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How to replace gas water heater |
 Electric water heater thermostats Thermostats stick melt and come out of calibration... replace thermostat Symptoms: Cold water, uneven temperatures, reset tripping, TP releasing water Buy: Water heater thermostats at Amazon Resources: How to replace electric water heater thermostat Add another thermostat to water heater How to wire thermostats Marathon water heater thermostats Two water heaters Troubleshoot electric water heater |
  Gas water heater thermostats If tank is overheating or not heating correctly, replace thermostat Symptoms: Cold water, uneven temperatures, TP releasing water Buy: Gas water heater thermostats at Amazon Resources: How to replace gas water heater thermostat Add another thermostat to water heater Troubleshoot gas water heater |
| Select new water heater | |||
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-Propane
and natural gas are different: Propane: do not install below grade (in basement). Propane gas is heavier than air. Propane gas leak hugs floor and can fill basement with explosive gas. Natural gas is lighter than air, and will rise, and installation is suitable below grade.  Odorant is added to
both propane and natural gas. If you smell gas, leave house. Call gas
company.-BTU rating: Check label on side of old heater, and buy same-similar BTU rating for new heater. Larger BTU rating might require larger gas line or starve gas appliances and cause malfunctions when more than one appliance is operating. Typically residential tank water heaters will not cause a gas shortage. However tankless gas unit might. -Physical dimensions: Water heaters manufactured after April 2015 are larger diameter because of thicker insulation added to DOE standards. Measure height and diameter if necessary. Water heaters over 55 gallon must be condensing type heater. Cost of over-55 gallon heater plus installation and maintenance are an expensive choice. Install 2 water heaters.  -TP valve location: Check if TP needs to be specific height. Important if overflow tube goes through a wall or cannot be moved. TP overflow tube must drain downward, and cannot tip upward. Resources: Which is best gas water heater Two water heaters TP valve code |
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 -If Air intake is located on bottom: Applies to AO Smith, Kenmore, Whirlpool, State, Reliance, Craftmaster, GSW etc Air intake on bottom is easy to clean. Set 3-legged water heater on bricks so air intake screen, or flame arrestor screen, can be inspected and cleaned. How to clean air intake How to inspect flame arrestor screen |
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-If Air intake is
located on side of tank Rheem,
Reliant, Ruud, GE, Bradford White etcAir intake on side of tank means that combustion parts have to be removed to clean air intake screen. If arrestor screen becomes clogged with dust, the amount of air entering combustion chamber is reduced, and this slows draft going up vent pipe, which causes slow draft, vent odors, sooting, possible danger from incomplete gas combustion, and eventually causes combustion chamber to overheat, which trips FV lockout system. Repairs required. Keeping arrestor screen is important, so choose water heater with screen located on bottom of tank where it is easier to inspect and clean. Air intake screen How to clean water heater burner |
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 Ok for electric heater, but not gas |
Avoid dust and dirty locations.
Dirty, dusty environments pose hazards for all gas appliances. Water heater air intake will clog, and shut down burner or cause FV lockout. FV lockout  Avoid stored chemicals Do not expose water heater to stored chemicals, swimming pool chemicals, laundry equipment Remove chemicals from same room as water heater. -Chemicals corrode water heater parts and vent pipe. 'Spray propellants, cleaning solvents, refrigerants, swimming pool chemicals, calcium and sodium chloride, household bleach, waxes and process chemicals are corrosive at very low levels with no odor." |
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 Manufactured home/ Small un-vented closet/ Small home Mobile home water heater is designed to draw air from underneath structure. This ensures adequate air supply to support combustion, and allows water heater installation inside small closet. Air intake must be kept clean, and no flammable vapors stored nearby. Spec sheet illustration of air intake Install electric water heater instead? Note: any ordinary electric water heater can be installed in mobile home when circuit breaker box can support rated wattage. 4500 watt electric water heater = 10 gauge wire and 240volt 30 amp breaker Replace elements with smaller wattage 3800 watt electric water heater = 12 gauge wire and 240volt 20 amp breaker |
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4.
