American Water Heater Residential Gas Water Heaters manual

1 Instruction Manual PRINTED 01 14 326466-000 KEEP THIS MANUAL IN THE POCKET ON HEA TER FOR FUTURE REFERENCE WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED. POWER VENT/POWER DIRECT VENT GAS MODELS WITH DIRECT SP ARK IGNITION MODELS VG6250T100/VGD6275T100 SERIES 130/131 ALL TECHNICAL AND W ARRANTY QUESTIONS: SHOULD BE DIRECTED T O THE LOCAL [...]

2 T ABLE OF CONTENTS SAFE INST ALLA TION, USE AND SERVICE.................................3 APPROV ALS .................................................................................3 GENERAL SAFETY INFORMA TION .............................................4 Precautions .............................................................................[...]

3 The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions through[...]

4 PRECAUTIONS DO NOT USE THIS W A TER HEA TER IF ANY P ART HAS BEEN UNDER W A TER. Immediately call a qualied service agency to inspect the water heater and to make a determination on what steps should be taken next. If the unit is exposed to the following, do not operate heater until all corrective steps have been made by a qualied service a[...]

5 GENERAL SAFETY INFORMA TION[...]

6 Fire Hazard Do not install water heater on carpeted floo r. Do not operate water heater if flood damaged. For continued protection against risk of fire: Fire or Explosion Hazard Read instruction manual before installing, using or servicing water heater . Av oid all ignition sources if you smell gas. Do not store or use gasoline or other flammable[...]

7 Thank Y ou for purchasing this water heater . Properly installed and maintained, it should give you years of trouble free service. ABBREVIA TIONS USED Abbreviations found in this Instruction Manual include : • ANSI - American National Standards Institute • ASME - American Society of Mechanical Engineers • AHRI - Air-Conditioning, Heating an[...]

8 DIMENSIONS AND CAP ACITY DA T A ROUGH IN DIMENSIONS: 50 GALLON UNIT Figure 1A: DIMENSIONS FOR 75 GALLON UNIT ROUGH IN DIMENSIONS: 75 GALLON UNIT Figure 1: DIMENSIONS FOR 50 GALLON UNIT T able 1 – ROUGH-IN-DIMENSIONS Units A B C D E F G H I 50G Inches 66.75 49.25 22.00 15.75 3.00 8.00 8.00 62.00 65.00 cm 169.5 125.09 55.88 40.00 7.62 20.32 20.32[...]

9 DIMENSIONS AND CAP ACITY DA T A T able 2 – CAP ACITY , GAS AND ELECTRICAL CHARACTERISTICS Approximate Capacity Manifold Pressure Electrical Characteristics U.S. Gals. Liters Gas T ype “WC k PA V olts/Hz Amperes 50 189 Nat./LP 0 0 120/60 <5 75 284 Nat/LP 0 0 120/60 <5 All models - Maximum Supply Pressure: 14 inches W .C. (3.48kPa) Minimu[...]

10 * CAUTION HARNESS HAS 120 VAC. IN OPERATION. ** See Planning the V ent System, Installation of V ent System and Condensate P ipi ng for more information. Figure 1B: 50 GALLON UNIT V ACUUM RELIEF VA LV E *INST ALL PER LOCAL CODES 50 GALLON UNIT FEA TURES AND COMPONENTS 24 18 35 31 9 4 2 3 19 **29 20 22 23 21 1 12 16 25 11 17 33 13 26, 27 34 (SEE [...]

11 * CAUTION HARNESS HAS 120 VAC. IN OPERATION. ** See Planning the V ent System, Installation of V ent System and Condensate P ipi ng for more information. V ACUUM RELIEF VA LV E *INST ALL PER LOCAL CODES 75 GALLON UNIT FEA TURES AND COMPONENTS (CONT .) 24 18 35 31 9 4 2 3 19 22 23 21 1 12 17 25 11 **29 5 18 21 20 16 26, 27 28 34 30 32 Figure 1C: [...]

