American Water Heater 6510319 User Manual

Gas Water Heater

®

with the Flame Guard

Safety System

Installation

Instructions and

Use & Care Guide

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 neighbor’s phone. Follow the
gas supplier’s instructions.

!

If you cannot reach your gas
supplier, call the fire department.

R

Made under license from Flame Guard Water Heaters, Inc.

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

Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.

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.

6510319

November 2004

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 Toxic 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
monoxide, and soot.

Table Of Contents

PAG E

Water Heater Safety .................................................................... 1-2

Installing Your Gas Water Heater ................................................ 3-16

Unpacking the Water Heater ....................................................... 3

Location Requirements .............................................................. 4

Gas Supply ................................................................................. 6

Combustion Air Supply and Ventilation ....................................... 7

Water System Piping ................................................................ 12

Installation Checklist ................................................................ 16

Operating Your Water Heater .................................................... 17-19

Lighting Instructions ................................................................. 17

Operational Conditions ............................................................ 19

Maintenance of Your Water Heater ............................................ 20-25

Troubleshooting Chart ............................................................ 26-27

Repair Parts Illustration ............................................................ 28-29

2

INSTALLING YOUR GAS WATER HEATER

Consumer Information

This water heater is design-certified by CSA
International as a Category I, non-direct vented water
heater which takes its combustion air either from the
installation area or from air ducted to the unit from the
outside.

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:

American Gas Association
1515 Wilson Boulevard
Arlington, VA 22209

National Fire Protection Agency
1 Batterymarch Park
Quincy, MA 02269

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.

Service to the Flame Guard Safety System should
only be performed by a qualified service technician.

Examples of qualified service technicians include:
those trained in the plumbing and heating industry,
local gas utility personnel, or an authorized service
person.

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

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. 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.

instructions outlined in this manual.

®

Unpacking the Water Heater

Excessive Weight Hazard

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.

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

FLAMMABLES

Flammable Vapors

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 death.

Read and follow water heater warnings
and instructions.

Location Requirements

Carbon Monoxide Poisoning Hazard
Do not install in a mobile home.
Doing so can result in death or carbon

monoxide poisoning.

The Flame Guard Safety System is designed to reduce
the risk of flammable vapor-related fires. The patented
system protects your family by trapping the burning
vapors within the water heater combustion chamber
through the special Flame-trap. The burning vapors
literally “burn themselves out” without escaping back
into the room. In the event of a flammable vapor
incident, the Flame Guard Safety System shuts off the
gas supply to the water heater's burner and pilot,
preventing re-ignition of any remaining flammable
vapors in the area. This will permanently disable the
water heater.

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.

®

®

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.

!

Locate the water heater as close to the chimney or
gas vent as practical. Consider the vent system
piping and combustion air supply requirements
when selecting the water heater location. The
venting system must be able to run from the water
heater to termination with minimal length and
elbows.

!

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: 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.

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.

1 3/4” max

Pipe to

adequate

drain

At least 2” 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.

!

Do not locate the water heater near an air-moving
device. The operation of air-moving devices such
as exhaust fans, ventilation systems, clothes
dryers, fire-places, etc., can affect the proper
operation of the water heater. Special attention
must be given to conditions these devices may
create. Flow reversal of flue gases may cause an
increase of carbon monoxide inside of the dwelling.

!

If the water heater is located in an area that is
subjected to lint, dirt, and oil, it may be necessary
to periodically clean the Flame-trap (see “External
Inspection & Cleaning of the Flame-trap,” Page 22).

Figure 1
Air-moving
Devices

Exhaust

Fan

Reverse flow
of gases

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 three inches (76.2mm) in any direction; or if in a
alcove or closet installation, the entire floor must be
covered by the panel.

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.

Figure 2
Minimum Clearance
Locations

Back

Top

View

Sides

Front
24” min.
for service

Top

to

ceiling

Sides

State of California
Note: 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.

Vent

5

Gas Supply

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: An odorant is added by the gas supplier to the
gas 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.

Gas Piping

This gas piping 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.

Tables 1 and 2 on page 7 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 3
Note: When installing gas piping, apply approved pipe
joint compound.

1. Install a readily accessible manual shut-off 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 three 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 shut-off valve.
This is to allow easy removal of the gas valve/
thermostat.

4. Turn the gas supply on and check for leaks. Use a
chloride-free soap and water solution (bubbles
forming indicate a leak) or other approved method.

