American Water Heater 6510238 User Manual
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
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 neighbors phone. Follow the
gas suppliers instructions.
· If you cannot reach your gas supplier,
call the fire department.
Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.
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, please have the following
information ready:
1. Model number
2. 7 Digit product number
3. Serial number
4. Date of installation
5. Place of Purchase
Table of Contents ................................................... 2
INSTALLER: AFFIX THESE INSTRUCTIONS TO OR
ADJACENT TO THE WATER HEATER.
OWNER: RETAIN THESE INSTRUCTIONS AND
WARRANTY FOR FUTURE REFERENCE. RETAIN
THE ORIGINAL RECEIPT AS PROOF OF
PURCHASE.
6510238
January 2005
Supercedes 6510220
Your safety and the safety of others are very important.
We have provided many important safety messages in this manual and on your appliance. Always read and obey all
safety messages.
This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word DANGER or
WARNING. These words mean:
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.
Important Instructions
· Do not use this appliance if any part has been under water. Immediately call a qualified service
technician. Water heaters subjected to flood conditions or anytime the gas controls, main burner or pilot have
been submerged in water require replacement of the entire water heater.
· Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame.
To prevent the possibility of injury under these conditions, we recommend the hot water faucet be opened for
several minutes at the kitchen sink before using any electrical appliance which is connected to the hot water
system. If hydrogen is present, there will probably be an unusual sound such as air escaping through the faucet
as water begins to flow. Do not smoke or have any open flame near the faucet at the time it is open.
The California Safe Drinking Water and T oxic Enforcement Act requires the Governor of California to publish a list of
substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires
businesses to warn of potential exposure to such substances.
Warning: This product contains a chemical known to the State of California to cause cancer, birth defects, or other
reproductive harm.
This appliance can cause low-level exposure to some of the substances listed, including formaldehyde, carbon monxide,
and soot.
Table of Contents
Water Heater Safety...........................................................
Installing Your Gas Water Heater............................
Unpacking the Water Heater..................................
Location Requirements...........................................
Vent Cap Termination............................................
Gas Supply..............................................................
Combustion Air Supply and Ventilation..................
Vent Pipe System....................................................
Water System Piping..............................................
Special Applications..........................................
Installation Checklist...............................................
Operating Your Water Heater............................................
Lighting Instructions............................................................
Operational Conditions...........................................
Maintenance of Your Water Heater........................
Troubleshooting Chart........................................................
Repair Parts Illustration...............................................
PAGE
1-2
3-16
3
4-5
5-6
7-8
9
9-11
12-14
15
16
17-18
17-18
20
21-24
25-26
27-28
2
INSTALLING YOUR GAS WATER HEATER
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 all local
and state codes or, in the absence of local and state
codes, the National Fuel Gas Code, ANSI Z223.1(NFPA
54)- latest edition. This is available from the following:
CSA America, Inc.
8501 East Pleasant Valley Road
Cleveland, OH 44131
National Fire Protection Agency
1 Batterymarch Park
Quincy, MA 02169-7471
Check your phone listings for the local authorities having
jurisdiction over your installation.
Consumer Responsibilities
This manual has been prepared to acquaint you with the
installation, operation, and maintenance of your gas
water heater and provide important safety information in
these areas.
Read all of the instructions thoroughly before attempting
the installation or operation of this water heater.
Do not discard this manual. You or future users of this
water heater will need it for future reference.
The manufacturer and seller of this water heater will not
be liable for any damages, injuries, or deaths caused by
failure to comply with the installation and operating
instructions outlined in this manual.
If you lack the necessary skills required to properly install
this water heater, or you have difficulty following the
instructions, you should not proceed but have a qualified
service technician perform the installation of this water
heater. Examples of qualified service technicians include:
those trained in the plumbing and heating industry, local
gas utility personnel, or an authorized service person.
Massachusetts code requires this water heater to be
installed in accordance with Massachusetts Plumbing
and Fuel Gas Code 248 CMR Section 2.00 and 5.00.
A data plate identifying your water heater can be found
next to the gas control valve/thermostat. When referring
to your water heater, always have the information listed
on the data plate readily available.
Retain your original receipt as proof of purchase.
Unpacking the Water Heater
Use two or more people to move and install
water heater unless proper handling
equipment is utilized.
Failure to do so can result in back or other
injury.
Removing Packaging Materials
Important: Do not remove any permanent instructions,
labels, or the data label from outside of the water heater
or on the inside of panels.