12 FEA TURES AND COMPONENTS (CONT .) 1: Control Assembly 2: Blocked Intake Switch 3: Blocked Outlet Switch 4: Blower Prover Switch 5: Blower Assembly 6: Burner Assembly 7: Flame Sensor 8: Igniter Assembly 9: Junction Box 10: Gas Control V alve Assembly 1 1: Display Board 12: T op Plastic Enclosure 13: Display Enclosure ** 14: Exhaust Elbow Assembly[...]

13 CONTROLS AND SWITCHES This model is provided with three pressure switches. These switches are essential to the safe and proper operation of the unit. All switches are wired in series. The controller is set up to shut the unit down whenever there is a failure of any of the switches. It is important to understand the purpose of each switch. 50 GAL[...]

14 LOCA TING THE W A TER HEA TER Caref ull y cho os e a loc ati on fo r the new water he ater. Th e plac em ent is a ve r y im po r t ant c on side rat io n for t he s afet y of t he oc cup ants in the build ing a nd fo r th e mo st ec on omi c al us e of th e water heater. Property Damage Hazard All water heaters eventually leak. • Do not instal[...]

15 Minimum clearances between the water heater and combustible con stru ction are 0 in ch at the sides an d rear , 5. 5” (14.0 cm) from the fro nt and 18” (45.7 cm) from the top. (Standard clearance.) If clearances stated on the heater differ from standard clearances, install water heater according to clearances stated on the heater . Adequate [...]

16 UNCONFINED SP ACE An Unconned Space is one whose volume IS NOT LESS THAN 50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input rating of all appliances installed in the space. Rooms communicating directly with the space, in which the appliances are installed, through openings not furnished with doors, are considered a pa[...]

17 Alternatively a single permanent opening, commencing within 12 inches (300 mm) of the top of the enclosure, shall be provided. See Figure 6. The water heater shall have clearances of at least 1 inch (25 mm) from the sides and back and 6 inches (150 mm) from the front of the appliance. The opening shall directly communicate with the outdoors or s[...]

18 INST ALLA TION REQUIREMENTS CHEMICAL V APOR CORROSION Corrosion of the ueways and vent system may occur if air for combustion contains certain chemical vapors. Such corrosion may result in failure and risk of asphyxiation. Spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calciu[...]

19 MIXING V AL VES Wa ter temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death. Children, the elderly and the physically or mentally disabled are at highest risk for scald injury . Feel water before bathing or showering. Te mperature limiting devices such as mixing valves must be installed when requir[...]

20 GAS SUPPL Y SYSTEMS Low pressure building gas supply systems are dened as those systems that cannot under any circumstances exceed 14” W .C. (1/2 PSI Gauge). These systems do not require pressure regulation. Measurements should be taken to insure that gas pressures are stable and fall within the requirements stated on the water heater ratin[...]

21 SP ACE HEA TING AND POT ABLE W A TER SYSTEM Y our water heater is equipp ed with inlet /outl et conne ct io ns for use in spac e h eati ng appl ic ati ons (see Fi gure 9). If this water heate r is to b e us ed to s upp ly bo th sp ac e heat ing and p ota ble ( dri nki ng ) water , the in str uc ti ons l isted b el ow must b e fol lowe d: • Be [...]

22 Wa ter Damage Hazard Te mperature-Pressure Relief V alve discharge pipe must terminate at adequate drain. • CAUTION T&P V AL VE DISCHARGE PIPE REQUIREMENTS: • Shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions. • Shall not be plugged or blocked. • Shall not be exp[...]

23 CONDENSA TE PIPING This water heater is a condensing unit and requires a drain to be located in close proximity to allow the condensate to drain safely . The condensate drains from the unit at the exhaust tee located at the bottom of the unit (see Figure 1 1). Condensate from this water heater is mildly acidic. Please note that some local codes [...]

