A.O. Smith PCG6240T403NOV, PCG250T403NOV, PCG2J5040T3NOV, PCG2J4040T3NOV, 12 40GPC T 100 User Manual

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SERVICE HANDBOOK FOR

STANDARD RESIDENTIAL

HIGH EFFICIENCY ATMOSPHERIC VENT

(FVIR) GAS WATER HEATERS

MODELS:

GAHH 40 100,

GP 6 40YPC T 100, PCG6240T403NOV 100, PCG2J4040T3NOV 100, 12 40GPC T 100, PCG2J4040T3NOV 100,

GAHH 50 100,

GP 6 50YPC T 100, PCG250T403NOV 100, PCG2J5040T3NOV 100, 12 50GPC T 100, PCG2J5040T3NOV 100

Printed in U.S.A. 10/10

318181-000

1

ALL TECHNICALAND WARRANTY QUESTIONS

SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED.

IF YOU ARE UNSUCCESSFUL, CONTACTA. O. SMITH WATER HEATERS RESIDENTIAL TECHNICALASSISTANCE

AT 1-800-527-1953 OR WWW.HOTWATER.COM.

2

SERVICE HANDBOOK

Your safety and the safety of others is extremely important in the servicing of this water heater. Many safety-related messages and instructions have been provided in this handbook and on the water heater to warn you and others of a potential hazard. Read and obey all safety messages and instructions throughout this handbook. It is very important that the meaning of each safety message is understood by you and others who service this water heater.

The information contained in this handbook is designed to answer commonly faced situations encountered in the operation of the standard Residential Gas product line and is not meant to be all-inclusive. If you are experiencing a problem not covered in this handbook, please contact the Technical Information Center listed on the back of this handbook for further assistance. Additional information is also available on the web site listed on the back of this handbook. This handbook is intended for use by licensed plumbing professionals and reference should be made to the Installation Instructions and Use & Care Guide accompanying the product. This handbook contains supplemental information to the Installation Instructions and Use & Care Guide.

When servicing residential water heaters, it is essential that you return the unit to a safe condition before you leave the site. All original components must be re-installed and all safety measures must be implemented. In addition, the recommended water temperature setting is 120° F.

IMPORTANT: It is recommend that on every service call an inspection & cleaning of the air intake chamber screen and combustion chamber and air diverter assembly be performed. See page 24.

Tools Required (for servicing gas models):

• phillips head screw driver

• 3/8, 7/16, & 3/4 inch open end wrenches

• 3/16 inch Allen wrench

• 1-1/16 inch – 6 point – socket – for anode removal

• 5/16” nut driver

• pliers

• electrical multimeter (with alligator leads)

• digital or analog manometer

• gas pressure gauge

• Teflon® tape

• hose – to drain tank

Digital manometer shown.

Teflon® is a registered trademark of E.I. Du Pont De Numours and Company.

3

Fire or Explosion Harzard

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

Avoid all ignition sources if you smell Natural or LP gas.

Do not expose water heater control to excessive gas pressure.

Use only gas shown on rating plate.

Maintain required clearances to combustibles.

Keep ignition sources away from faucets after extended period of non-use.

Read instruction manual before installing, using or servicing water heater.

Breathing Hazard - Carbon Monoxide Gas

Install vent system in accordance with codes.

Do not operate water heater if flood damaged

Heater should not be installed for High Altitude operation above 10,100 feet (3,078 m).

Do not operate if soot buildup.

Do not obstruct water heater air intake with insulating jacket.

Do not place chemical vapor emitting products near water heater.

Gas and carbon monoxide detectors are available.

Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.

Improper installation and use may result in property damage.

Do not operate water heater if flood damaged.

Install in location with drainage.

Fill tank with water before operation. Be alert for thermal expansion.

Refer to instruction manual for installation and service.

4

TABLE OF CONTENTS

 

INTRODUCTION:

 

Service Handbook Introduction...........................................................................................................................

3

Warnings and Cautions.......................................................................................................................................

4

Table Of Contents ...............................................................................................................................................

5

INSTALLATION / OPERATION:

 

Basic Installation & Operation.............................................................................................................................

6

Combustion Air and Vent System Requirements ..........................................................................................

