American Water Heater 318935-003 manual

1 Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHA T 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 building. • Immediately call your gas supplier from a neighbor ’ s phone. Follow the gas sup[...]

2 T able Of Contents W ater Heater Safety .............................................................................. 1-2 Installing Y our Gas W ater Heater ........................................................ 3-16 Unpacking the W ater Heater ........................................................... 3 Location Requirements ................[...]

3 INST ALLING YOUR GAS W A TER HEA TER Important Information About This W ater Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation e[...]

4 Location Requirements The Flame Guard™ Safety System is designed to reduce the risk of flammable vapor-related fires. The patented system protects your family by trapping the burning vapors within the water heater combustion chamber through the special flame-trap. The burning vapors literally “burn themselves out” without escaping back into[...]

5 IMPORT ANT : The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure. Due to the normal corrosive action of the water , the tank will eventually leak after an extended period of time. Also any external plumbing lea[...]

6 Gas Supply Gas Requirements IMPORT ANT : Read the data plate to be sure the water heater is made for the type of gas you will be using in your home. This information will be found on the data plate located near the gas control valve/thermostat. If the information does not agree with the type of gas available, do not install or light. Call your de[...]

7 Combustion Air Supply and V entilation IMPORT ANT : Air for combustion and ventilation must not come from a corrosive atmosphere. Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage. The following types of installation (not limited to the following) will require outdoor air for combustion due to chemical exp[...]

8 Unconfined Space A water heater in an unconfined space uses indoor air for combustion and requires at least 50 cubic feet for each 1,000 BTU/HR of the total input for all gas appliances. The table below shows a few examples of the minimum square footage (area) required for various BTU/HR inputs. IMPORT ANT : • The area must be open and be able [...]

9 All Air from Outdoors Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and horizontal ducts. The fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors. Attic or crawl spaces cannot be closed and must be properly ventilated to the outside. Duct[...]

10 V ent Pipe System This water heater uses a non-direct, single-pipe vent system to remove exhaust gases created by the burning of fossil fuels. Air for combustion is taken from the immediate water heater location or is ducted in from the outside (see “Combustion Air Supply and V entilation” section). This water heater must be properly vented [...]

11 Chimney Connection IMPORT ANT : Before connecting a vent to a chimney , make sure the chimney passageway is clear and free of obstructions. The chimney must be cleaned if previously used for venting solid fuel appliances or fireplaces. Also consult local and state codes for proper chimney sizing and application or , in the absence of local and s[...]

12 W ater System Piping Piping Installation Piping, fittings, and valves should be installed according to the installation drawing (Figure 13). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation. The water supply pressure should not exceed 80 psi. If this occurs, a pressure reducing[...]

13 Please note the following: • The system should be installed only with piping that is suitable for potable (drinkable) water such as copper , CPVC, or polybutylene. This water heater must not be installed using iron piping or PVC water piping. • Use only pumps, valves, or fittings that are compatible with potable water . • Use only full flo[...]

14 T emperature and Pressure Relief V alve For protection against excessive pressures and temperatures, a temperature and pressure relief valve must be installed in the opening marked “T & P RELIEF V AL VE” (see Figure 15A). This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection [...]

15 Special Applications Combination Space Heating/Potable W ater System Some water heater models are equipped with inlet/outlet tappings suitable for combination water (potable) heating and space heating and not suitable for space heating applications only . If this water heater is to be used to supply both space heating and domestic potable (drink[...]

16 W ater Heater Location W ater heater location is important and can affect system performance. Please check the following: □ Installation area free of corrosive elements and flammable materials. □ Centrally located with the water piping system. Located as close to the gas piping and vent pipe system as possible. □ Located indoors and in a v[...]

17 OPERA TING YOUR W A TER HEA TER Lighting Instructions Read and understand these directions thoroughly before attempting to light or re-light the pilot. Make sure the viewport is not missing or damaged. (See Figure 23) Make sure the tank is completely filled with water before lighting the pilot. Check the data plate near the gas control valve/ th[...]

18 FOR YOUR SA FETY REA D B EFORE L IGHTING A. T his a pplia nce ha s a pilot which is lighte d by a pie z oe le ctric ignite r . W he n lighting the pilot, follow the se instructions e xa ctly . B. BE F O R E LI G H T I N G sme ll a ll a round the a pplia nce a re a for ga s. Be sure to sme ll ne xt to the floor be ca use some ga s is he a vie r t[...]

19 Burner Flames Inspect the burner flames through the viewport. Flames should be very small with a blue haze and small amounts of yellow or orange at the edges. After several minutes of operation, the burner screen may glow red. If large flames are observed at any time, shut-off unit and call a qualified person. W ater T emperature Stacking Stacki[...]