24 For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven ([...]

25 VENT INST ALLA TION CONSIDERA TIONS This water heater can be vented using room air for intake combustion air , or direct vented so that all intake air for combustion comes from the outside through a sealed pipe. This water heater may be installed in 4 separate orientations depending on the requirements of the building and the water heater . The [...]

26 POL YPROPYLENE INST ALLA TIONS The water heater has been approved to be installed with Polypropylene vent material as shown in T able 5 and T able 6. The approved application of single wall, non-exible, non-concentric Polypropylene vent material is offered by two specic manufacturers (Centrotherm ECO Systems and DuraV ent Polypropylene. Th[...]

27 INST ALLA TION OF HORIZONT AL THROUGH THE W ALL VENT SYSTEM I f y o u a r e i n s t a l l i n g y o u r s y s t e m s o t h a t i t v e n t s t h r o u g h r o o f , p l e a s e r e f e r t o s e c t i o n t i t l e d V E R T I C A L V E N T T E R M I N A L I N S T A L L AT I O N . VENT T ERMINAL INST ALL A TION, SIDEW ALL 1 . I n s t a l l t h [...]

28 DIRECT VENT TERMINAL INST ALLA TION The air intake provided on the unit contains an air intake screen to prevent large particles from entering the unit. Figure 13: AIR INT AKE SCREEN When the unit is to be setup as a direct vent, the air intake screen must be removed. The air intake pipe may then be glued to the air intake (see Figure 13) provid[...]

29 TERMINA TION CLEARANCES SIDEW ALL POWER VENT V X VEN T TERMINAL AIR SUPPL Y INLE TA RE A WHERE TERMINAL IS NO T PERMITTED v v A G V FIXED CLOSED FIXED CLOSED OPERABLE OPERABLE V C B B B B F B V V A J V H M X X V V K B E D L POWER VENT (using room air for combustion) EXTERIOR CLEARANCES FOR SIDEW ALL VENT TERMINA TION Figure: 15 V ent terminal cl[...]

30 TERMINA TION CLEARANCES SIDEW ALL DIRECT VENT V X VENT TERMINAL AIR SUPPL Y INLE TA RE A WHERE TERMINAL IS NO T PERMITTED v v A G V FIXED CLOSED FIXED CLOSED OPERABLE OPERABLE V C B B B B F B V V A J V H M X X V V K B E D L DIRECT VENT (using outdoor air for combustion) EXTERIOR CLEARANCES FOR SIDEW ALL VENT TERMINA TION Figure: 16 V ent termina[...]

31 VERTICAL VENT TERMINAL INST ALLA TION WHEN TERMINA TING THROUGH A ROOF , THE FOLLOWING SPECIFICA TIONS PERT AINING TO TERMINAL LOCA TION MUST BE FOLLOWED. 1. Proper support must be provided for all pipe protruding through the roof. 2. The vertical roof terminations should be sealed with a plumbing roof boot or equivalent ashing. 3. The air in[...]

32 12” MINIMUM CLEARANCE ABOVE HIGHEST ANTICI PAT ED SNOW LEVEL 12” MINIMUM CLEARANCE ABOVE HIGHEST ANTICI PA TED SNOW LEVEL 24” MINIMUM SEP ARA TION. EXHAUST MUST BE AT SAME LEVE L OR ABOVE INT AKE TERMINAL. Figure: 20 Figure: 22 Figure: 23 Figure: 21 DIRECT VENT DIAGRAM[...]

33 CONCENTRIC VENT INST ALLA TION This water heater is certied for concentric venting with concentric vent kit #9006328005. Follow instructions below for proper installations. T able 8 – KIT COMPONENTS Field supplied pipe and ttings are required to complete the installation. This concentric vent termination kit may be used with 3 inch diame[...]

34 NOTE: Do not allow insulation or other materials to accumulate inside pipe assembly when installing through hole. 5. Sec ure asse mbl y to ro of s tr uc ture as shown in “Fi gur e: 27 ” usin g f i eld sup plie d m eta l st ra ppin g o r e quival ent supp or t mater ial. NOTE: Ens ure ter minat io n he ight is above t he roof sur f ac e o r a[...]

