is a self-help
website
| See new water heating ideas 2010 |  |
How to install gas water heater |
||||||||||||||
| Homework first: | ||||||||||||||
 |
1)
Check label on side of old tank Check gallons and BTUs of water heater. Check if water heater is NG natural gas or LP propane gas > these are two different water heaters Measure height so new tank fits without moving vent pipes. |
|||||||||||||
 How to replace TP valve |
2)
Check if TP needs to be specific height This is only important if overflow tube goes through a wall or cannot be moved. Some water heater have TP on top and others have TP on side. In both cases the TP overflow tube must drain downward, and cannot tip upward. |
|||||||||||||
Ask for 10% OFFFind couponsSHOP in advance before you need water heater |
3)
Shopping: Buy from local box store or hardware. Look for scratch-n-dent markdowns 10% off is not Extreme Couponing, but prices are negoiated. The cheapest car is not always the best car. 6-year water heater that is maintained will last longer than 6 years. All water heater brands are good See list of manufacturers and sellers Tanks with longer warranty last longer 12 and 15-year tanks have 2 anode rods or thicker anode rods so tank does not rust as quickly. You can change anode rods yourself without buying longer-warranty tank. Anode rods Read warranty: some warranties depend on professional installation. Limited and pro-rated warranties: shorter warranty is better warranty-value. All water heaters have 1 year parts and labor: So 6 year tank has parts and labor covered for 16% of expected life. While 12 year tank has parts and labor covered for 8% of expected life. 6-year tank that is maintained will last just as long. How to maintain water heater |
|||||||||||||
|
||||||||||||||
 Rheem FV sensor  Larger image Whirlpool resettable ECO (TCO) located on combustion cover |
5)
Understand FVIR prevention and resettable ECO. Today's gas water heaters need regular maintenance and plenty of fresh air to avoid FVIR and ECO shut-off problems. Do not expose water heater to flammable vapors, or dusty environments. Keep belongings away from front and top of water heater. Read the manual and avoid problems that cost money and shorten life of heater The more you can do yourself, the lower long-term cost. FVIR= flammable vapor ignition retardation. ECO = energy cut off. TCO = thermal cut off. Read more Bradford White has FVIR resistant water heater. Rheem, Ruud, Richmond, GE water heater needs to be replaced after FVIR event Water heaters with intellivent gas control can be reset Always turn off water heater when painting or working with fuels Make sure water heater has adequate air supply. Avoid dusty atmospheres and exposure to clorox and pool chemicals. Clean air intake yearly. Clean combustion parts frequently to avoid ECO shutdown caused by overheating. |
|||||||||||||
|
||||||||||||||
|
||||||||||||||
 |
8)
Avoid
tankless promotion Typical family, tankless save $1-8 on monthly energy bill, but installation, maintenance, repairs and purchase price never payback Tankless are maintenance heavy. All costs are energy. Read1 Read2 Tankless require yearly maintenance, tank-type require periodic maintenance |
|||||||||||||
 Do not set gas water heater on carpet or near flammables |
Cautions:
Do not install GAS water heater on top of carpet. Must be on wood or metal surface. Keep household and building materials 6" away from front; 0-1" away from side and back; and 24" away from top of water heater. Check that water heater is NG natural gas or LP propane gas > these are two different water heaters Do not install LP gas water heater below grade (basement) since gas leak will fill basement with explosive gas. NG is fine for basement since NG natural gas leak is lighter than air and will rise, so basement will not fill with gas Gas water heater should be set 18" above floor level. Adequate incoming air supply is needed. Do not install LP gas water heater below grade (in basement). Read water heater safety precautions before starting Water heater precautions/ pdf |
|||||||||||||
 |
Steps for installing gas water heater: 1) Turn off water and identify hot and cold. Notice that shut off valve is located on COLD water pipe. Hot pipe must go to side of heater marked HOT, and cold to COLD or heater will not work. Disconnect water pipes from water heater. If you are unsure which pipe is hot, then run hot tap for a minute and feel which pipe on top of water heater is hot |
