gas consuming 
appliances are not operating during this interval.
  3,600  X  H  =  Btu/h
     T
  T  =  Time in seconds needed to burn one cubic foot of gas.
  H = Heating value of gas in Btu’s per cubic foot of gas.
  Btuh = Actual heater input rate.
 Example:
  T  =  47.2 seconds/ft
3
  H  =  1,050 Btu/ft3 (natural gas)
  Btuh  =  ?
  3,600  X  1,050  =  75,100 Btu/h (22Kw)
  50.3
Compare the actual input rate to that given on the heater’s rating plate.  
In the example, the full input rate should be 75,100 Btu/h (22 Kw) for 
natural gas.
VENT SYSTEM
Examine the venting system every 6 months for obstructions and/or 
deterioration of vent piping.
BLOWER MAINTENANCE
For safety and satisfactory operation it is recommended that the blower 
be checked once a year by a competent service person.
1.  MOTOR - The motor is factory oiled and sealed and requires no 
further maintenance.
2.  WHEEL - Wheel must be clean of soot, ash or any other coating 
which inhibits either rotation or air fl ow.  Remove all foreign material 
from vent system.
3.  The pressure switch is inside the blower control box and is connected 
to the blower housing with a tube.  This tubing should be soft and 
pliable and show no sign of deterioration. 
RELIEF VALVE
At least once a year the temperature and pressure relief valve should 
be checked to ensure that it is in operating condition.  (During manual 
operation of this valve, avoid any contact with hot water and take 
preventive steps for water damage).  Lift the lever at the top of the valve 
several times until the valve seats properly and operates freely.
  WARNING
THE WATER PASSING OUT OF THE VALVE DURING THIS CHECKING 
OPERATION MAY BE EXTREMELY HOT.  AVOID CONTACT AND 
DISCHARGE SAFELY TO PREVENT WATER DAMAGE.
If the temperature and pressure relief valve on the heater discharges 
periodically or continuously, a problem exists.  This may be due to 
unusually high water temperatures or pressures in the system, or to a 
faulty relief valve.  Contact your dealer or a qualifi ed service technician 
to fi nd the cause of the problem and to correct it.  This may also be due 
to thermal expansion in a closed water supply system.  Contact the water 
supplier or local plumbing inspector on how to correct this situation.  
DO 
NOT PLUG THE TEMPERATURE AND PRESSURE RELIEF VALVE.
  WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO 
SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO THE 
APPLIANCE.
HOT WATER ODOR
On occasion, hot water may develop a strong odor.  If this occurs drain 
the heater completely, fl ush thoroughly, and refi ll.  If the problem persists, 
chlorination of the heater and replacement of the factory installed 
magnesium anode with aluminum anode may correct the condition.
Occasionally water softener companies recommend removal of heater 
anodes for odor reasons. 
						

							16
CHECKLIST
Before contacting your dealer, check the water heater to see if the apparent 
malfunction is caused by some external fault. Consulting this checklist 
may eliminate the need for a repair call and restore hot water service.
NOT ENOUGH OR NO HOT WATER
1.  Look  for leaking or open hot water faucets.  Check for excessive 
usage.
2.  Your gas company can check the gas input to the heater to see that 
it is correct.  An underfi red heater will not produce hot water at its 
normal recovery rate.
3.  If the heater was installed when incoming water temperatures were 
warm, colder incoming temperatures will create the effect of less 
hot water.
4.  The thermostat water temperature adjusting dial may be set too low.
5.  If you cannot determine the cause of the problems, contact your 
dealer.
WATER TEMPERATURE IS TOO HOT
1.  The thermostat water temperature adjusting dial may be set too high.
2.  If lowering control setting does not reduce the water temperature 
contact your dealer.
GAS SMELL AT THE HEATER
1.  Close the main shutoff valve in the gas supply pipe near the heater, 
see Figure 5 on page 9.
