American Water Heater DIRECT VENT GAS WATER HEATER manual

238-45839-00D REV 07/07 DIRECT VENT GAS WATER HEATER WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplie[...]

2 CONGRATULATIONS! You have just purchased one of the finest water heaters on the market today! This installation, operation and instruction manual will explain in detail the installation and maintenance of your new Direct Vent Gas Water Heater. We strongly recommend that you contact a plumbing professional for the installation of this water heater[...]

3 TABLE OF CONTENTS page GENERAL INFORMATION ........................................................... 4 INSTALLATION ........................................................................... 5 Locating The Water Heater .......................................................... 5 Minimum Clearances ..............................................[...]

4 GENERAL INFORMATION This gas-fired water heater’s design is certified by CSA International under the American National Standard Z21.10.1 - (as indicated on the rating plate) and CSA 4.1-M - (as indicated on the rating plate). This water heater must be installed in accordance with local codes or, in the absence of local codes, the National Fuel [...]

5 General Information continued- IMPORTANT Before proceeding, please inspect the water heater and its components for possible damage. DO NOT install any damaged components. If damage is evident then please contact the supplier where the water heater was purchased or the manufacturer listed on the rating plate for replacement parts. Make sure that y[...]

6 Installation (Locating The Water Heater) c ontinued - Water heaters in residential garages must be installed and located, or protected, to avoid phy sical damage. For other installations refer to local codes. In the absence of local codes, the w ater heater must be installed in compliance w ith the National Fuel Gas Code, (ANSI Z223.1- Latest Edi[...]

7 Installation (Locating The Water Heater) c ontinued - WARNING Liquefied petroleum gases/propane gas are heavier than air and will remain at floor level if there is a leak. Basements, crawl spaces, closets and areas below ground level will serve as pockets for accumulation of leaking gas. Before lighting, smell all around the appliance area for ga[...]

8 Installation (Locating The Water Heater) c ontinued- The water heater must be located close enough to the outside wall to keep the venting distance within the maximum distance described in the installation instructions. Note: The direct vent-air intake terminal must be installed on a vertical wall. Read the venting section in this installation in[...]

9 OPTIONAL DIRECT VENT-AIR INTAKE TERMINAL GUARD WARNING The direct vent-air intake terminal is HOT while the w ater heater is in operation. Do not touch. Keep children, combustibles, gasoline and other liquids having flammable vapors away. It is recommended that a vent-air intake terminal guard be installed when the vent-air intake terminal is loc[...]

10 Installation continued- Figure 2 Figure 3[...]

11 VENTING This is a Direct Vent Gas Water Heater where all air for combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere. WARNING The vent-air intake sy stem must be properly installed. Failure to properly install the v ent-air intake system properly could result in property damage, personal[...]

12 Venting continued- Canadian Installations 1 US Installations 2 I= Clearance to service regulator vent outlet or oil tank vent 36 inches (91 cm) *b J= Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance 12 inches (30 cm) 9 inches (23 cm) K= Clearance to a mechanical air supply inlet 6 feet ([...]

13 Venting continued- The co-axial vent-air intake tubes of this water heater can be installed in any 360 ° configuration as long as the proper clearances for installation, plumbing, operation and servicing are maintained. (See Figure 5). Figure 5 Note: Maintain proper clearances for installation, plumbing, operation and service. HORIZONTAL AND VE[...]

14 Installation (Horizontal and Vertical Vent-Air Intake L en g th s) continued- The water heater is shipped with the following standard vent and air intake system: 239-41097-00. The components of this vent and air intake systems is as follows: 3” Vent Tube* Vent Terminal Hardware 5” Air Intake Tube* RTV Silicone Sealant Vent Terminal 3” Vent[...]

15 Installation (Horizontal and Vertical Vent-Air Intake L en g th s) continued- Figure 6[...]

16 VENT-AIR INTAKE SYSTEM INSTALLATION WARNING The vent-air intake sy stem must be properly installed. Failure to properly install the v ent-air intake system could result in property damage, personal injury or death. Do not install any damaged v ent-air intake system components. Contact the manufacturer of the w ater heater for replacement parts. [...]

17 Installation (Vent-Air Intake System Installation) con tin u ed- 1. Measure the vertical height “Y” requi red in your installation. (See Figure 6). Reference the appropriate Table A to determine number of vent-air intake kits required in your installation. 2. Measure the horizontal length “X” required in your installation (See Figure 6).[...]

18 Installation (Vent-Air Intake System Installation) con tin u ed- 5. Insert the straight end of the three (3) inch (7.6 cm) diameter elbow into the flue reducer until firmly seated and oriented in the correct direction. With a 1/8 inch diameter drill bit ( not supplied), drill three (3) holes, 120 o apart, through the flue reducer into the three [...]

19 Installation (Vent-Air Intake System Installation) con tin u ed- Figure 9 7. Extend the three (3) inch (7.6 cm) diameter telescopic tube to its maximum length and slide the backing plate over it. Place the large end of the three (3) inch (7.6 cm) diameter telescopic tube through the hole in the outside wall. Insert the smalle r end of the three [...]

20 Installation (Vent-Air Intake System Installation) con tin u ed- Figure 10 8. Extend the five (5) inch (12.7 cm) diameter telescopic tube to its maximum length. Place the large end of the five (5) inch (12.7 cm) diameter telescopic tube over the co llar on the outer wall mount plate. Drill three (3) 1/8 inch diameter holes, 120 o apart, through [...]

