American Water Heater Residential Gas Water Heater with the Flame Guard Safety System manual

1 LOW LEAD C O NTENT 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.[...]

2 T able Of Contents W ater Heater Safety .............................................................................. 1-2 Installing Y our Gas W ater Heater ........................................................ 3-15 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 FVIR System is designed to reduce the risk of flammable vapor-related fires. Flammable liquids (such as gasoline, solvents, propane, etc,) emit flammable vapors which can be ignited by a gas water heater ’ s spark igniter or main burner . The resulting flashback and fire can cause death or serious burns to anyone in th[...]

5 • The water heater should be located in an area not subject to freezing temperatures. W ater heaters located in unconditioned spaces (i.e., attics, basements, etc.) may require insulation of the water piping and drain piping to protect against freezing. The drain and controls must be easily accessible for operation and service. Maintain proper [...]

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 16). 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 18). This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection o[...]

15 Special Applications Combination Space Heating/Potable W ater System Some water heater models are equipped with inlet/ outlet connections for use in space heating applications. Note: this water heater , “Suitable for combination water (potable) heating and space heating and not suitable for space heating applications only .” If this water he[...]

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. □ W ater heater must be loca[...]

17 OPERA TING YOUR W A TER HEA TER Lighting Instructions Read and understand these directions thoroughly before attempting to start or re-start the water heater . Make sure the viewport is not missing or damaged. (See Figure 28) Make sure the tank is completely filled with water before turning the power switch on. Check the data plate near the gas [...]

18 L.P .G. (Bottled Propane) Models Lique fi ed petroleum gas is over 50% heavier than air and in the occurrence of a leak in the system, the gas will settle at fl oor level. Basements, crawl spaces, skirted areas under mobile homes (even when ventilated), closets and areas below ground level will serve as pockets for the accumulation of gas. Bef[...]

19 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 22.[...]

20 Electrical Connections Before plugging in the water heater , always make sure: • The V oltage and frequency correspond to that specified on the water heater . • The electrical outlet has the proper overload fuse or breaker protection. • W ater heater to be located within 6 feet of 120V AC outlet. • Unit is to connect to a 120V AC electri[...]

21 Operating the T emperature Control System Figure 24: Status Codes ON OFF ST A TUS A B C • • VE RY HOT HOT LOW VA C St at u s Light W ater T emperature Adjustment The water temperature setting can be adjusted from 70°F to 160°F . T urn the Gas Control/T emperature Knob to the desired setting/temperature. Operating Modes and Settings • Sta[...]

22 Operational Conditions Condensation Moisture from the products of combustion condenses on the tank surface and the outside jacket of the water heater and forms drops of water which may fall onto the burner or other hot surfaces. This will produce a “sizzling” or “frying” noise. NOTE: This condensation is normal and should not be confused[...]

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 part[...]

25 Figure 31 Pilot/Thermopile Assembly Pilot/Ignitor-Flame Sensor Assembly Igniter Wire Pilot Tube Filter Installation and Cleaning IMPORT ANT : It is essential that the fi lter be installed properly . If you encounter dif fi culty installing the fi lter or have a question, please call the Service & W arranty Department at 1-877-817-6750. Fa[...]

26 External Inspection & Cleaning of the Flame-trap Although not likely to occur , if debris collects on the flame- trap, use a vacuum, compressed air , or a soft bristle brush to remove it. NOTE: If unable to inspect or clean the flame trap from underneath, follow the “Cleaning the Combustion Chamber and Flame-trap” section instructions. F[...]

27 Figure 34 Manifold Assembly Close-up Close-up inside view of the combustion chamber. Manifold Tube Bracket Tab Slot Burner Igniter System The STP (Spark to Pilot) igniter system consists of the pilot, electrode, and wire. The pilot is ignited by an electric spark generated when the gas control valve/thermostat sends an electrical signal to the e[...]

28 Removing and Replacing the Gas Control V alve/Thermostat IMPORT ANT : The gas control valve/thermostat is a standard valve with wire leads that connect to a thermal switch, flue damper , igniter , and flammable vapor sensor Removing the Gas Control V alve/Thermostat: 1. T urn off the gas at the manual shut-of f valve on the gas supply pipe (Figu[...]

29 PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION BURNER FLAME YELLOW - LAZY 1. Insufficient secondary air 2. Low gas pressure 3. Flue clogged 4. Flue damper partially open 5. Main burner line clogged 6. Heater installed in a confined area 7. Obstruction in main burner orifice 1. Provide ventilation to water heater 2. Check with gas utility company 3.[...]

30 ST A TUS LIGHT CODE TROUBLESHOOTING T ABLE Status Light Code LED FLASH SEQUENCE CONTROL ST A TUS CORRECTIVE ACTION Short flash once every four second IDLE (No call for heat, no fault conditions) “Heartbeat”, alternates bright/dim Call for Heat (No fault conditions) One Flash, three second pause Low Flame Signal (control continues to oper- at[...]

31 LED FLASH SEQUENCE CONTROL ST A TUS CORRECTIVE ACTION Six-T wo Flash, three second pause Soft Lockout - Recycle Limit - Flame Lost - END Switch Fails Turn the power switch on the gas control valve to the “OFF” position and unplug the power cord from the power outlet. 1. Check all wiring connections to insure all harness and wire connections [...]

32 SEQUENCE OF OPERA TION CHART Apply Power to Appliance. Is Damper Closed? Y Is there a Call for Heat. Is Damper Open? Will not attempt to light 2 flash error code. See Corrective Action T able on page 30. N Damper Energizes. Gas V alve attempts to open damper for 30 seconds, then waits 2 mintues. 3 flash error code. See Corrective Action T able p[...]

33 REP AIR P ARTS ILLUSTRA TION 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 1 2 3 4 8 5 10 11 9 7 6 13 12 14 18 Item No. Parts Description 1 DRAFT HOOD 2 FLUE DAMPER 3 FLUE BAFFLE 4 HEA T TRAP (COLD) - SOME MODELS 5 HEA T TRA[...]

34 Listed Parts Kits and Illustrations Item 12A: Pilot/Igniter-Flame Sensor assembly kit, which contains the pilot, igniter-flame sensor , and retainer clip (Natural Gas) Item 12B: Pilot/Igniter-Flame Sensor assembly kit, which contains the pilot, igniter-flame sensor , and retainer clip (L.P . Gas ) Item 13A: Burner (Natural Gas/L.P . Gas) Item 13[...]

35 NOTES[...]

36 Copyright © 2013 American W ater Heater Company . All rights reserved.[...]