· Remove exterior packaging and place installation
components aside.
· Inspect all parts for damage prior to installation
and start-up.
· Completely read all instructions before attempting
to assemble and install this product.
· After installation, dispose of packaging material
in the proper manner.
3
Figure 1: Residential Garage Installation
Vehicle
Stop
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 vehicles or flooding.
Do not use or store flammable products such as gasoline,
solvents, or adhesives in the same room or area near the
water heater. If such flammables must be used, all gas
burning appliances in the vicinity must be shut off and their
pilot lights extinguished. Open the doors and windows for
ventilation while flammable substances are in use.
If flammable liquids or vapors have spilled or leaked in the
area of the water heater, leave the area immediately and
call the fire department from a neighbor's home. Do not
attempt to clean the spill until all ignition sources have
been extinguished.
Drain
Pan
Drain
NOTE:
In the State of California, the water heater must be braced,
anchored, or strapped to avoid moving during an earthquake.
Contact local utilities for code requirements in your area or
call 1-800-999-9515 and request instructions.
Site Location
· Select a location near the center of the water
piping system. The water heater must be installed
indoors and in a vertical position on a level surface.
DO NOT install in bathrooms, bedrooms, or any
occupied room normally kept closed. Note: The water
heater may be installed in a closet with a door off a
bedroom or bathroom providing the units are installed
and vented per the manufacturers instructions.
· Consider the vent piping and vent cap termination
location. This is a direct vent water heater and
may be vented through-the-wall. See Vent Cap
Termination on pages 5-6 of this manual for the
proper vent cap locations.
· Locate the water heater near the existing gas
piping. If installing a new gas line, locate the water
heater to minimize the pipe length and elbows.
Note: The water heater must be installed according to all
local and state codes or, in absence of the local and state
codes, the "National Fuel Gas Code, ANSI Z223.1 (NFPA
54)-latest edition.
4
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, including those from
improper installation, may cause early failure of the
tank due to corrosion if not repaired. If the
homeowner is uncomfortable with making the repair
a qualified service technician should be contacted.
A suitable metal drain pan should be installed under
the water heater as shown below, to help protect the
property from damage which may occur from condensate
formation or leaks in the piping connections or tank.
The pan must limit the water level to a maximum depth
of 1-3/4 and be two inches wider than the heater and
piped to an adequate drain. The pan must not restrict
combustion air flow. Locate the water heater near a
suitable indoor drain. Outside drains are subject to
freezing temperatures which can obstruct the drain line.
The piping should be at least 3/4 ID and pitched for
proper drainage. Under no circumstances will the
manufacturer or seller of this water heater be held liable
for any water damage which is caused by your failure
to follow these instructions.
Figure 2: Minimun Clearance Locations
Back 0
Top
View
Sides 0
Front
4 Inches
From
Combustibles
Sides
0
Vent Cap Termination
Vent 0
1 3/4 Max
Pipe to
Adequate
Drain
At least 2 inches greater
than the diameter of the
water heater.
· The water heater should be located in an area not
subject to freezing temperatures. Water 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 clearances as specified on the data plate.
Clearances and Accessibility
Notice: Minimum clearances from combustible materials
are stated on the data plate adjacent to the thermostat
of the water heater.
· The water heater is certified for installation on a
combustible floor.
Important: If installing over carpeting, the carpeting must
be protected by a metal or wood panel beneath the water
heater. The protective panel must extend beyond the full
width and depth of the water heater by at least 3 inches
(76.2mm) in any direction or if in a alcove or closet
installation, the entire floor must be covered by the panel.
The panel must be strong enough to carry the weight of
the heater when full of water.
Figure 2 may be used as a reference guide to locate the
specific clearance locations. A minimum of 24 inches of
front clearance should be provided for inspection and
service.
The termination of the vent cap must be in accordance with
the local code or the authority having jurisdiction, or in the
absence of such, the National Fuel Gas Code, ANSI Z223.1,
NFPA 54, Latest Edition.
Do not terminate the vent cap in areas containing acid forming
chemicals. Inlet air must not contain any corrosive elements.
Any water heater failure due to corrosive elements in the
atmosphere is excluded from warranty coverage.
See Figures 3 and 4 for correct Vent Cap Termination
Locations.
Figure 3: Alcove Installation Minimums
18 Min.
24
Max.