7-10

KNOW YOUR WATER HEATER:

 

Know the Water Heater’s Component Parts ................................................................................................

11-13

Water Heater Operation ....................................................................................................................................

14

Filling and Draining the Water Heater ...............................................................................................................

15

Lighting Instructions ..........................................................................................................................................

16

ADJUSTING TEMPERATURE CONTROL:

 

Adjusting the Temperature on the Electronic Control Display...........................................................................

17

Using the Electronic Control Display...........................................................................................................

18-19

Electronic Control Display Troubleshooting ................................................................................................

20-23

COMPONENTS REMOVAL / REPLACING:

 

External Inspection and Cleaning .....................................................................................................................

24

Electronic Control Display Removal / Replacement .........................................................................................

25

Powered Anode Removal / Replacement ...................................................................................................

26-27

Pressure Switch Removal / Replacement.........................................................................................................

28

Transformer Removal / Replacement .........................................................................................................

29-30

Air Intake Chamber Box Removal / Replacement ......................................................................................

31-33

Wiring Harnesss Removal / Replacement ..................................................................................................

34-36

Air Intake Chamber Fan Removal / Replacement ......................................................................................

37-38

Pressure Tubing Removal / Replacement ..................................................................................................

39-40

Inner Door/Manifold/Burner Assembly Removal / Replacement.................................................................

41-42

Flame Sense/Hot Surface Igniter Removal / Replacement ..............................................................................

43

Burner Removal / Replacement..................................................................................................................

44-46

Burner Orifice Removal / Replacement ......................................................................................................

47-49

Gas Control Valve/Thermostat Removal / Replacement.............................................................................

50-52

CHECKPOINTS / GENERAL INFORMATION:

 

Checking the Gas Supply Pressure ..................................................................................................................

52

Gas Water Heater Sizing Guide -and- Leakage Checkpoints.........................................................................

53

General Information ....................................................................................................................................

54-55

5

BASIC INSTALLATION & OPERATION

INSTALLATION OF RESIDENTIAL GAS WATER HEATER

See Labels and Installation Instructions and Use & Care Guide for clearances.

Use Draft Hood supplied with unit

Union

Exhaust Vent to Ouside of Building

Union

To Fixtures - Hot

 

Tempered Water

Gas

 

Supply

Untempered

To Fixtures

Cold

 

Hot Water

 

 

Water

Control

 

Inlet

 

 

Display

Hot

Water

Outlet

Mixing Valve (Set to 120°F)

Follow the Mixing Valve

Manufacturer’s Instructions

Union

Sediment Trap

(Drip Leg) 3” Minimum.

FV Sensor

Bracket

 

Water

Water

SupplyCold*

Shut-Off

 

Valve

 

*Massachusett: Install a vacuum relief in cold water line per section 19 MGL 142.

Expansion Tank Pressurize to Equal

Supply Water Pressure* (Relieve water pressure on the expansion tank before adjusting air pressure.)

Temperature-Pressure Relief Valve with discharge piped to an adequate drain. Do not cap or plug.

Manual Gas Shut-off Valve

Air Intake Chamber

Air is drawn in for combustion. Keep area clean and free from flammables and flammable vapors.

Gas Control Valve/Thermostat

Recommended setting of 120°F.**

Do not cap or plug.

6” Maximum Air Gap

NOTE: Local codes may vary.

Drain

Electrical Plug

Metal Drain Pan piped to an adequate drain. NOTE: Drain pan diameter must be at least 2 inches wider than the diameter of the water heater.

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)- current edition.

*NOTE: If on a well system the expansion tank should be set to the maximum pressure of the pump tank.

**White-Rodgers® gas control valve/thermostat shown in this figure.

Figure 1

6

COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS

Combustion Air Requirements:

WARNING

Carbon Monoxide Warning

Water heater must be vented to outdoors.

Vent must be installed by a qualified technician using the local and state codes or, in the absence of local and state codes, the National Fuel Gas Code,

ANSI Z223.1 (NFPA 54) - current edition, and/or the installation instructions.

Examples of a qualified technican include: gas technicians, authorized gas company personel, and authorized service persons.