20 W ater T emperature Regulation The thermostat is adjusted to the pilot position when it is shipped from the factory . Water temperature can be regulated by moving the temperature dial to the preferred setting. The preferred starting point is 120°F at the “HOT” setting. Align the knob with the desired water temperature as shown in Figure 19A[...]

21 Operating the T emperature Control System Figure 19B: Status Codes VAC List of status codes are shown at top of gas control valve/thermostat. W ater T emperature Adjustment The water temperature setting can be adjusted from 55°F to 155°F . T urn the Gas Control/T emperature Knob to the desired setting/temperature. NOTE: The temperatures indica[...]

22 NOTE : This rod may reduc e but not eliminate w ater odo r problems. The water supply system ma y require spec ial f iltration equipment from a water co nditioning company to succ essfully eliminate all water odor problems. Ar tif icially sof tened water is e xceedingly c orrosive because the proc ess substitutes sodium i ons for magnesium and c[...]

23 MAINTENANCE OF YOUR W A TER HEA TER Draining and Flushing It is recommended that the tank be drained and flushed 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. T o drain the tank, perform the following steps: 1. T urn off the gas to the wa[...]

24 Replacement Parts IMPORT ANT : The following maintenance procedures are for the Flame Guard™ Safety System components and should be performed by a qualified person. Replacement parts may be ordered through your plumber or the local distributor . Parts will be shipped at prevailing prices and billed accordingly . When ordering replacement parts[...]

25 Replacing the Pilot/Thermopile Assembly 1. Remove the burner assembly . See Removing the Burner Door Assembly Section. 2. Lift the retainer clip straight up from the back of the manifold component block (using a flat-blade screwdriver), then remove the manifold component block from the burner door (Figure 25). IMPORT ANT : Be careful not to bend[...]

26 Pilot Thermopile Pilot/Thermopile Assembly Pilot Tube (Ferrule Nut Not Shown) Igniter Connector Thermopile Connectors Figure 28 Pilot/Thermopile Assembly (50K Models) 6. Push the new pilot/thermopile assembly connectors through the opening in the burner door (See Figure 27). Do not to scrape or nick the wires during installation. IMPORT ANT : DO[...]

27 if the door gasket does not create a seal between the burner door and the combustion chamber . 6. Reconnect the manifold tubing (3/4” wrench), pilot tubing (7/16” wrench), temperature sensor wires, and thermopile wires to the gas control valve/thermostat. (See Figure 22 for the correct position of the thermopile wires.) Do not cross-thread o[...]

28 Flame Guard™ Safety System Operational Checklist TROUBLESHOOTING CHART 4. Manifold component block properly installed. 5. No leaks at pilot and manifold connection. 6. Burner door screws securely tightened. 1. Burner door gasket properly sealed. 2. V iewport not damaged or cracked. 3. Flame-trap free of debris and undamaged. PROBLEM POSSIBLE C[...]

29 PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION PILOT WILL NOT LIGHT OR REMAIN LIT (continued) 9. ECO switch open 10. Pilot line or orifice clogged 1 1. Non-functioning thermopile 12. Air for combustion obstructed 13. Flammable vapors incident, Flame Guard™ function utilized 9. Replace gas control valve/thermostat 10. Clean, locate source and corr[...]

30 ST A TUS LIGHT CODE TROUBLESHOOTING CHART LED ST A TUS PROBLEM CORRECTIVE ACTION 0 FLASHES (LED NOT LIT) Pilot light is not lit. Not enough power (millivolts) to keep it lit. Follow the lighting instructions on the front of the water heater and record any diagnostic codes. See Diagnostic Status Light Code section. 1 FLASH (EVERY 3 SECONDS) Norma[...]

31 PILOT LIGHT TROUBLESHOOTING CHART Have you bled all the air from the pilot tube and gas supply line? NO While repeatedly depressing the igniter button, push in and hold the gas control/ temperature knob until the pilot is lit and maintains a stable flame, (status light will blink) then release the gas control/ temperature knob. Section A: Pilot [...]

32 REP AIR P ARTS ILLUSTRA TION 1A 2 3 8 5A 10 11 9 7 6A 6B 5B 4 1B LEGEND Special anode rod (see page 21) T emperature and Pressure Relief V alve is required, but may not be factory installed Unique: Flame Guard™ Safety System parts When ordering repair parts always give the following information: 1. Model, serial, and product number 2. T ype of[...]

33 Listed Parts Kits and Illustrations Item 12A: Pilot assembly kit, which contains the pilot, electrode, and thermopile (Natural Gas) Item 12B: Pilot assembly kit (50K Models), which contains the pilot, electrode, and thermopile (Natural Gas) Item 13A: Burner Door assembly , which contains the burner , gasket, door , pilot tube, manifold component[...]

34 NOTES[...]

35 NOTES[...]

36 Copyright © 2012 American W ater Heater Company . All Rights Reserved. Printed in the U.S.[...]