2.  Call your gas company.
WATER LEAKAGE IS SUSPECTED
1.  Check to see if the heater drain valve is tightly closed.
2.  The apparent leakage might be condensation.  In warm or humid 
locations, condensation can accumulate and run from within the 
heater or its piping.
  •  When a water heater is fi rst installed and fi lled, the bottom of the 
tank might condense water.  The water accumulation, if excessive, 
can drip into the fl oor shield.  Also, during normal operation there 
may be occasions when large quantities of water are drawn, 
chilling the tank bottom.  This too can result in condensation.
  •  Condensation, appearing in the vent pipe (water dripping from 
draft diverter) during heater operation is evidence of poor vent 
action.  Possible causes are too long a vent pipe or improper 
chimney operation.
3.  If the leakage is from the temperature and pressure relief valve or 
its discharge pipe, it may represent a normal condition.  However, 
see RELIEF VALVE section on page 7.  DO NOT PLUG THE 
TEMPERATURE AND PRESSURE RELIEF VALVE.  Also, the 
leakage could be due to unusually high water pressures or 
temperatures in the system, or to a faulty relief valve.  Your dealer 
or a qualifi ed service technician should be called to determine the 
cause of the problem and to correct it.
4.  If you cannot identify or correct the source of water leakage:
  •  Close the main shutoff valve in the gas supply pipe at the heater. 
See Figure 5, page 9.
  •  Close the valve which feeds water to the cold water inlet at the 
top of the heater.
  •  Contact your dealer.WATER HEATER MAKES SOUNDS
1.  Occasional excessive condensation, as explained under LEAKAGE, 
can cause a sizzling sound as the moisture is vaporized by the gas 
fl ame. This is a normal sound and may be disregarded.
2.  Sediment and water scale accumulations may cause rumbling 
noises. See MAINTENANCE or contact your dealer for details of 
fl ushing the heater.
3.  If you cannot identify or remedy the condition, contact your dealer.
CONDENSATION
Water vapor can condense on the cooler surfaces of the tank forming 
droplets, these drip into the fi re or run out on the fl oor.  This is common at 
the time of startup after installation, during periods of time when incoming 
water is very cold, or the heater may be undersized for the requirements.
Droplets from the bottom of the fl ue may be due to corrosive combustion 
products or improper vent.  Check with your dealer for more information.
ANODE ROD INSPECTION
Each water heater contains at least one anode rod, which will slowly 
deplete (due to electrolysis) prolonging the life of the water heater 
by protecting the glass-lined tank from corrosion. Adverse water 
quality, hotter water temperatures, high hot water useage, and water 
softening methods can increase the rate of anode rod depletion
. Once 
the anode rod is depleted, the tank will start to corrode, eventually 
developing a leak.
Certain water conditions will cause a reaction between the anode 
rod and the water. The most common complaint associated with the 
anode rod is a rotten egg smell produced from the presence of 
hydrogen sulfi de 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 rodthat can be ordered if water odor or 
discoloration occurs. NOTE: This rod may reduce but not eliminate 
water odor problems. 
Artifi cially softened water is exceedingly corrosive because the 
process substitutes sodium ions for magnesium and calcium ions. The 
use of a water softener may decrease the life of the water heater tank.
The anode rod should be inspected after a maximum of three years 
and annually thereafter until the condition of the anode rod dictates its 
replacement. NOTE: Artifi cially softened water requires the anode rod 
to be inspected annually.
The following are typical (but not all) signs of a depleted anode rod:
*  The majority of the rods diameter is less than 3/8
* Signifi cant sections of the support wire (approx. 1/3 or more of 
the anode rods length) are visible.
If the anode rod shows signs of either or both it should be replaced. 
NOTE: Whether re-installing or replacing the anode rod, check for any 
leaks immediately, correct if found.
In replacing the anode:
1.  Turn off gas supply to the water heater.
2.  Shut off the water supply and open a nearby hot water faucet to 
depressurize the water tank.