Warranties are same across all brands First year parts-tank-labor are covered for original homeowner and non-commercial installation Must be installed by instructions shown in product manual. Cannot be installed for commercial purpose, or placed in damp, dusty environment etc. Some warranty sellers cover labor for installing new heater during first year. After first year, parts-and-tank are covered, but no labor. Some warranties are pro-rated on parts and tank, and do not give full coverage as unit gets older. Main difference between 6 year 9 year 12 year is anode rod diameter, or sometimes 2 anode rods. Other difference can include drain valve, inlet tube, nipples, burner orifice and manifold door assembly, weight and durability of materials. Generally you can convert 6 year tank into 12 year or 15 year by inspecting anode each 1-3 years, and maintaining tank as shown in product manual. How to Replace-anode-rod.html How to maintain water heater Simple math comparison between 6 and 12 year heaters: if 6 year heater costs $550, and 12 year heater costs $800, the cost difference is $250. In exchange you get 6 years of extended part warranty, or $41 per year for longer warranty. Since a typical gas control valve costs $100 - $140 to purchase at retail (2016), the longer warranty might be best choice. DIY resource: Gas valve resource Extended warranty Extended warranty should include labor. |
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| 7)
EF (energy factor) is not efficiency ... EF is a formula for finding
efficiency 30-40-50 gallon heaters have EF .675 - (.0015 x V where V is tank gallonage). 50 gallon gas water heater has .60 efficiency. 40 gallon has efficiency of .62 30 gallon has efficiency of .63 How much does it cost to run gas water heater? |
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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 9) KEEP IT SIMPLE: Expensive water heaters will not pay pack Review GE Hybrid Things you should ask before buying solar water heating system |
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Remove flammables away from water heater Explosion inside your home wastes precious fuel, and could burn down neighbor's garage. FVIR water heaters are NOT 100 effective for protecting home and life from explosion. Do not set gas water heater on carpet or near flammables. Ok for electric, but not gas Buy: Gas safety cans at Amazon Read about FVIR (flammable vapor retardation) |
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| Installation starts here | |||||
 Cold side has shut off Run water and feel which pipe is hot |
1) Identify hot and cold sides Look for markings on top of old tank. Letters H and C are usually stamped into top of tank. Water heater must be connected Hot-to-hot and Cold-to-cold. Shut off valve should be located on Cold side. But never ASSUME... always check Hot and Cold sides. Identify Hot pipe: run hot out of tap for a minute and use hand to check temperature of pipes on top of heater. 1) Turn off water 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 |
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No
shut off valve Shut off water to house Rotate shut off 1/4 turn so valve is perpendicular across water line Located water meter box, remove lid, dig away dirt to find shut off Shut off is located on house-side of meter Use water key or pipe wrench Buy: Water keys at Amazon |
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 Drain water heater |
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 3) Shut off gas Locate gas line. Gas line is black-colored metal pipe or a yellow-colored flexible tube. Follow gas line back a few feet away from water heater and find gas shut-off. When gas is ON, handle is positioned same direction as gas line. Turn gas OFF, rotate shut off handle 1/4 turn. When shut-off handle is perpendicular across gas line, then gas is off. |
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 Keep end of pipe clean   |
4)
Disconnect gas line from control valve using
crescent wrench or pipe
wrench. Keep end of gas line clean. You can reuse old flex line. 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. Buy: Knipex channel locks Irwin pliers |
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  Keep pipe clean |
Union Gas line, and water lines can be connected with UNION. Use black pipe for gas. Loosen large nut. Take apart union using two wrenches. To re-install union: Clean connection surface with rag and apply thin film of approved pipe sealant to each surface using finger to help pick up last bits of debris and to help seal pipe. No teflon tape needed on threads of big nut. Thread sealant must be rated for gas... buy at local hardware.... read product label. Apply to beveled surface of union. Apply thread sealant completely over the surfaces that will connect together when union is reattached. Keep parts clean so debris does not enter gas control valve -or- replace union with flexible connection. |
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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 |
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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 or PVC. Aluminum vent pipe is not code, and is unsafe for gas appliance vents. Use aluminum on dryer only.. 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, or 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. Troubleshoot water heater vent |
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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 |
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 Holly removes anode rod for periodic inspection Larger image |
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 Larger image Water heater stands at Amazon  Drip pan saves damage See drip pan installation Buy: Water heater drip pans at Amazon Buy: Water detectors at Amazon Auto-shut-off valve at Amazon |
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. Earthquake straps at Amazon 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 |
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11)