Figure 3
Gas Piping

Manual Gas
Shut-off Valve

Ground

Joint

Union

Check with
local utility
for min. height

3” min.

Drip leg

Gas Pressure

Important: 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 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 shut-off 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 shut-off valve.

U.L. recognized fuel gas and carbon monoxide (CO)
detectors are recommended in all applications and
should be installed using the manufacturer’s
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.

LP Gas

Explosion Hazard

Have a qualified service technician make
sure L.P. gas pressure does not exceed
13” water column.

Failure to do so can result in death,
explosion, or fire.

6

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.

1-1/4
1-1/2

After the length of pipe has been determined, select the pipe size which will provide the minimum cubic 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/FT )
may be determined by consulting the local natural gas utility.

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
Size, in.

1-1/4

Example: Input BTU requirement of the water heater 100,000 BTUH.

10 20 30 40 50 60 70 80 90 100 125 150 175 200

1/2
3/4

1/2
3/4

132
278

1

520
1050
1600

1

92

73

63

56

50

46

43

40

38

34

190

152

130

115

350

285
590
890

152
315
590

1212

245
500
760

129
267
504

1039

730

1100

Cu. Ft. Per Hr. Required=

10 20 30 40 50 60 70 80 90 100 125 150

275

576
1071
2205

189
393
732

1496

Total pipe length, 80 feet = 3/4" IPS required.

105

215

195

440

400

670

610

Gas Input of Water Heater (BTU/HR)

Heating Value of Gas (BTU/FT³)

Length of Pipe, Feet

114
237
448
913

96
180
370
560

103
217
409
834

90
170
350
530

196
378
771

96

84
160
320
490

89
185
346
724

79
150
305
460

130
275
410

83
173
322
677

72

31

64
120
250
380

78
162
307
630

110
225
350

69
146
275
567

28
59

26

55
100
210
320

3

63
132
252
511

Additional tables are available in the latest edition of the "National Fuel Gas Code", ANSI Z223.1.

Combustion Air Supply and
Ventilation

Carbon Monoxide Warning

Follow all the 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 to properly
install vent system.

Failure to do so can result in death,
explosion, or carbon monoxide poisoning.

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.

The following types of installation (not limited to the
following) will require outdoor air for combustion due to
chemical exposure and may reduce but not eliminate
the presence of corrosive chemicals in the air:

!

beauty shops

!

photo processing labs

!

buildings with indoor pools

!

water heaters installed in laundry, hobby, or
craft rooms

!

water heaters installed near chemical storage
areas

Combustion air must be free of acid-forming chemicals
such as sulfur, fluorine, and chlorine. These elements
are found in aerosol sprays, detergents, bleaches,
cleaning solvents, air fresheners, paint, and varnish
removers, refrigerants, and many other commercial and
household products. When burned, vapors from these
products form highly corrosive acid compounds. These
products should not be stored or used near the water
heater or air inlet.

Combustion and ventilation air requirements are
determined by the location of the water heater. The
water heater may be located in either an open
(unconfined) area or in a confined area or small
enclosure such as a closet or small room. Confined
spaces are areas with less than 50 cubic feet for each
1,000 BTUH of the total input for all gas-using
appliances.

7

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 BTUH of the total input for all gas
appliances. The table below shows a few examples of
the minimum square footage (area) required for
various BTUH inputs.

Table 3

BTUH

Input

Min. Sq. Feet with

8' Ceiling

Typical Room
with 8' Ceiling

Figure 4
Opening Locations­Confined Spaces

Permanent
openings to
the outside or
additional
rooms within
the building

12” maximum

Closet

or

other

confined

space

30,000

45,000

60,000

75,000

90,000

105,000

120,000

135,000

188

281

375

469

563

657

750

844

9 x 21

14 x 20

15 x 25

15 x 31

20 x 28

20 x 33

25 x 30

28 x 30

Important:

!

The area must be open and be able to provide the
proper air requirements to the water heater. Areas
that are being used for storage or contain large
objects may not be suitable for water heater
installation.

!

Water heaters installed in open spaces in buildings
with unusually tight construction may still require
outdoor air to function properly. In this situation,
outside air openings should be sized the same as
for a confined space.

!

Modern home construction usually requires
supplying outside air into the water heater area.