3.  Drain approximately 5 gallons of water from the tank (Refer to 
Draining and Flushing for proper procedures). Close drain 
valve.
4.  Reomve old anode rod.
5. Use Tefl on® 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. 
						

							17 Restart the water heater as directed under Operating Your Water 
Heater. See the repair parts illustration for anode rod location.
                 
Figure 9
SERVICE AND REPAIR
The water heater requires no special care other than the normal 
maintenance as noted above.  If you are having a problem with your 
water heater, before calling for service please refer to the following 
TROUBLESHOOTING sections.  If service becomes necessary, 
contact your dealer, installer or an authorized service agent.  Do not 
attempt to repair the water heater yourself.  Any work performed by 
unauthorized personnel may void the warranty.
TROUBLESHOOTING
Water heaters may exhibit problems that are unrelated to a malfunction 
of the water heater itself.  The following information and tables may 
serve to answer your question about a problem that you are having 
without having to call a service agent.
For your safety, water heater service should be performed only 
by a qualifi ed service technician.  Read the GENERAL SAFETY 
INFORMATION section fi rst.
WATER HEATING CYCLE
(GAS AND ELECTRIC POWER ARE ON,“OFF/ON” SWITCH IS 
ON)
1)  CALLS FOR HEAT
  A)  THERMOSTAT SENSES NEED FOR HEATING WATER
  B)  CONTACTS CLOSE IN THERMOSTAT, POWER (115 VAC) 
FLOWS TO BLOWER MOTOR
2)  BLOWER MOTOR ROTATES BLOWER WHEEL
  A)  BLOWER WHEEL SPEED INCREASES
  B)  WHEEL SPEED INCREASES, AIR PRESSURE SWITCH 
CONTACTS CLOSE
3)  120 VAC FLOWS TO HOT SURFACE IGNITER
NOTE: THE CONTROL MODULE ON THIS UNIT WILL TRY A 
MAXIMUM OF THREE TIMES TO LIGHT THE UNIT.  CYCLE CAN 
BE RESTARTED AT ANY TIME BY TURNING OFF SWITCH AND 
THEN TURNING BACK ON.  IF UNIT HAS GONE THROUGH THREE 
CYCLES AND DID NOT LIGHT, THEN REPAIRMAN SHOULD BE 
CALLED TO CHECK OPERATION OF HEATER.
4)  MAIN BURNER IGNITES
  A)  GAS FLOWS TO MAIN BURNER PORTS AND IS IGNITED
5)  GAS VALVE SENSES BURNER FLAME  
6)  BURNER HEATS WATER
  A)  BURNER HEATS WATER TO THERMOSTAT SETTING
  B)  CONTACTS IN THERMOSTAT OPEN,
  C)  CYCLE IS COMPLETED 
						

							18
TROUBLESHOOTING 
For your safety, water heater service should be performed only by a qualifi ed service technician.  
Read the GENERAL SAFETY INFORMATION section fi rst. 
PROBLEMPOSSILBE MALFUNCTIONSERVICE TO BE PERFORMED
NOT ENOUGH OR NO HOT WATER1) Blower will not run.
A) ON/OFF control switch turned off. Turn switch to the on position.
B) Blower unplugged. Plug blower back into 115 vac. outlet.
C) No power at outlet. Repair service to outlet.
D) ON/OFF switch defective. Replace switch.
E) Control harness defective. Replace control harness.
F) Blower motor defective. Replace blower and motor.
2) Blower running, burner not onReplace switch.
A) Fan not running fast enough to close
    air switch contacts.Check for low voltage, less than 102 vac., 
have service checked and repaired.
B) Air pressure switch defective. Replace switch.
C) Gas valve defective. Replace gas control valve/thermostat.
D) Control harness defective. Replace harness.
E) Igniter defective. Replace ignitor.
