American Water Heater 40-42K BTU manual

1 Power Direct V ent Gas W ater Heater Installation Instructions and Use & Care Guide 6510418 September 2007 Flammable V apor Ignition Resistant Compliant 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 n[...]

2 T able Of Contents W ater Heater Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installing Y our Gas Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Unpacking the W ater Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Location Requirements . . . . . . . . . .[...]

3 INST ALLING YOUR GAS W A TER HEA TER Consumer Information 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 [...]

4 Location Requirements FIRE AND EXPLOSION HAZARD Can result in serious injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Storage of or use of gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or d[...]

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 Requirements 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 dealer . NOTE: An odorant [...]

7 V enting This water heater has a direct vent system in which all air for combustion is taken from the outside atmosphere and all combustion products are discharged to the outdoors. This water heater must be properly vented for removal of exhaust gases to the outside atmosphere. Correct installation of the vent pipe system is mandatory for the saf[...]

8 V ent Pipe Installation The following guidelines should be followed when installing the air inlet and exhaust outlet piping: • V enting should be as direct as possible with a minimum number of pipe fittings. • V ent diameter must not be reduced unless specifically noted in the installation instructions. • Support all horizontal pipe runs ev[...]

9 V ent T ermination Locations The air inlet and exhaust outlet must be installed with the following minimum clearances (see figure 4): • T welve inches above grade or maximum anticipated snow level. • T welve inch minimum clearance on top or four foot clearance below or to the side of door or window that may be open. • Four feet horizontally[...]

10 V ertical T ermination The vertical inlet and exhaust outlet require a return bend or two medium or long sweep radius 90° elbows to keep the air inlet and exhaust outlet downward and prevent entry of rain. Do not include these elbows when calculat- ing the maximum allowable vent pipe because they have already been considered in the vent tables.[...]

11 W A TER SYSTEM PIPING FIGURE 8 T ypical W ater Piping Installation FIGURE 9 T ypical T empering V alve Installation Tempered Water to fixtures Cold Water Inlet Tempering Valve (set to 120°F or lower) Piping Installation Piping, fittings, and valves should be installed according to the installation drawing (Figure 8). If the indoor installation [...]

12 FIGURE 10A T emperature and Pressure Relief V alve Installation T&P V alve and Pipe Insulation (Some Models) 1. Locate the T&P V alve on the water heater . 2. Locate the slit running the length of the insulation. 3 Spread this slit open and slip it over the T&P V alve. See Figure 10B. Apply gentle pressure to the insulation to ensure[...]

13 ELECTRICAL CONNECTIONS Before plugging in the water heater , always make sure: • The voltage and frequency correspond to that specified on the water heater wiring diagram. • The electrical outlet has the proper overload fuse or breaker protection. WIRING DIAGRAM The T emperature and Pressure Relief V alve: • Must not be in contact with any[...]

14 INST ALLA TION CHECKLIST W ater Heater Location • 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 c[...]

15 OPERA TING YOUR W A TER HEA TER Lighting Instructions Read and understand these directions thoroughly before attempting to operate the water heater . Make sure the tank is completely filled with water before operating the water heater . Check the data plate near the gas control valve/thermostat for the correct gas. Do not use this water heater w[...]

16 W ater temperature over 125°F can cause severe burns instantly or death from scalds. Children, disabled and elderly are at highest risk of being scalded. Feel water before bathing or showering. T emperature limiting valves are available. W ARNING L.P .G. (Bottled Propane) Models Lique fi ed petroleum gas is over 50% heavier than air and in the[...]

17 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. This condensation is normal and should not be confused with [...]

18 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. Turn of f the gas to the wa[...]

19 Replacement Parts 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 “Repair [...]

20 Replacing the Manifold Assembly 1. Check the door gasket for damage or embedded debris prior to installation. 2. Inspect the viewport for damage and replace as required. 3. Insert the manifold assembly into the burner compartment making sure that the manifold tab engages the slot inside the combustion chamber . See Figure 18. 4. Inspect the door[...]

21 TROUBLESHOOTING LED ST A TUS PROBLEM SOLUTION An open earth ground circuit to the ignition system. 1. Check that the earth ground connection is properly connected. 2. Check that the earth ground conductor on the water heater is properly connected. Wiring error or a high resistance to earth ground. 1. Check for proper connection of line neutral a[...]

22 TROUBLESHOOTING cont. PROBLEM CAUSE SOLUTION NO HOT W A TER Blower will not run. A) Blower unplugged. Plug blower back into 1 15 V AC. outlet. B) No power at outlet. Repair service to outlet. C) Thermostat defective. Replace thermostat. D) High limit control circuit open. Replace ECO. E) Blower motor defective. Replace Blower Assembly . F) Press[...]

23 REP AIR P ARTS ILLUSTRA TION Item No. Parts Description 1 Blower 2 Pressure Switch (Not Pictured) 3 Flue Baffle 4 Heat T rap (Cold) 5 Heat T rap (Hot) 6 Cold W ater Dip T ube 7 Anode Rod* 8 T emperature and Pressure V alve 9 Drain V alve 10 Gas Control V alve/Thermostat 1 1 Hot Surface Igniter (HSI)** 12 Natural Gas Burner 13 L.P . Gas Burner** [...]

24 Listed Parts Kits and Illustrations Item 1 1: Flame Sense/Hot Surface Igniter Assembly . Item 12: Burner (Natural Gas) Item 13: Burner (L.P . Gas) Item 14: Manifold door assembly which contains the manifold tube, gasket, manifold door , two piece wire connector with retainer clip, and flame sense/hot surface igniter assembly . (Natural Gas) Item[...]