American Water Heater ADCG, 71681, DCG, DCG3 User Manual
Commercial Gas
Index
Water Heater
Installation
Instructions and
Use & Care Guide
for models with prefix DCG and ADCG
To obtain technical, warranty or service assistance during
or after the installation of this water heater, call toll free:
1-800-456-9805
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
71681 REV.A 03-09
what can happen if the instructions are not followed.
Table of Contents
Water Heater Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Unpacking the Water Heater . . . . . . . . . . . . . . . . . . . . . . 3
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . ..4
Site Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clearances and Accessibility . . . . . . . . . . . . . . . . . . . . . . 5
Combustion Air Supply and Ventilation . . . . . . . . . . . . . . . . . . . . . 6-9
Water System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Gas Supply and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operating Your Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Maintenance of Your Water Heater . . . . . . . . . . . . . . . . . . . . . . . 22-23
Trouble Shooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
Repair Parts Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2
INSTALLATION INSTRUCTIONS
Index
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, with the “National Fuel Gas Code”, ANSI
Z223.1(NFPA 54)- latest edition. Canadian installations
must be performed in accordance with CAN/
CSA-B149.1. 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
Canadian Standards Association
5060 Spectrum Way
Mississauga, ON
L4W 5N6
Check the phone listings for the local authorities having
jurisdiction over this installation.
Installer and Owner Responsibilities
This manual has been prepared to acquaint you with
the installation, operation and maintenance of this gas
water heater and provide important safety information in
these areas.
Massachusetts code requires this water heater to be
installed in accordance with Massachusetts Plumbing
and Fuel Gas Code 248 CMR Sections 2.00 and 5.00.
A data plate identifying this water heater can be found
on the front of the water heater. When referring to this
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
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.
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.
Read all of the instructions thoroughly before attempting
the installation or operation of this water heater. Keep
this manual for future reference.
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.
The manufacturer of this water heater recommends
that it be professionally installed by qualified
service technicians. Examples of qualified service
technicians include: those trained in the plumbing
and heating industry, local gas utility personnel or
an authorized service person.
3
Vapors from flammable liquids will
explode and catch fire causing death or
severe burns.
Do not use or store flammable products
such as gasoline, solvents or adhesives
in the same room or area near the water
heater.
Keep flammable products:
1. far away from heater
2. in approved containers,
3. tightly closed and
4. out of children’s reach.
This water heater has a main burner and
an automatic ignition system. The ignition
system:
1. can come on at any time and
2. will ignite flammable vapors.
Vapors:
1. cannot be seen,
2. are heavier than air,
3. go a long way on the floor and
4. can be carried from other
rooms to the water heater by air
currents.
Do not install this water heater where
flammable products will be stored.
FLAMMABLE VAPORS
FLAMMABLES
Index
Installation Requirements
The 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. Canadian installations must be
performed in accordance with CAN/CSA-B149.1.
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 1-800-456-9805 and
request instructions.
4
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.
• Locate the water heater as close to the 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.
• 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.
• 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. Note: Special
attention must be given to the location of these
devices and the conditions they may create.
Flow reversal of flue gases may cause an
increase of carbon monoxide inside of the
dwelling.
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 (but 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
Important:
1 3/4” Max
Pipe to
adequate
drain
At least 2” greater than the
diameter of the water heater
Vent
Top to
ceiling
Sides
Front 24” min.
for service
Sides
Back
Top View
Front View
Index
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. 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 leaks in the piping connections or tank.
The pan must limit the water level to a maximum depth of
1 3/4 inches (45mm) and be 2 inches (51mm) wider than
the water heater and piped to an adequate drain. The
pan must not restrict combustion airflow. 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” (19mm)
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.
Figure1: Minimum Clearance Locations
Clearances and Accessibility
Notice: Minimum clearances from combustible
materials are stated on the data plate located on the
front of the water heater.
• If the water heater is installed in a restaurant
or food service location where the floor is
cleaned frequently, NSF International requires
the water heater to maintain 6 inches (150mm)
of clearance above the floor. To comply with the
NSF International requirement, install leg
extension kit. For availability contact
1-800-456-9805
• 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 (76mm) in any direction, or if in an
alcove the entire floor must be covered by the panel.
The panel must be strong enough to carry the weight of
the water heater when full of water.