|||||||||||||
 Drain water heater |
|
|||||||||||||
 Larger image |
|
|||||||||||||
   |
4)
Disconnect gas line from water heater control valve using
crescent wrench or pipe
wrench. Keep end of gas line clean. If you have flexible gas line, take care not to twist or kink tube so you can use it again. Spray a bit of WD40. Note size of gas line: If you buy same BTU heater, then gas line is correct size. If you buy heater with more BTUs, check that gas line is large enough. Tip: Home center sells yellow-colored flexible gas line. Back of flex-line package has BTU chart to help select correct size gas line. New flex gas line can cost about $30 so use old one when possible. |
|||||||||||||
 |
5)
Disconnect vent pipe from draft hood Support vent pipe with wire so it will not fall down. Flue pipe joints should have 3 sheet metal screws at each joint. Purpose of vent pipe is to remove combustion gases from house |
|||||||||||||
 |
6)
Inspect vent pipes/ Do not use aluminum vent pipe Vent pipe must be approved material as shown in product manual. For example galvanized or stainless steel. Aluminum vent pipe is not code, and is unsafe. Install 3 sheet metal screws per joint, and then add metal tape over screws if required by local code. Taping vent joints without using screws is not code. If vent pipes are rusted, covered with white condensate, or have holes, then vent pipes must be replaced. If top of old water heater has black soot, that can indicate vent pipe is not working correctly. Danger. A plumber may be necessary to correct vent problems. Check that vent cover is still on top of vent pipe located on roof and that vent pipe has no obstructions. Read more near bottom this page. |
|||||||||||||
 |
7)
Check if vent has proper draft by lighting match See if smoke drafts immediately upward. The smoke should not linger. It should draw upwards quickly. If vent does not have draft or if furnace vent is blowing out of water heater vent each time furnace turns on, then vent pipes must be repaired. All gas appliances must vent out of house to avoid CO poisoning. Read checking the draft |
|||||||||||||
 |
|
|||||||||||||
 Holly removes anode rod for periodic inspection Larger image |
|
|||||||||||||
 Larger image |
Avoid
installing water heater where it is exposed to stored chemicals.
Read about corrosive atmospheres 10) Set new water heater in place Read manual for advisories. Water heater should sit at least 18" off floor since flammable vapors, such as stored lawn mower gasoline and paint thinners, will gather close to floor. Leave space so water hose can be connected to drain valve. Water heater weighs 75-220 lbs empty. 40 gallon steel water heater filled with water weighs approx 400-500+lbs. If area is prone to high water, set heater higher. Warranty is void if water heater floods. Manufacturers recommend replacement of flooded heater. Do not touch water heater that has been flooded. Electric shock danger. Turn off breakers. Use earthquake straps as required by code. Set water heater in drip pan. If air intake is on bottom, then stand heater on bricks. Drip pan cannot be deeper than 2", and must be 1-2" wider on all sides than water heater so the pan does not interfere with air supply entering water heater. Install 3/4" or larger drain connection that goes to a drain. Many people don't use drain pan. Tank failure can render home unlivable until repairs are made. Leaking water heater |
|||||||||||||
 Larger image |
11)
Connect draft hood to new water heater 2 or 3 sheet metal screws directly into top of heater |
|||||||||||||
 Attach vent pipe to draft hood using sheet metal screws. See image |
|
|||||||||||||
 |
12a)
Solder for copper water pipe Use 95/5 tin-antimony solder or other equalevent when soldering copper water pipe. Use non-lead solder Do not use 50/50 tin-lead solder or lead-based solder for potable water lines. How to solder pipe |
|||||||||||||
c Larger image |
|
|||||||||||||
 |
14)