F) Unit has completed three trials to light
    and fail.Reset cycle by turning switch off and then 
back on. If unit does not light in three tri-
als, contact a qualifi ed person for service.
3) Thermostat problems
A) Thermostat set too low. Set temperature control higher.
B) Thermostat or ECO defective. Replace thermostat.
C) High limit control circuit open. Replace high limit control.
4) Others
A) Heater undersized. Reduce hot water usage.
B) Low gas pressure. Contact a qualifi ed person for service.
C) Incoming water is unusually cold. Allow more time for heater to re-heat.
D) Leaking hot water pipes or fi xtures. Have plumber check and repair leaks.
CONDENSATIONA) Water on the fl oor under heater. See Condensation
WATER LEAKSImproperly sealed, hot or cold supply 
connections, relief valve, drain valve or 
thermostat threads.Turn off heater & water, repair unit.
Leakage from other appliances or water 
lines.Inspect other appliances near water 
heater.
Condensation of fl ue products. Refer to CONDENSATION
LEAKING T&P VALVEThermal expansion in closed water sys-
temInstall thermal expansion tank (DO NOT 
PLUG T&P VALVE)
Improperly seated valves Check relief valve for proper operation 
(DO NOT PLUG T&P VALVE)
HOT WATER ODORS OR COLOR
(Refer to ANODE ROD)High sulfate or mineral content in water 
supply or iron or sulfate reducing bacteria 
in water supplyDrain and fl ush heater thoroughly, chlori-
nate, refi l and fl ush again then chlorinate 
water supply. 
						

							19
  WARNING:  DO NOT BY-PASS ANY CONTROLS TO MAKE HEATER OPERATE. 
OPERATE ONLY AS WIRED FROM FACTORY.
TROUBLE SHOOTING
Please check guidelines below.  For your safety, water heater service should be performed only by a qualifi ed service technician.  
Read the GENERAL SAFETY INFORMATION section fi rst.
# LED STATUS PROBLEM SOLUTION
1
The gas control valve/thermostat 
has sensed inadequate or no earth 
ground.1  Ensure the wall outlet (power supply) is properly 
grounded.
2  Ensure all ground connections/wires on the water 
heater are securely connected.
2
The gas control valve/thermostat 
has sensed reversed polarity in the 
120 VAC power supply.1  Ensure the wall outlet/power supply is properly wired.
2  Ensure all internal 120 VAC wiring connections and 
wiring harness have no reversed wires. 120 VAC hot 
wire must connect to the on/off switch.
3
Pressure switch circuit remaining 
closed for more than 5 seconds 
after heating cycle begins.
Blower may not start in this 
condition.1  Ensure air pressure switch circuit wiring is correct and 
the air pressure switch is not jumpered.
2  Replace the air pressure switch.
4
Pressure switch circuit remains 
open longer than 5 seconds after 
the blower is energized.
Blower may run continuously in 
this condition.1  Ensure the air pressure switch sensing tube is properly 
connected at both ends and is not kinked or damaged.
2  Ensure the correct size of vent and intake air pipe (direct 
vent products) was used per the installation instructions 
in the manual that came with the water heater.
3  Ensure maximum number of elbows or maximum 
equivalent feet of vent or intake air pipe has not been 
exceeded per the installation instructions in the manual 
that came with the water heater.
4  Ensure there are no obstructions in the vent or intake air pipe.
5
The gas control valve/thermostat 
has detected an open igniter circuit.1  Check wiring to the hot surface igniter assembly - 
replace igniter assembly if wiring is damaged or worn.
2  Check resistance of the igniter at igniter assembly 
plug - should be between 11 and 18 ohms at room 
temperature (77° F at plug end) - replace igniter if open 
or shorted.
3  Check igniter assembly plug and the socket on the gas 
control valve/thermostat for good connection.
4  Replace igniter assembly if the plug is worn or damaged.
5  Replace the gas control valve/thermostat if the igniter 
assembly socket on the bottom of the control is worn or 
damaged.
