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American Water Heater 6510238 manual

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  • Page 1

    6510238 January 2005 Supercedes 6510220 Direct Vent Gas Water Heater Installation Instructions and Use & Care Guide To obtain technical, warranty, or service assistance during or after the installation of this water heater, visit our website at: http://www.americanwaterheater.com or call toll free: 1-800-999-9515 When calling for assistance, pl[...]

  • Page 2

    2 You can be killed or seriously injured if you don't immediately follow instructions. You can be killed or seriously injured if you don't follow instructions. All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can happen if the instructions are not followed. Your[...]

  • Page 3

    3 Consumer Informa tion This water heater is design-certified by CSA International as a Category I, direct vented water heater which takes its combustion air from the outside of the structure and exhausts all products of combustion to the outside of the structure. This water heater must be installed according to all local and state codes or, in the[...]

  • Page 4

    4 This water heater design has been tested by CSA International and complies with ANSI Z21.10.1, Section 2.35 Flammable Vapors Resistance. Therefore this water heater does not need to be installed 18 inches above the floor unless specifically required by state or local codes. The water heater must be located or protected to avoid physical damage by[...]

  • Page 5

    Important: 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 leak, in[...]

  • Page 6

    6 The Vent terminal is HOT when the water heater is in operation. Do not touch the vent terminal or place any object where contact with the vent terminal may occur. A protective louvered wall or fence is recommended when the hot vent cap is low enough to be touched accidentally (see Figure 5). A Vent guard kit (Kit # 6907245) may be ordered by cont[...]

  • Page 7

    7 Manual gas shutoff valve Ground joint union 3 In. Min. Check with local utility for min. height Drip leg Figure 6: Gas Piping Gas Pressure Import ant : The gas supply pressure must not exceed the maximum supply pressure as stated on the water heaters data plate. The minimum supply pressure is for the purpose of input adjustment. Gas Requiremen[...]

  • Page 8

    8 Nominal Iron Pipe Length of Pipe, Feet Size, in. 1/2 3/4 1 1-1/4 1-1/2 132 278 520 1050 1600 92 190 350 730 1100 73 152 285 590 890 63 130 245 500 760 56 115 215 440 670 50 105 195 400 610 46 96 180 370 560 43 90 170 350 530 40 84 160 320 490 38 79 150 305 460 34 72 130 275 410 31 64 120 250 380 28 59 110 225 350 26 55 100 210 320 10 20 30 40 50 [...]

  • Page 9

    9 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. Vent Pipe System This is a direct vent water heater which draws its combustion air from outside of the structure and exhausts all products of combustion to the outsid[...]

  • Page 10

    10 9. Position and fasten the inner wall plate to the inside wall using an appropriate fastener for the specific wall construction. Apply silicone sealant between the inner wall plate and the inside wall. 10. Make certain the 5 telescoping pipe has been fully engaged onto the 5 inch elbow. Drill two 1/8 holes 180° apart at the junction of th[...]

  • Page 11

    11 THROUGH THE ROOF VENTING* 1. Center the heater directly under the roof opening. This vent system must be installed vertically only. 2. All the pipes needed to assemble the vent are included in the kit. Do not add to the length of the vent system. The total height is limited to 15 feet on a 50-gallon heater (See Figure 11). The 40-gallon heater i[...]

  • Page 12

    Water System Piping Piping Inst alla tion Piping, fittings, and valves should be installed according to the installation drawing (Figure 12). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation. Water supply pressure should not exceed 80% of the working pressure of the water heater. [...]

  • Page 13

    Please note the following: DO NOT install this water heater with iron piping. The system should be installed only with piping that is suitable for potable (drinkable) water such as copper, CPVC, or polybutylene. DO NOT use PVC water piping. DO NOT use any pumps, valves, or fittings that are not compatible with potable water. DO NOT use valves that [...]

  • Page 14

    For protection against excessive pressures and temperatures, a temperature and pressure relief valve must be installed in the opening marked T & P RELIEF VALVE (see Figure 14). This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or mater[...]

  • Page 15

    15 Solar Installation If this water heater is used as a solar storage hea ter or as a backup for the solar system, the water supply temperatures to the water heater tank may be in excess of 120°F. A tempering valve or other temperature limiting valve must be installed in the water supply line to limit the supply temperature to 120°F. Note : Solar[...]