Connect gas line exactly as it was connected before. Apply yellow teflon tape, and leave first two threads clean with no tape. Do not let dirt, stray teflon, or any debris enter gas line. Make sure gas line is clean. If you can install water line successfully, you can connect gas line. Gas line has less pressure than water line. When using pipe joint compound, use approved compound for gas. Do not over-dope pipe so compound can enter gas control valve. Make sure inside diameter of pipe is clean and free of cuttings and loose dirt. Don't overtighten gas line to gas control valve or damage to gas control valve can occur. |
|||||||||||||
 Do not overtighten |
Re-use yellow flexible gas line If product manual requires solid pipe, do not use flexible connection. For example hybrid, or tankless ect might require solid pipe. Local code might require solid pipe, otherwise flexible gas line is easier to install. Do not use copper pipe for water heater gas connection. Gas will react with copper. There are regional exceptions that allow copper pipe, when the regional gas supply does not react with the copper. Check local codes. Use yellow teflon tape on flex line connections Home center sells flexible gas line for easy installation. Back of flex line package has BTU chart. Match flex-line diameter with BTUs of new heater. 3" drip leg required to keep moisture and contaminates from entering gas control valve |
|||||||||||||
 |
||||||||||||||
 Do not overtighten |
Use 'black pipe' Black pipe is for gas Do NOT use galvanized pipe that is reactive to gas. Zinc flakes will come off galvanized pipe and enter gas valve causing malfunction. Put yellow teflon tape on each pipe joint. Yellow-colored teflon tape is for gas pipes. Gas pipe capacity .pdf |
|||||||||||||
 Install overflow tube |
15)
Install TP overflow tube that runs down to at least 6
inches of floor. Use pipe off old heater. Overflow tube must be same diameter as valve discharge connection. Do not downsize pipe into smaller pipe. Overflow tube can have maximum 4 elbows and 30 feet length. End of overflow tube cannot be threaded. Tube cannot be lower than top edge of drip pan. Tube must terminate 6" above open drain. TP valve can draw water back into water heater if overflow tube is under water. Do not cap off TP valve or obstruct overflow tube Overflow tube cannot have shut off valve installed, or any obstructive valve TP valve is first line of safety for water heater. TP valve releases water when pressure or temperature is too high, and prevents possible water heater explosion How to test and replace TP valve |
|||||||||||||
 |
Tank
is installed ✔ Water heater set 18" above floor in drip pan ✔ Vent hood and vent pipe connected with 3 screws at each joint ✔ Water pipes installed ✔ Gas line connected to water heater control valve. ✔ Overflow tube connected to TP valve Next: Turn on gas Check for leaks Fill tank with water Turn on burner |
|||||||||||||
 |
15a)
Water heaters that connect to electrical outlet. If water heater has power vent blower etc, it will connect to electrical outlet. Use surge protector. New gas valves and electronics can be damaged by simple power outage. Surge can happen when power resumes. Outlet surge Whole house surge Outlet must be wired correctly, with correct polarity and ground. See chart Best result is dedicated outlet that does not connect to other circuits inside home, and does not have fluorescent lights on same circuit. Use cheap circuit analyzer from hardware to test outlet. See image Use multi-meter and test continuity between manifild tube on gas control and ground prong on plug. Gas controls are damaged by surge: Use surge protector. |
|||||||||||||
 Gas valve is ON |
16)
Turn gas ON Rotate gas shut-off handle until parallel with gas line. This lets gas flow to water heater control valve. Now that gas is ON: NO SMOKING, no flame, do not turn light switch on-or-off OK to have lights ON, just don't turn ON any other electrical appliance until leak test is completed You can easily smell gas. LP gas is heavier than air, so smell close to floor. NG is lighter than air and will rise. Be prepared to leave house immediately if you smell gas. Lp gas falls to floor level, so smell close to floor. NG rises so you can smell NG leak when standing. Do not worry excessively |
|||||||||||||
 Larger image |
17)