Figure 1 may be used as a reference guide to locate
the specific clearance locations. A minimum of 24
inches (610mm) of front clearance and 4 inches
(102mm) on each side should be provided for inspection
and service.
5
COMBUSTION/VENT PIPE SYSTEM
Carbon Monoxide Hazard
Follow all instructions to locate and install
the vent pipe system.
Instructions can be found in this manual,
in state or local codes (or the authority
having jurisdiction), or in the absence of
such, the National Fuel Gas Code, ANSI
Z223.1, NFPA 54, Latest Edition. Canadian
installations must be performed in
accordance with CAN/CSA-B149.1
Failure to properly locate and install the
vent pipe system can result in death,
explosion, or carbon monoxide poisoning.
Index
Important: Check to make sure the vent pipe is not
blocked in any way.
• Venting should be as direct as possible with a
minimum number of pipe fittings.
• Exhaust gas vents must be installed with U.L.
listed type B vent pipe according to the vent
manufacturer’s instructions and the terms of its
listing.
• Single wall vent connectors must have 6”
(152mm) of clearance from unprotected com-
bustible surfaces.
• If sidewall venting is necessary, a power vent
kit is required. For availability contact 1-800456-9805.
• Vents that run through unconditioned spaces
where below freezing temperatures are expected should be properly insulated to prevent
freezing.
• Existing vent systems must be inspected for
obstructions, corrosion and proper installation.
Combustion
Combustion air must be free of acid-forming chemicals.
These chemicals are found in aerosol sprays, detergents, bleaches, cleaning solvents, air freshener, paint
and varnish removers, refrigerant, and many other commercial 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.
Venting
Vent pipe installation must be installed according to all
state and local codes, or in the absence of local and
state codes, the National Fuel Gas Code, NFPA 54,
ANSI Z223.1-latest edition. Canadian installations must
be performed in accordance with CAN/CSA-B149.1
It is the responsibility of the installing contractor to
provide a vent adequate in capacity and in good usable
condition. Btu/hr capacity limitations are governed by
the style and height of the vent/chimney. For installations in the United States, capacity tables are available
in the National Fuel Gas Code (ANSI Z223.1- latest edition). Canadian installation information can be found in
CAN/CSA-B149.1
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.
• Vents must be connected to the water heater’s
drafthood by a certified vent connector or by
directly originating at the drafthood opening.
• Vertical gas vents must terminate with a listed
cap or other roof assembly and be installed
according to their manufacturer’s instructions.
• Horizontal vent connections must have an
upward slope of at least 1/4” (6mm) per
foot (305mm).
• Gas vents must be supported to prevent
damage, joint separation, and maintain
clearances to combustible materials.
• Vent connection joints should be fastened by
sheet metal screws or by other approved
methods.
• Vent and vent connectors should have
adequate support to keep weight off the
draft hood.
All pipe, fittings, and procedures must conform to
American National Standard Institute and American
Society for Testing and Materials (ANSI/ASTM) standards in the United States.
Important: If you lack the necessary skills required to
properly install this venting system, you should not
proceed, but get help from a qualified service
technician.
6
Air Requirements
Index
An adequate air supply shall be provided
for combustion and ventilation of this
water heater.
An insufficient supply can result in poor
combustion and possible sooting of the
burner, combustion chamber or flue
passageway. This may present a potential
fire hazard or could create a serious
health hazard by producing carbon
monoxide.
General
Where an exhaust fan or any other air consuming
appliance (Eg. Clothes dryer, furnace, etc.) is installed
in the same space as the water heater, sufficient air
openings must be available to provide fresh air when all
appliances are operating simultaneously.
The area in which the heater is located is classified as
either “an unconfined space” or “a confined space.”
An unconfined sp
volume not less than 50 cubic feet per 1000 BTU/hour
(4.8 cubic meters per kilowatt) of combined input rating
of all appliances using the space. Adjacent open rooms
may be included as part of the unconfined space.
There shall be no closeable doors between these
rooms. An example of this is an open basement.
A confined sp
Air shall be supplied through permanent openings as
described in Figure 2. At no time shall an air opening
have a dimension of less than 3” (75 mm) and at no
time shall any top opening be lower than the top of the
water heater.
ace is defined as a space having a
ace is one smaller than described above.
For buildings that are not well sealed (do not have tight
fitting doors and windows) natural air infiltration may
provide sufficient air required for combustion and ventilation. For buildings using tight construction (newer and
renovated structures), the air supply shall be introduced
from the outdoors, regardless of whether the space is
confined or unconfined.