  • Page 16

    Wa ter Hea ter Loca tion · 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 vertical position. Protected from freezing temperatures. · Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor. · Provisions [...]

  • Page 17

    17 OPERATING YOUR WATER HEATER Lighting Instructions Read and understand these directions thoroughly before attempting to light or re-light the pilot. Make sure the tank is completely filled with water before lighting the pilot. Check the data plate near the gas valve control/thermostat for the correct gas. Do not use this water heater with any gas[...]

  • Page 18

    L.P.G. (Bottled Propane) Models Liquefied Petroleum Gas is over 50% heavier than air and in the occurrence of a leak in the system, the gas will settle on the floor 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. Before l[...]

  • Page 19

    Burner Flames Inspect the burner flames through the viewport and compare them to the drawings in Figure 16. A properly operating burner should produce a soft blue flame. Blue tips with yellow inner cones are satisfactory. The tips of the flame may have a slight yellow tint. The flame should not be all yellow or have a sharp blue-orange color. Conta[...]

  • Page 20

    A thermocouple is used to determine if a pilot flame is present and will shut off the gas supply to the main burner and the pilot burner if the flame is absent. A high temperature limit switch or ECO (Energy Cut Off) in the tank is used to shut off the unit if the water temperature exceeds 180°F (83°C). The ECO is a single use switch and requires[...]

  • Page 21

    Explosion Hazard If the temperature and pressure relief valve is dripping or leaking, have a licensed plumber correct the problem. Do not plug valve. Do not remove valve. Failure to follow these instructions can result in death, or explosion. MAINTENANCE OF YOUR WATER HEATER Draining and Flushing It is recommended that the tank be drained and flush[...]

  • Page 22

    Replacement P art s 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, always have the following information ready: 1. Model, serial and product number. 2. Type of gas. 3. Item number. 4. Parts Description. See page 27 fo[...]

  • Page 23

    Replacing the Thermocouple Import ant : Use only a factory authorized thermocouple for replacement. 1. Remove the manifold assembly as directed previously. 2. Remove the retainer clip from the back of the t wo piece wire connector. Remove the t wo piece wire connector from the manifold door. Remove the thermocouple (Figure 22). 3. Pull the thermoco[...]

  • Page 24

    5. Replace the (6) screws which secure the manifold assembly door to the combustion chamber. Tighten securely. There should be no space between the gasket part of the manifold door and combustion chamber. Do not opera te the w a ter hea ter if the door gasket is not sealed. 6. Reconnect the manifold tubing (L.P. models have left- hand threads), pil[...]

  • Page 25

    25 TROUBLESHOOTING CHART 1. Light pilot 2. Turn temp. dial to desired temperature 3. Check with gas utility company 4. Notify utility-install trap in gas line 5. Clean, locate source and correct 6. Clean, locate source and correct 7. Replace thermocouple 8. Replace thermostat 1. Pilot not lit 2. Thermostat set too low 3. No gas 4. Dirt in the gas l[...]

  • Page 26

    26 TROUBLESHOOTING CHART BURNER FLAME FLOATS AND LIFTS OFF PORTS 1. High gas pressure 2. Orifice too large 3. Flue clogged 4. Cold drafts 1. Check with gas utility company 2. Replace with correct orifice 3. Clean flue and burner-locate source & correct 4. Locate source and correct BURNER FLAME TOO HIGH 1. Orifice too large 1. Replace with corre[...]

  • Page 27

    27 * 1 2 8 7 4 10 9 11 21 25 26 5 3 27 15 17 19 22 19 20 16 6 12 31 13 18 14 32 23 32 REPAIR PARTS ILLUSTRATION LEGEND Special anode rod (see page 20) Temperature and Pressure Relief Valve is required, but may not be factory installed. Pilot Assembly includes Piezo Igniter, thermocouple, and pilot. See Page 28. When ordering repair parts always giv[...]

  • Page 28

    28 IMPORTANT: The replacement main burner, orifice, manifold, pilot burner, and the thermostat must be ordered for the proper gas type. © 2005 American Water Heater Company. All Rights Reserved. Natural Gas Manifold Door Assembly L.P. Gas Manifold Door Assembly 30 17 28 20 18 6 33 16 18 6 30 15 20 17 33 28 35 24 36 34 34 35 24 15[...]