Test for gas leak a) Test pipes: Mix liquid soap with water and use brush to put around around gas line joints to see if there are bubbles. Use plenty of soapy water. May take some time for bubbles to appear since gas is under low pressure. Soap bubbles coming from joint indicate leak: retighten pipes, use teflon tape on yellow flex pipe and black pipe. Do not overtighten pipes or damage can occur to gas control valve. b) Test factory-installed connections located below gas control valve Manifold and pilot tube connections located under the gas control valve do NOT use teflon tape. See image of manifold and pilot tubes If either tube under gas control valve is leaking, just tighten a little bit. Do not overtighten. Manifold and pilot tube: look for reverse thread on LP water heater. Regular thread on NG water heater Remember: Natural gas and propane gas both have less pressure on the line than water pipes, so gas pipes are easy to seal with ordinary wrench. If you can install water line without leaking, you can do the same with gas line. Do not over-tighten connections. Gas odor will be present if gas line has leak. Smell close to floor since some gas can be heavier than air and will settle downward. If gas is present, leave house immediately and call gas company. Turn off main shut-off at gas meter. |
|||||||||||||
 Bathtub running full stream before lighting water heater |
Tank
must be full of water or steam explosion could occur!! 18) Fill tank completely with water until water is coming out of tub spout. Open tub spout on hot side and wait for full stream of water. Next open TP valve for a moment to bleed last of air from tank. Turn off tub spout and light heater. Tank cannot have any air when burner is turned on or damage can occur to tank. |
|||||||||||||
 How to light typical gas water heater Read directions printed on side of your tank |
19)
Light new water heater as shown in water heater manual. Read the manual for tips and advisories. Watch video Note: New gas heater might have small water leak when first fired up because of condensation Ignore a bit of water inside combustion area or bottom of tank. This water is condensation and will disappear as tank reaches set temperature. Any cold tank can show same condensation when fired up. Water pipes should not be leaking. Water should not be dripping down vent pipe: this signals bad venting ot other vent problem. Don't worry excessively, but if needed, post questions on professional water heater forum: The Tank |
|||||||||||||
 Set temperature to 120 degrees |
20)
Adjust temperature to 120 degrees, or higher if family has
more people. Tank will heat 41 gallons per hour, so expect tank to be fully heated in an hour for example. How to adjust water heater temperature  Intelli-vent gas control valve and Honeywell Gas control valves are increasingly common |
|||||||||||||
 |
21)
Save water heater manual like gold. Read everything in manual. Record date of purchase and warranty period Follow maintenance schedule and installation, operation advisories Manual will save money and heater will last longer. Read 9 ways to save with water heater
|
|||||||||||||
 |
Maintain
water heater and it will last many years beyond warranty.
Read
manual and links below. How to maintain water heater 1) Read about anode rods 2) Read about stray current corrosion 3) How to flush water heater 4) Inspect for leaks 5) 9 ways to save with water heater 6) Water heater safety precautions 7) Read manual and follow maintenance schedule and precautions |
|||||||||||||
| 2012 Troubleshoot gas water heater starts here: Your manual will have troubleshooting steps SEARCH using Ctrl+F for browser Find feature Water heater manufacturers |
||||||||||||||
| Links below contain valuable resources for troubleshooting gas water heater. Recommend also Tank water heater forum Post a question, or Use search feature at tank to find information available nowhere else. Burner will not stay lit Burner flame is yellow | ||||||||||||||
|
||||||||||||||
| Troubleshoot by gas control valve | ||
 Adjust temp on Honeywell gas valve Icon gas valve error codes Full service manual Honeywell Gas valve video Bradford White Service manual Bradford White service manual 2 More Bradford White service manuals How to clean burner Kenmore: Temperature settings and error codes |
 ECO limit 199° F How to light Honeywell gas valve Dampered Fury gas troubleshooting codes Error codes Error codes2 Service manual How to replace Honeywell gas control valve |