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

IMPORTANT: Air for combustion and ventilation must not come from a flammable or corrosive atmosphere. Any failure due to flammable or 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

water softeners

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, air inlet, or air intake path.

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.

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 1:

 

Minimum Square

Typical Room

BTUH Input

Feet with

with 8’ Ceiling

 

8’ Ceiling

 

 

30,000

188

9 x 21

45,000

281

14 x 20

60,000

375

15 x 25

75,000

469

15 x 31

90,000

563

20 x 28

105,000

657

20 x 33

120,000

750

25 x 30

135,000

844

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.

Room exhaust fans may effect air requirements.

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.

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 rating plate. Additional air can be provided by two methods:

1.All air from inside the building.

2.All air from outdoors.

12” MAXIMUM

CLOSET

OR

OTHER

CONFINED

PERMANENT SPACE

OPENINGS TO

THE OUTSIDE OR

ADDITIONAL

ROOMS WITHIN

THE BUILDING

12” MAXIMUM

Figure 2.

7

COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS

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. 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 for each opening.

CONFINED

SPACE

PERMANENT

OPENINGS

1 SQUARE

INCH/1000

BTUH

(MINIMUM

100 SQ. IN.

FOR EACH

OPENING)

Figure 3.

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 the table below to calculate the minimum free area for each opening.

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.

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

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

 

Minimum Free Area

Reference

Opening Source

Per Opening (sq. in.)

Drawing

*Direct to outdoors

1 sq. in, per 4000 BTUH

Figure 4

Vertical Ducts

1 sq. in, per 4000 BTUH

Figure 5

Horizontal Ducts

1 sq. in, per 2000 BTUH

Figure 6

Single Opening

1 sq. in, per 3000 BTUH

Figure 7

 

 

 

Example: A water heater with an input rating 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. in.

*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

ABLE VENT

TO OUTDOORS

 

INSTALL ABOVE

 

INSULATION

CONFINED

OUTLET

SPACE

AIR TO

 

 

ATTIC 1 SQ.

 

INCH PER

 

4000 BTUH

ALTERNATE

INLET AIR FROM

AIR INLET

THE CRAWL SPACE

1 SQ. INCH PER

OPEN

4000 BTUH

 

 

FOUNDATION

100 SQ. INCH MINIMUM (EACH)

VENT

 

 

ALL AIR FROM OUTDOORS: INLET AIR FROM VENTILATED

CRAWL SPACE/OUTLET AIR TO VENTILATED ATTIC

CONFINED SPACE

Figure 4.

GABLE VENT

TO OUTDOORS

INSTALL ABOVE

INSULATION

OUTLET AIR TO ATTIC 1 SQ. INCH PER 4000 BTUH - 100 SQ. INCH MIN. (EACH)

INLET AIR DUCT 1 SQ. INCH PER 4000 BTUH - 100 SQ. INCH MIN.

(EACH)

12” MAXIMUM ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC

Figure 5.

8

COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS

 

1 SQ. INCH PER

 

2000 BTUH

 

100 SQ. INCH

 

MINIMUM (EACH)

CONFINED

OUTLET

SPACE

 

 

OUTDOOR

 

AIR DUCTS

 

INLET

1 SQ. INCH PER

2000 BTUH 100 SQ. INCH MINIMUM (EACH)

ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS

Figure 6.

 

ALTERNATIVE

 

OPENING

 

LOCATION

CONFINED

1 SQ. INCH

PER 3000 BTUH

SPACE

100 SQ. INCH

 

MINIMUM (EACH)

ALL AIR FROM OUTDOORS - USING A SINGLE PERMANENT OPENING

Figure 7.

Vent Pipe System: This water heater must be properly vented for the removal of exhaust gases to the outside atmosphere. Correct installation of the vent pipe system is mandatory for the proper and efficient operation of this water heater and is an important factor in the life of the unit.

The vent pipe 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)-current edition. The vent pipe installation must not be obstructed so as

to prevent the removal of exhaust gases to the outside atmosphere.

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.

Vent Pipe Size: It is important that you follow the guidelines in these instructions for sizing a vent pipe system. If a transition to a larger vent size is required, the vent transition connection must be made at the draft hood outlet. DO NOT reduce the vent size to less than the draft hood outlet diameter.