6
Ignition/fl ame failure.
The gas control valve/thermostat 
has reached the maximum number 
of retries (3) for ignition and is 
currently locked out for one hour.
Cycle the power to the water heater 
off and on to reset.1 Ensure fl ame sensor is making good contact with the 
burner fl ame and ensure fl ame is steady.  Also ensure 
supply and manifold gas pressures are within the 
requirements in the installation manual.  
2  Gas supply is turned off - pressure is too low. 
3 Ensure the fl ame sensor is clean - use fi ne steel wool 
to clean the fl ame sensor.
4  Check igniter assembly plug and the socket on the 
bottom of the gas control valve/thermostat for good 
connection. Replace igniter assembly if the plug is worn 
or damaged.  Replace the gas control valve/thermostat if 
socket is worn or damaged.
5  Replace igniter assembly. 
						

							20
# LED STATUS PROBLEM SOLUTION
7
8
9
Self diagnostic check has detected 
a problem with the gas valve driver 
circuit, internal microprocessor, or 
other internal circuits.1  Turn the power off for 10-20 seconds then on again to 
clear these error codes.
2  If any of these error codes persist or cannot be cleared 
- replace the gas control valve/thermostat.
10
The gas control valve/thermostat 
has sensed main burner fl ame out 
of proper sequence.1  Turn the power off for 10-20 seconds then on again to 
clear these error codes.
2  Replace the gas control valve/thermostat if this error 
code persists.
11
Water temperature in the tank has 
exceeded 195° F and has activated 
the ECO (energy cut off) high 
temperature limit.1  Turn the power off for 10-20 seconds then on again to 
clear these error codes.
2  Replace the gas control valve/thermostat if the error 
code persists.
12
Self diagnostic check has detected 
that one or both of the temperature 
adjust buttons are stuck.1  Press and release both temperature adjust buttons 
several times - cycle water heater power off and on.
2  Replace the gas control valve/thermostat if the error 
code persists.
13
Self diagnostic check has detected 
the water temperature sensor 
(located in the control valves 
immersion probe) is either open or 
shorted.1  Turn the power off for 10-20 seconds then on again to 
clear these error codes.
2  Replace the gas control valve/thermostat if the error 
code persists.
14
Self diagnostic check has detected 
the FV (fl ammable vapor) sensor is 
either open or shorted.1  Turn off power to the water heater.  Ensure all FV 
sensor wiring, the ignitor assembly plug, and the ignitor 
assembly socket on the bottom of the Intellivent control 
are making good contact.  Repair or replace any 
worn/damaged components that are not making good 
connection.
2  Replace the FV sensor.
15
Self diagnostic check has detected 
the presence of fl ammable vapors 
from the FV (fl ammable vapor) 
sensor.1  Do not touch any electrical switch, do not use any 
phone in your building, and do not try to light any 
appliance.
2  Smell around the water heater to ensure there are 
no gas leaks at the gas control valve/thermostat, in 
the supply gas line(s), or any other type of fl ammable 
vapor(s) in the area.
3  Carefully inspect the area surrounding the water heater 
for any substances such as gasoline, paint, paint 
thinners, varnish, or cleaners that could emit fl ammable 
vapors. Remove anything that can potentially emit 
fl ammable vapors from the area and store it properly in 
a different location.
4  Call the technical information support phone number 
shown on the water heater labeling for further 
assistance.
16
The gas control valve/thermostat 
has detected the air pressure switch 
circuit is opening repeatedly during 
one heating cycle.
LDO (Lint, Dust, and Oil) lockout 
condition.1  On models equipped with a dilution air intake screen on 
the blower assembly - check/clean this screen.
2  On models equipped with a combustion air intake 
screen on the base ring (bottom) of the water heater - 
check/clean the screen.
3  Ensure intake air screen(s) on models so equipped are 
not obstructed.