 Error
codes and adjust
temp on Intelli-vent gas valve
Troubleshoot Intellivent/ pdf Intellivent service manual Intellivent FVIR trpubleshoot and reset Sample manual |
 |
 Service manual Service manual 2 White Rodgers gas control valve replacement pdf |
|
 How to read gas meter |
 Definitions and formulas/ pdf Pipe size BTU chart Pipe capacity Square footage per BTU |
 Pilot tube orifice Clean with compressed air or carburetor cleaner Standing pilot light maintenance |
|||
 Use wire brush to clean burner assembly and combustion chamber. When re-starting cold tank, expect condensation dripping until tank reaches temperature. Example: how to clean combustion chamber |
 Expanded image |
||||
 Water heater burner assembly with piezo igniter How to clean burner Larger image |
 Burner for LP gas is made of cast iron because LP gas burns hotter. Comparison NG-LP Manifold tube and pilot tube are also made heavier to resist pressure & high heat of burning LP gas Example shows rusty burner that has not been cleaned Gas control valve for LP gas will accept left-hand threads for pilot and manifold tubes |
||||
 Larger image NG gas burners are different than LP burners. LP has more pressure and higher temp |
 Bradford White Piezo igniter How to test piezo igniter Bradford White gas water heater service manual |
 Gas water heater |
|||
 Location of flame sensor and igniter vary by model and brand of water heater. Larger image Hot surface igniter troubleshoot Sand carbon deposits off igniter. Avoid touching igniter |
 Larger image Intellivent troubleshoot Manual Power vent surface ignition Tip of flame sensor must be directly in front of burner port. Use a nickle to set 7/64 gap. Natural gas flame sensor will be bent, while propane will be straight. |
 Larger image Burner flame is yellow |
|||
 Larger imageWhite Rodgers gas control valve replacement pdf ECO wires/ thermocouple/ manifold tube/ pilot tube/ piezo igniter How to test water heater thermocouple LP heaters have left-hand threads |
 Larger image Don't overtighten gas line to control valve or damage to control valve can occur. How to set temperature on gas valves  How to replace gas control Replace gas control |
 Whirlpool resettable ECO thermal switch trips when combustion get too hot. Prevents overheating: Clean burner parts. If pilot or burner is
reveiving any amount of gas, then ECO is not tripped
Test ECO |
|||
|
|||||
|
FVIR
water heater: How to repair Rheem FVIR
FVIR troubleshooting guide Symptom of FV failure 'If pilot stays on without problems as long as gas valve is in PILOT position, but you then turn to ON position and main burner flutters and disappears within 30 seconds then 99% chance TRD is tripped.' (On Rheem heaters, look for signs of shattered glass on combustion floor.) Same symptoms can be bad gas control |
|||||
|
Air
enters combustion chamber from below burner.
 SP20172 FV sensor shuts off gas and trips air shut-off  |
 Rheem uses glass vial that cannot be replaced How to fix Rheem TRD If system is tripped, the bulb glass is visible on floor of combustion chamber. |
FV
system: When water heater is exposed to flammable
vapor, and the vapor ignites
inside combustion chamber, the FV system immediately
shuts off air supply to combustion and prevents a flashover or
explosion inside the room. Each water heater has a different design. Call manufacturer for instructions for replacing or resetting FV. FVIR troubleshoot guide Rheem water heater parts list 2006 Rheem parts list 2010 |
|||
| Read more2 Read more3 | |||||
Raise water heater 18" off floor to avoid flood damage and flammable vapors |
Help
prevent FVIR event by installing gas water heater at least
18" off the floor. #1) Make sure there is adequate fresh air, and that air is clean and list free, and does not have trace chemicals. #2) Always turn off gas to water heater when painting with oil-base paint or oil-base varnish, and when cleaning with solvent-based products, and when pouring gasoline etc. For example when storing gasloine near water heater, the water heater should sit minimum 18" off floor, gasoline should be tightly capped, and do not pour gas to fill gas tank in same room as water heater. |
 Larger image Read pdf Attic ventilation is needed for gas water heater. Increase ventilation to water heater |