18 Min.
5
U.S. Installation
Figure 4: Vent Cap Termination Locations
A. 12 in (30 cm) min. clearance above grade, veranda,
porch, deck, balcony, or maximum anticipated snow
level.
B. 9 in (23 cm) min. clearance on top and side of window
or door that may be opened. Do not install below a
window or door that may be opened.
C. Clearance to permanently closed window.**
D. 12 in (30 cm) min vertical clearance to ventilated soffit.
E. 12 in (30 cm) min. clearance to unventilated soffit.
F. Clearance to outside corner **
**Clearance in accordance with local installation codes and the requirements of the gas supplier
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 contacting
the manufacturer of this water heater at 1-800-999-9515.
The exhaust outlet must not terminate under a patio, deck,
or any covered area.
Do not terminate the exhaust outlet near walkways or into
alleys or other publicly accessible areas.
Do not locate the vent terminal too close to shrubs or
bushes.
Caulk all cracks, seams, and joints within 6 feet horizontally
above and below the vent.
Do not terminate the vent within 12 inches of any other
direct vented appliance vent
G. 12 in (30 cm) min. clearance to inside corner formed
by two exterior walls.
H. 4 ft (122 cm) min. clearance to each side of center line
extending above meter/regulator assembly.
I. 4 ft (122 cm) min. clearance to service regulator vent
outlet.
J. 12 in (30 cm) min. clearance to nonmechanical air
supply inlet to building or the combustion air inlet to
any other appliance.
K. 3 ft (91 cm) above if within 10 ft (3 m) horizontally of
mechanical air supply inlet.
Figure 5: Protective Louvered Wall or Fence
HOT
Hot Vent Cap
Protective Louvered
Wall or Fence
3 feet Min.
6
Explosion Hazard
Use a new AGA or CSA approved gas
supply line.
Install a shut-off valve.
Do not connect a natural gas water heater
to a L.P. Gas Supply.
Do not connect a L.P. gas water heater to
a natural gas supply.
Failure to follow these instructions can
result in death, explosion, or carbon
monoxide poisoning.
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. If the information does not agree with the
type of gas available, do not install or light. Call your dealer.
Note:
used by this water heater. This odorant may fade over an
extended period of time. Do not depend upon this odorant
as an indication of leaking gas.
An odorant is added by the gas supplier to the gas
Gas Piping
The gas piping must be installed according to all local and
state codes or, in absence of local and state codes, the
National Fuel Gas Code, ANSI Z223.1 (NFPA 54)-latest
edition.
Tables 1 and 2 on page 8 are provided as a sizing reference
for commonly used gas pipe materials. Consult the National
Fuel Gas Code for the recommended gas pipe size of other
materials.
Refer To Figure 6
1. Install a readily accessible manual shutoff valve
in the gas supply line as recommended by the
local utility. Know the location of this valve and
how to turn off the gas to this unit.
2. Install a drip leg (if not already incorporated as
part of the water heater) as shown. The drip leg
must be no less than 3 inches long for the
accumulation of dirt, foreign material and water
droplets.
3. Install a ground joint union between the gas
valve/thermostat and the manual shutoff valve.
This is to allow easy removal of the gas valve/
thermostat.
Figure 6: Gas Piping
Manual gas
shutoff valve
Ground joint
union
Check with
local utility
for min. height
3 In. Min.
Drip leg
Gas Pressure
Important: The gas supply pressure must not exceed the
maximum supply pressure as stated on the water heaters
data plate. The minimum supply pressure is for the purpose
of input adjustment.
7
Gas Pressure Testing
Important: This water heater and its gas connection
must be leak tested before placing the appliance in
operation.
· If the code requires the gas lines to be tested at
a pressure exceeding 14 W.C., the water heater
and its manual shutoff valve must be disconnected
from the gas supply piping system and the line
capped.
· If the gas lines are to be tested at a pressure less
than 14 W.C., the water heater must be isolated
from the gas supply piping system by closing its
manual shutoff valve.
U.L. recognized fuel gas and carbon monoxide (CO)
detectors are recommended in all applications and
should be installed using the manufacturers instructions
and local codes, rules, or regulations.
Note: Air may be present in the gas lines and could
prevent the pilot from lighting on initial start-up. The gas
lines should be purged of air by a qualified service
technician after installation of the gas piping system.
TABLE 1
NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR)
Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity
of 0.60 (natural gas).
Nominal Iron Pipe Length of Pipe, Feet
Size, in.