35 5. In sta ll ra in c ap and s mall d iam eter pip e as semb ly in Y c on ce ntr ic t ti ng and la rge pi pe as sem bly. Ensur e small di amete r pipe i s bot to med a nd c eme nted in Y c o nc entr ic  t tin g. 6. Se cur e ass embl y to str uc ture as sh own in “ Fig ure: 28” u sing el d - supp lie d met al str app ing o r equi vale[...]

36 LOW PROFILE TERMINA TION INST ALLA TION This water heater is certied for sidewall direct venting with IPEX System 636 Low Prole V ent Kit. Follow instructions below for proper installations. All termination kits must be located and installed in accordance with local codes or the current editions of the National Fuel Gas Code (ANSI Z223.1/N[...]

37 LIGHTING AND OPERA TION LABELS[...]

38 V alves for re duc ing the p oint- of- use temper ature b y m ixi ng co ld and hot water a re availa ble. A ls o availab le are i nexpe nsi ve devic es t hat at tac h to f auc ets to limit hot wat er temper atur es. Cont act a licens ed plum ber o r the l oc al p lumb ing au tho r it y . The table below shows the approximate time -to - burn rela[...]

39 THE DESKTOP SCREEN During normal operation the control system will display the Desktop screen on the LCD which is the default screen. The control system will return to the Desktop screen when there are no active Fault or Alert conditions or when there has been no user input for several minutes. • Manufacturer and water heater model information[...]

40 ST A TUS ICONS The Status Icons are displayed on the Desktop screen and convey operational and diagnostic information. The icons are described in the table below . T able 12 – ST A TUS ICONS Icon Description W ater temperature in the tank has fallen. Shaded area of the animated thermometer icon will rise and fall in response to water temperatu[...]

41 OPERA TING ST A TES The current operational state of the water heater is displayed on the Desktop screen as the Status. The common operational states are described in the table below . T able 13 – OPERA TING ST A TES State Description Standby The water heater is not in an active heating cycle. IE: the T ank T emperature is at or above the Oper[...]

42 USER SETTINGS & CONTROL SYSTEM MENUS TEMPERA TURES OPERA TING SET POINT AND DIFFERENTIAL ADJUSTMENT The Operating Set Point is adjustable from 90°F (42°C) to 160°F (71°C). The factory setting is 120°F (49°C). The Differential is adjustable from 2° to 20°. The factory setting is 8°. These user settings are accessed from the T emperat[...]

43 TEMPERA TURES (CONT) DESCRIPTION/ACTION DISPLA Y • T ank Probe Offset - adjustable user setting, range -5° to +5°F (factory setting 0°F). The T ank Probe Offset is used to calibrate control system temperature sensing. This offsets to more effectively read point of use temperature in the tank. This feature can also be used to compensate for [...]

44 DISPLA Y SETTINGS DESCRIPTION/ACTION DISPLA Y Select Display Settings from the Main Menu and press the Operational Button under "SELECT" to enter this menu. This menu contains adjustable display options for viewing information on the LCD screen. Use the Up & Down Buttons to navigate the menu. • T emperature Units - Adjustable use[...]

45 CURRENT F AUL T DESCRIPTION/ACTION DISPLA Y Select Current Fault from the Main Menu and press the Operational Button under "SELECT" to enter this menu. This menu contains non adjustable operational information. Use the Up & Down Buttons to navigate the menu. This menu contains the current Fault or Alert error message. The time the [...]

46 SERVICE CONT ACT INFORMA TION The control system has a discrete menu that Installing contractors and/or qualied service technician can access to enter contact information for their customers. This contact information will be displayed with all Fault and Alert messages. DESCRIPTION/ACTION DISPLA Y From the Desktop Screen press and hold down th[...]

47 ST ART UP CONDITIONS SMOKE/ODOR It is not uncommon to experience a small amount of smoke and odor during the initial start-up. This is due to burning off of oil from metal parts, and will disappear in a short while. THERMAL EXP ANSION W ater supply systems may , because of such events as high line pressure, frequent cut-offs, the effects of wate[...]