Combustion Air “Supply” Ducts
Air supply ducts shall be of galvanized steel or equivalent corrosion resistant material. A single air duct may
not be substituted when required for upper and lower
air openings. Horizontal upper combustion air ducts
shall not slope downward toward the air inlet.
Louvers and Grills
Openings for air supply ducts must provide free unobstructed air movement. Louver and grill openings must
be sized to ensure that the FREE OPEN AREA is never
less than the area of the air duct.
LOCATION:
The location for top and bottom openings are as follows;
For U.S. installations:The top opening shall commence within 12” (300 m) of the top of space and the
bottom opening shall commence within 12” (300mm) of
the bottom of the enclosure.
For Canadian installations:The top opening shall be
located as close to the ceiling as practical but never
lower than the relief opening of the lowest draft control
device. The bottom opening shall be located neither
more than 18 inches (450 mm), nor less than 6 inches
(150 mm), above floor level.
7
Combustion
Air Duct
Permanent
Ventilation
Air
12” Grade
12”
Outdoor
Air Ducts
Venting
Combustion
Inlet
Air Ducts
Outlet Air
(a)
(b)
(d)
(c)
Air Opening Requirements
A
1
B
2
BTU/hr(kW)
in2(mm2)
in(mm) in(mm)
75,000(23) 11(7,000) 4(100) 5(125)
100,000(30) 14(9,000) 4(100) 5(125)
125,000(37) 18(12,000) 5(125) 6(150)
150,000(45) 22(14,000) 5(125) 6(150)
175,000(53) 25(16,000) 6(150) 7(175)
200,000(60) 29(19,000) 6(150) 7(175)
225,000(68) 32(21,000) 6(150) 7(175)
250,000(75) 36(23,000) 7(175) 8(200)
275,000(83) 40(26,000) 7(175) 8(200)
300,000(90) 43(28,000) 7(175) 8(200)
325,000(98) 47(30,000) 8(200) 9(225)
350,000(105) 50(32,000) 8(200) 9(225)
375,000(113) 54(35,000) 8(200) 9(225)
400,000(120) 58(37,000) 9(225) 10(250)
Acceptable Equivale nt duct
diam eter
Combined input of a ll
appli ances in
confined space
Require d
free area of
duct
Index
(a) EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM
INSIDE THE BUILDING.
Two permanent openings (top and bottom) shall be provided connecting
the confined space (e.g., closet/small room) with the unconfined space.
Each opening shall have a free area of one square inch per 1,000
BTU/hour (22 cm²/kW) input of all appliances in the confined space, but
not less than 100 square inches (645 cm²).
b) BASEMENT INSTALLATION, EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM OUTDOORS.
Outside air inlets shall be a minimum of 12” (300mm) above the grade
(snow) line. When supplying air directly from the outdoors:
For American installations: Two openings (top and bottom) shall be
provided with each opening having a minimum free area of one square
inch per 4,000 BTU/hour input (5.5 cm²/kW) of total input rating of all
appliances in the confined space.
For Canadian installations: Canadian codes specify single air supply
source. Canadian customers and authorities having jurisdiction may use
the sizing listed in Table 1. When using a single air supply, the duct shall
terminate within 1 foot (300 mm) above and within 2 feet (600 mm) horizontally from the burner level of the appliance having the largest input.
Figure: 2 Equipment Location
and Combustion/Ventilation Air
Requirements
Table 1
Notes:
1.Maximum lenght of ducts in column A is 20 equivalent feet(6.1 meters).
2.Maximum lenght of ducts in column B is 50 equivalent feet(15.2 meters).
(c) EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM
OUTDOORS.
For American installations: When supplying air directly from the out-
doors using horizontal ducting, each opening shall have a free minimum
area of one square inch per 2,000 BTU/hour (11 cm²/kW) of total input
rating of all appliances in the confined space.
For Canadian installations: Refer to Table 1 of part (b).
(d) EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM
OUTDOORS THROUGH VENTILATED ATTIC
For American installations: When supplying air directly through vertical
ducting, each opening shall have a free minimum area of one square
inch per 4,000 BTU/hour (5.5 cm²/kW) of total input rating of all appliances in the confined space.
8
.
*U.S. installations require a dual duct system.
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