1/2
3/4
1-1/4
1-1/2
After the length of pipe has been determined, select the pipe size which will provide the minimum cubit feet per hour required for the
gas input rating of the water heater. By formula:
The gas input of the water heater is marked on the water heater data plate. The heating value of the gas (BTU/FT3) may be determined
by consulting the local natural gas utility.
10 20 30 40 50 60 70 80 90 100 125 150 175 200
132
278
1
520
1050
1600
92
73
190
152
350
285
730
1100
Cu. Ft. Per Hr. Required =
590
890
63
130
245
500
760
56
115
215
440
670
Gas Input of Water Heater (BTU/HR)
Heating Value of Gas (BTU/FT³)
50
105
195
400
610
Explosion Hazard
Have a qualified person make sure L.P.
gas pressure does not exceed 13 water
column.
Failure to do so can result in death,
explosion, or fire.
46
43
40
38
34
31
28
96
180
370
560
90
170
350
530
84
160
320
490
79
150
305
460
72
130
275
410
64
120
250
380
110
225
350
59
26
55
100
210
320
TABLE 2
LP GAS CAPACITY TABLE
Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches water column pressure).
Based on a Pressure Drop of 0.5 Inch Water Column.
Nominal Iron Pipe Length of Pipe, Feet
Size, in.
1/2
3/4
1-1/4
Example: Input BTU requirement of the water heater, 100,000 BTUH
Total pipe length, 80 feet = 3/4" IPS required.
8
10 20 30 40 50 60 70 80 90 100 125 150
275
576
1
1071
2205
Additional tables are available in the latest edition of the "National Fuel Gas Code", ANSI Z223.1
189
393
732
1496
152
315
590
1212
129
267
504
1039
114
237
448
913
103
217
409
834
96
196
378
771
89
185
346
724
83
173
322
677
78
162
307
630
69
146
275
567
63
132
252
511
Figure 7: A & B Dimensions
Combustion Air Supply and
Ventilation
Important: 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 outside of the structure.
Through-the-wall installations require locating the water
heater next to an outside wall. All necessary components
are supplied for the standard through-the-wall installation.
Optional vertical and horizontal extension kits are available
for installations that exceed the standard horizontal and
vertical distances (see table at right). Only one vertical and
one horizontal kit can be used on the same installation.
Through the Wall Venting
1. Make sure a proper location has been selected for the
water heater installation. Consider the following:
· Water piping
· Gas Piping
· Access for service
· Proper clearance for combustibles
· Drainage for the temperature and pressure relief
valve and drain pan.
· Vent cap termination
2. Determine the A dimension for your specific water heater
by referencing figure 7. Cut a 6 inch opening through the
wall in the location as shown. Determine the location of
electrical wiring, pipes, or wall studs before cutting.
NOTE: Installations requiring an A dimension (vertical
height) greater than what is shown as standard in the table
will require the use of a vertical extension kit (See Vertical
Install Kit on Page 10).
Figure 7: A & B Dimensions
A
B
NOTE:
1. Dim. A measured from center of cutout to bottom of heater.
2. Dim. B measured from center of heater to outside of wall.
CAPACITY
KIT
STANDARD
HORIZONTAL
VERTICAL
BOTH
40 GALLON
A
62.75
62.75
62.75 - 89.75
62.75 - 89.75
B
15.75 - 24.50
27.00 - 38.00
15.75 - 24.50
27.00 - 38.00
3. If you are not using the vertical extension kit, place the
3 elbow on the flue pipe reducer on the air box and point
it in the desired direction (See Figure 8). Press it firmly
downward until seated. Drill 4 holes 90
drill bit and fasten the four #8 sheet metal screws provided.
Apply silicone sealant to the joint. Install the 5 elbow
over the 3 elbow and seat it into the collar on the air box.
Drill 4 holes 90° apart with a 1/8 drill bit and fasten the
four #8 sheet metal screws provided. Apply silicone
sealant to the joint. Place the inner wall cover plate over
the 5 elbow. This plate will be positioned later.
50 GALLON
A
71.00
71.00
71.00 - 98.00
71.00 - 98.00
° apart with a 1/8
B
15.75 - 24.50
27.00 - 38.00
15.75 - 24.50
27.00 - 38.00
Figure 8: Vertical Installation
3 Elbow
1
Screws &
Sealant
2
5 Pipe
3 Elbow
Inside Cover
Plate
Screws
& Sealant
9
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