Confined Space

For the correct and proper operation of this water
heater, ample air must be supplied for the combustion,
ventilation, and dilution of flue gases. Small enclosures
and confined areas must have two permanent openings
so that sufficient fresh air can be drawn from outside of
the enclosure. One opening shall be within 12 inches of
the top and one within 12 inches of the bottom of the
enclosure as shown in Figure 4.

The size of each opening (free area) is determined by
the total BTUH input of all gas utilization equipment
(i.e., water heaters, furnaces, clothes dryers, etc.) and
the method by which the air is provided. The BTUH
input can be found on the water heater data plate.
Additional air can be provided by two methods:

1. All air from inside the building.

2. All air from outdoors.

12” maximum

All Air from Inside the Building

When additional air is to be provided to the confined
area from additional room(s) within the building, the
total volume of the room(s) must be of sufficient size to
properly provide the necessary amount of fresh air to
the water heater and other gas utilization equipment in
the area. If you are unsure that the structure meets this
requirement, contact your local gas utility company or
other qualified agency for a safety inspection.

Each of the two openings shall have a minimum free
area of 1 square inch per 1,000 BTUH of the total input
rating of all gas utilization equipment in the confined
area, but not less than 100 square inches (Figure 5).

Confined

Space

Permanent
Openings

1 square
inch/1000
BTUH
(min. 100
sq. In.)

Figure 5
All Air from Inside Building
Confined Space Installation

8

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.

Ductwork must be of the same cross-sectional area as
the free area of the opening to which they connect. The
minimum dimension of rectangular air ducts cannot be
less than three inches.

The size of each of the two openings is determined by
the method in which the air is to be provided. Refer to
Table 4 to calculate the minimum free area for each
opening. Figures 6, 7, and 8 are typical examples of
each method.

Louvers and Grilles

In calculating free area for ventilation and combustion
air supply openings, consideration must be given to the
blocking effect of protection louvers, grilles, and
screens. These devices can reduce airflow, which in
turn may require larger openings to achieve the
required minimum free area. Screens must not be
smaller than 1/4” mesh. If the free area through a
particular design of louver or grille is known, it should
be used in calculating the specified free area of the
opening. If the design and free area are not known, it
can be assumed that most wood louvers will allow
20 - 25% of free area while metal louvers and grilles will
allow 60 - 75% of free area.

Louvers and grilles must be locked open or
interconnected with the equipment so that they are
opened automatically during equipment operation.

Keep louvers and grilles clean and free of debris or
other obstructions.

Table 4

Minimum Free Area of Permanent Openings for Ventilation and
Combustion Air Supply - All Air from Outdoors Only.

Based on the total BTUH input rating for all gas utilizing equipment
within the confined space.

Opening
Source

Direct to
outdoors

Vertical ducts

Horizontal ducts

Example: A water heater with an input rate of 50,000 BTUH using
horizontal ducts would require each opening to have a minimum
free area of 25 square inches.

Minimum free area = 50,000 BTUH x 1 sq. in. / 2000 BTUH = 25
Sq. Inches.

Minimum Free Area

Per Opening

(sq. in.)

1 Square inch per 4000

1 Square inch per 4000

1 Square inch per 2000

BTUH

BTUH

BTUH

These openings connect directly with the outdoors
through a ventilated attic, a ventilated crawl space,
or through an outside wall.

Consult the local codes of your area for specific
ventilation and combustion air requirements.

Reference
Drawing

Figure 6

Figure 7

Figure 8

Gable vent
to outdoors

Install above
insulation

Confined
Space

Alternate
Air Inlet

1 sq. inch per
4000 BTUH

Figure 6
All Air from Outdoors; Inlet Air from Ventilated
Crawl Space/Outlet Air to Ventilated Attic

Confined
Space

Figure 7
All Air from Outdoors
Through Ventilated Attic

1 sq. inch

per

2000 BTUH

Confined
Space

Figure 8
All Air from Outdoors
Using Horizontal Ducts

Outlet
air to attic
1 Sq. inch per
4000 BTUH

Inlet air
from the
crawl
space

Open
Foundation
Vent

Gable vent
to outdoors

Install above
insulation

Outlet air
to attic
1 Sq. inch per
4000 BTUH

Inlet air duct
1 sq. inch per
4000 BTUH

12” max.

Outlet

Inlet

1 sq. Inch

2000 BTUH

Outdoor

Air Ducts

per

9