48 VENTING SYSTEM INSPECTION At least once a year a visual inspection should be made of the venting system. Y ou should look for: 1 . Obstructions which could cause improper venting. The combustion and ventilation air ow must not be obstructed. 2. Damage or deterioration which could cause improper venting or leakage of combustion products. Be su[...]

49 POWERED ANODE ROD (OPTIONAL MODELS) T o insure a long, trouble-free operating life, certain models of water heaters covered in this manual are factory equipped with a powered anode system. The anode rod is of a permanent design and does not need replacing unless damaged. Inspection and cleaning should be performed once a year . NOTE: Follow the [...]

50 TO DRAIN THE W A TER HEA TER ST ORAGE T ANK: 1. T urn off the electrical supply to the water heater . 2. T urn off the gas supply at the Main Gas Shutoff V alve if the water heater is going to be shut down for an extended period. 3. Ensure the cold water inlet valve is open. 4. Open a nearby hot water faucet and let the water run until the water[...]

51 Never use this water heater unless it is completely lled with water . T o prevent damage to the tank, the tank must be lled with water. W ater must ow from the hot water faucet before turning “ON” gas to the water heater . A *Condensation may be seen on pipes in humid weather or pipe connections may be leaking. B. *The anode rod [...]

52 TROUBLESHOOTING SEQUENCE OF OPERA TION Read the Sequence of Operation below before attempting to correct any operational problems. See the Sequence Of Operation Flow Chart. 1. When the control system is rst powered, during boot up, the blowe r wi ll r un m ome nta ri ly an d stop, an d th e c ontr ol sys tem will display water heater model in[...]

53 SEQUENCE OF OPERA TION FLOW CHART YES NO Wa te r is heat ed to se t po in t 24 V Ga s Va lv e de -e nergi ze d 60 se co nd Inter-Purge cycle 24 V Ga s Va lv e de -e nerg iz ed Re tr ie s up to tw o mo re ti me s 60 se co nd Post-Purge cycle C ont ro l Sy st em Loc ks Ou t “I gni ti on Fa il ure” Fa ul t Ms g is di sp la ye d Wa te r heat er [...]

54 If the Main Burner ignites momentarily but does not sustain ignition allow the water heater to try to ignite up to two more times until control system locks out and the Ignition Failure Fault message is displayed on the control system's LCD. If the water heater is experiencing rough starts - see Rough Starting, Rough Operation on this page.[...]

55 Only qualied service technician, as dened in Qualications using appropriate test equipment, should perform any service procedures on the water heater . NOTE: If you are not qualied and licensed or certied as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the diagnostic or ser[...]

56 F AUL T AND ALERT MESSAGES Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualied service technician in your area. POSSIBLE CAUSES - CHECK/REP AIR DISPLA YED F AUL T/ALERT MESSAGE • The control system has failed to ignite the Main Burner . • Water heater is not properly gro[...]

57 F AUL T AND ALERT MESSAGES (CONT) Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualied service technician in your area. POSSIBLE CAUSES - CHECK/REP AIR DISPLA YED F AUL T/ALERT MESSAGE • The control system has detected the Blower Prover Switch contacts are closed when they [...]

58 CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERA TION. VERIFY PROPER OPERA TION AFTER SERVICING. Figure: 40 POWER VENT WIRING SCHEMA TIC WIRING DIAGRAM[...]

59 LIMITED RESIDENTIAL GAS W ARRANTY THIS W ARRANTY IS APPLICABLE TO THE ORIGINAL OWNER ONL Y . If the glass lined tank in this water heater shall prove upon examination by (the warrantor) to have leaked during the warranty period in normal residential use, due to natural corrosion from potable water therein, the warrantor will furnish the ORIGINAL[...]

60 T echnical Support and Parts: 800-456-98055 Copyright © 2014 American Water Heaters. All rights reserved.[...]