|||
|
|||||
 |
If gas valve is connected
to electricity, the outlet polarity must be correct Water heater must be grounded. Poor ground can prevent flame. GFCI circuit can cause short cycling. If outlet is not dedicated or has GFI, other loads such as florescent lighting can cause short cycling.  Unplug cord. Test for continuity between ground prong on plug and manifold tube on gas valve. Connect water heater to different outlet. Test outlet with circuit analyzer |
||||
 |
How to set temperature on gas valves | ||||
| If you maintain the tank: keep chemicals out of same room, attach bare copper ground wire between hot and cold pipes, flush tank each 6 months, clean burner each year as shown in manual, read the manual entirely for specific information about your model, and inspect/replace anode rod every 2-3 years then basic 6-year tank can last much longer. | |||||
|
How
to test water heater vent. Let main burner operate for 5 minutes. Then put match near vent hood. Smoke from match should get sucked into vent Water heater vent test/ pdf Checking the draft Read more at Tank |
 |
|
 See larger During typical water heater combustion, hydrogen content of fuel is burned and the result is hot gases. One of these hot gases is steam or water vapor. Adequate venting or air draw up vent is required so gases vent outside. When there is inadequate draw, the water vapor cools and condenses on inside wall of vent pipe. This condensation water is acidic (pH 3-5) and corrosive. It will corrode steel metals and other materials. Improper venting causes water to drip down vent into combustion chamber of gas water heater. Parts inside combustion chamber rust. Holes develop in bottom of water heater. Inspect combustion chamber for rust and water. If steel vent pipe is not venting, the vent pipe will rust and get holes, or joints will fall apart. This situation causes hot gases to enter home and poses serious risk of odorless CO poisoning. Simple test for proper venting: Pipes are not rusted or covered with white condensate. No water on top of tank. Burner inspection does not show excessive rusting. Light match under vent pipe and see if smoke immediately draws upwards. If smoke does not draw, then call plumber. |
Flue
Pipe Safety Read manual for flue pipe clearances so hot vent pipe does not touch or come near combustibles. Rusted flue pipe -or-water on top of gas water heater could indicate serious problem. Call a plumber if you are uncertain. Check pipes and flexible connectors for leaks. If water coming from flue pipe: 1. Vent cover could be missing > rain water entering flue (replace cover) 2. Flue pipe clogged with bird nest or come apart or damp from improper venting: danger of odorless Carbon Monoxide poisioning Serious danger from CO poisoning, a plumber should be called if you are uncertain about vent pipe water leak Read troubleshooting at forum See u-tube video Read about CO detector  How to replace anode rod |
|
Minimum
distance of vent pipe from window Side-wall vent pipe must be 4 feet away from windows and doors. And 3 feet away from inside corners. Larger image with more information Power direct-vent clearances Venting a gas water heater Conditions where outdoor air supply is needed |
 How to flush gas water heater |
 |
 9 ways to save with water heater |
 |
 |
 See basic 120V and 240V water heater circuits |
 Drop wire from attic |
 Replace circuit breaker |
||
 Wire nuts and how to twist wire |
 How to wire off-peak water heater |
 Home page |
 Hot water circulation system |
||
 9+ ways to save with water heater |
 Motorized shut off valve |
 Clean sediment from tank |
|||
 Contactors |
 Anode rods |
|
|||
 |
 My art website |
 Intermatic trippers and parts |
 Do it yourself water heater |
||
 Low hot water pressure |
 Atwater water heater resources |
 Leaking water heater |
Remove water heater from attic |
||
 Remove old element |
Water heater safety precautions |
 How to wire Cooper 277 |
|||
 |
UPM-timers-and-manuals.html |
Woods timers and manuals | |
 |
GE-timers-and-manuals.html |  |
Sylvania timers and manuals |
 |
Intermatic ST01C timer Utilitec-timers Aube timers |
 |
Horsepower ratings for countdown timers Leviton timers |
 |
Tork-consumer-timers-and-manuals.html |  |
Box timers |
 |
E-mail: info@waterheatertimer.org Site map |