21 Installation (Vent-Air Intake System Installation) con tin u ed- 9. From outside the building, slide the five (5) inch (12.7 cm) diameter telescopic tube through the opening in the wall until the outer wall mount plate is flush with the wall (See Figure 12). Figure 12 10. Using the supplied special RTV silicone sealant, apply a bead one (1) inch[...]

22 Installation (Vent-Air Intake System Installation) con tin u ed- Figure 13 11. From inside the building, slide the backing plate over the five (5) inch (12.7 cm) diameter telescopic tube until it is flush with the wall. Adjust the length of the five (5) inch (12.7 cm) diameter telescopic tube and insert the end into the flared end of the five (5[...]

23 Installation (Vent-Air Intake System Installation) con tin u ed- 12. Mark the mounting screw hole locati ons for the backing plate. Rotate the backing plate in order to gain access to the markings. With a 3/16 inch diameter drill bit (not suppli ed), drill holes for the supplied wall anchors. Install the wall anchors and secure the backing plate[...]

24 WATER CONNECTIONS Note: BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN WATER SUPPLY VALVE. After shutting off the main water supply, open a faucet to relieve the water line pressure to prevent any water from leaking out of the pipes while making the water connections to the water heater. After the pressure has been relieved, close the f[...]

25 Water Connections continue d- WARNING For protection against excessive temperatures and pressure, install temperature and pressure protective equipment required by local codes, but not less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of produc[...]

26 Water Connections continue d- WARNING FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED 3/4” X 3/4” TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE MANUFACTURER FROM ANY CL AIM, WHICH MIGHT RESULT FROM EXCESSIVE TEMPERATURES AND PRESSURES. If this water heater is installed in a closed water supply system, such as the one having a back-flo[...]

27 Water Connections continue d-                                                                        [...]

28 Gas Connections The gas supply lines must meet all requi rements of the National Fuel Gas Code (ANSI Z223.1-Latest Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.2 Propane Installation Code (Latest Edition). The minimum permissible gas supply pressure for the purpose of input adjustment is on[...]

29 GENERAL OPERATION WARNING Water heaters are heat producing appliances. To avoid damage or injury, do not store materials against t he water heater or vent-air intake system. Use proper care to avoid unnecessary contact (especially by children) with the water heater and vent-air intake system. UNDER NO CIRCUMSTANCES MUST FLAMMABLE MATERIALS, SUCH[...]

30 Lighting & Shutdown Instructions TO TURN OFF GAS TO APPLIANCE LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFOR E LIGHTING WARNING: If you do not follow these instruct ions ex actly, a fire or explosion m ay result causing pr operty dam age, personal inj ury or loss of life. This appliance has a pilot which is lit by a p iezo-electric spark g[...]

31 THERMOSTAT ADJUSTMENT 160°F Control 180°F Control Figure 16 The thermostat dial is set to its lowest te mperature setting when shipped from the factory. Remember that lower temperature settings are more energy efficient . Adjust the temperature by turning the thermostat dial. It is suggested that the starting point setting not be greater than [...]

32 Thermostat Adjusting continue d- Hotter water increases the risk of scald injury. Scalding may occur within five (5) seconds at a temperature setting of 140 ° F (60 ° C). To protect against hot water injury, install an ASSE approved mixing valve in the water system. This valve will reduc e point of discharge temperature by mixing cold and hot [...]

33 MAINTENANCE WARNING Water heaters are heat producing appliances. To avoid damage or injury, do not store materials against t he water heater or vent-air intake system. Use proper care to avoid unnecessary contact (especially by children) with the water heater and vent-air intake system. UNDER NO CIRCUMSTANCES MUST FLAMMABLE MATERIALS, SUCH AS GA[...]

34 Maintenance c ontinued- 6. Annually remove the inner door and main burner assembly to clean orifices and related parts of any dirt or other foreign material. Inspect the burner ports for obstructions or debr is and clean with a wire brush as needed. Wire brush and/or vacuum clean the combustion chamber as needed to remove scale deposits and debr[...]

35 Maintenance c ontinued- CAUTION FOR YOUR SAFETY, DO NOT ATTEMPT REPAIR OF COMBINATION GAS CONTROL, BURNERS OR GAS PIPING. REFER REPAIRS TO A QUALIFIED SERVICE TECHNICIAN. Contact your supplier or plumbing professional for replacement parts or contact the company at the address gi ven on the rating plate of the water heater. Provide the part name[...]

36 PARTS LIST PART NAME & DESCRIPTION 1. Direct Vent-Air Intake Terminal 21. Piezo Ignitor Assembly 2. Outer Wall Mount Plate 22. Drain Valve 3. Backing Plate 23. Outer Door 4. Five (5) inch (12.7 cm) Diameter Telescopic Air Intake Tube 24. Jacket 5. Three (3) inch (7.6 cm) Diameter Telescopic Vent Tube 25. Inner Door Assembly 6. Five (5) inch [...]

37 DIRECT VENT WATER HEATER[...]

38 VENT-AIR INTAKE KITS[...]

39 THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION OF: GAS WATER HEATERS SUITABLE FOR WATER (POTABLE) HEATING AND SPACE HEATING 1. All piping components connected to th is water heater for space heating applications must be suitable for use with potable water. In Massachusetts, space heating piping length must not exceed 50 feet. 2. Toxic chemicals[...]

40 NOTES[...]