Connect draft hood to new water heater 2 or 3 sheet metal screws directly into top of heater Install vent hood pdf from AO Smith |
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 Attach vent pipe to draft hood using sheet metal screws. See image |
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12a)
Solder for copper water pipe Use 95/5 tin-antimony solder or other equivalent 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. Do not solder on connection that is attached to water heater nipples. Solder parts and then connect to heater. How to solder pipe |
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Hot
to Hot and cold to cold Look for markings on top of heater If water pipes are reversed, water heater will not work Which is cold pipe? Cold pipe has the shut off valve Use flexible copper for EZ connection Buy: Flexible water heater connection |
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c Larger image |
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14)
Gas lines ... use yellow teflon tape 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. |
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| Do not overtighten connection at gas
control valve Just make it tight, but do not 'crank down' on the wrench or gas control valve can be damaged You will perform a gas leak test on last step, so take it easy on the big big wrench when attaching pipe to gas valve. |
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 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 etc might require solid pipe so gas flow is maximum, and gas flow is not restricted by bends in 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 gas line connections Home center sells yellow 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 (or sediment trap) is required to keep moisture and contaminates from entering gas control valve |
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 Do not overtighten pipe at gas valve |
Use 'black pipe'/ do not use galvanized
pipe for gas Black pipe is for gas Do NOT use galvanized pipe. Galvanized 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. Do not overtighten at gas control valve Union can be very tight. Re-install union: Clean connection surface with rag and apply thin film of approved pipe sealant using finger to help pick up last bits of debris and to help seal pipe. No teflon tape needed on threads of big nut. Gas pipe capacity .pdf |
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 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 |
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Tank
is installed ✔ Water heater set 18" above floor in drip pan ✔ Vent hood and vent pipe connected with 3 screws at each joint. Aluminum tape over 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 |
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 Type 3 surge protection outlet must be grounded |
Wall
outlet surge suppression/ protection for electronic gas controls and
gas water heaters with blowers Check product manual for electrical recommendation Two outlets/ Both outlets surge-protected/ can also protect other outlets in the circuit Meet standard for new water heaters that plug into outlet Hot, neutral and ground wire needed/ can replace any ordinary outlet Locate outlet within 10 feet of water heater ... do not use extension cord Buy: 15 amp surge suppressor receptacle Leviton J-box surge protection kit 15 amp duplex surge protector Surge block Resources Types and installation for home surge protection Outlet surge suppression manual Surge protection outlet manual |
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15a)
Water heaters that connect to electrical outlet. If water heater has power vent blower etc, it will connect to electrical outlet. Check product manual for electrical recommendation on surge protector. New gas valves and electronics can be damaged by simple power outage. Surge can happen when power turns off, then resumes. How to wire 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 manifold tube on gas control and ground prong on plug. Gas controls are damaged by surge: Use surge protector. |
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 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 |
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 Larger image Give gas time to show bubbles. Gas pressure is low, so it take time for leak to show. |
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. |
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 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. |
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 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 product manual for tips and advisories. How to light gas water heater by type of gas control valve 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 or other vent problem. Don't worry excessively, but if needed, post questions on professional water heater forum: The Tank |
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 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 How to increase amount of hot water  Intelli-vent gas control valve and Honeywell Gas control valves are increasingly common |
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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
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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 |
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 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 |
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 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 poisoning 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 |
 Woo Hoo |
How-to-troubleshoot-gas-water-heater.html Click link for gas water heater resources including troubleshoot by type of gas control valve. Troubleshoot electric water heater How to install under-counter water heater |
 How to flush gas water heater |
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 9 ways to save with water heater |
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Recirculation systems |
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