Vent Connectors:

1.Type B, Double wall, U.L. Listed Vent Pipe.

2.Single wall Vent Pipe.

Maintain the manufacturer’s specified minimum clearance from combustible materials when using type B double wall vent pipe.

Vent connectors made of type B, double wall vent pipe material may pass through walls or partitions constructed of combustible material if the minimum listed clearance is maintained.

Maintain a one inch minimum clearance from all combustible materials when using single wall vent pipe.

IMPORTANT: Single wall vent pipe cannot be used for water heaters located in attics and may not pass through attic spaces, crawl spaces or any confined or inaccessible location. A single wall metal vent connector cannot pass through any interior wall.

When installing a vent connector, please note the following

Install the vent connector avoiding unnecessary bends, which create resistance to the flow of vent gases.

Install without dips or sags with an upward slope of at least 1/4-inch per foot.

Joints must be fastened by sheet metal screws or other approved means. It must be supported to maintain clearances and prevent separation of joints and damage.

The length of the vent connector cannot exceed 75% of the vertical vent height.

The vent connector must be accessible for cleaning, inspection, and replacement.

Vent connectors cannot pass through any ceiling, floor, firewall, or fire partition.

It is recommended (but not mandatory) that a minimum 12 inches of vertical vent pipe be installed on the draft hood prior to any elbow in the vent system.

IMPORTANT: Existing vent systems must be inspected for obstructions, corrosion, and proper installation.

Chimney Connection: IMPORTANT: Before connecting a gas vent to a chimney, make sure the chimney passageway is clear and free of obstructions. The chimney must be cleaned if previously used for venting solid fuel appliances or fireplaces. Also consult local and state codes for proper chimney sizing and application or, in the absence of local and state codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition.

The connector must be installed above the extreme bottom of the chimney to prevent potentially blocking the flue gases.

9

COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS

The connector must be firmly attached and sealed to prevent it from falling out.

To aid in removing the connector, a thimble or slip joint may be used.

The connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

FT.

 

 

 

 

 

 

 

 

 

 

 

2 FT. Minimum Above Any Object

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Within 10 FT. Horizontally

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Support Strap

Minimum

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Maintain

 

 

 

 

 

 

 

Seal

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Clearance*

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Do Not Extend

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Vent Beyond Edge

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Of Chimney

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Vent

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Connector

 

 

Slope

Up

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1/4 Inch

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Per Foot

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Minimum

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Chimney Termination Vent System

Figure 8.

Do not reduce the vent to less than the draft hood outlet diameter. Do not terminate the vent connector in a chimney that has not been certified for this purpose. Some local codes may prohibit the termination of vent connectors in a masonry chimney.

Vertical Exhaust Gas Vent: Vertical 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.

It must be connected to the water heater’s draft hood by a listed vent connector or by directly originating at the draft hood opening.

Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer’s instructions.

Gas vents must be supported to prevent damage, joint separation, and maintain clearances to combustible materials.

IMPORTANT: This gas vent must be terminated in a vertical position to facilitate the removal of the burnt gases.

An unused chimney flue or masonry enclosure may be used as a passageway for the installation of a gas vent. NOTE: The chimney flue or masonry enclosure size may be too large to allow proper venting.

Common (combined) venting is allowable with vertical type B vent systems and lined masonry chimneys as long as proper draft for the water heater is established under all conditions of operation. CAUTION: DO NOT common vent this water heater with any power vented appliance.

The following figures are examples of vent pipe system installations and may or may not be typical for your specific application. Consult the “National Fuel Gas Code”, NFPA 54, ANSI Z223.1-current edition and the guidelines set forth by prevailing local codes.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2 FT. Minimum Above

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Any Object Within

 

 

 

 

 

 

3 FT.

 

 

 

 

10 FT. Horizontally

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Minimum

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Support Strap

 

 

 

 

 

 

 

 

Type B Double

 

 

 

 

 

 

 

 

 

 

 

 

 

Maintain

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Clearance*

 

 

 

 

 

 

 

 

 

 

 

 

Wall Vent Pipe

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

**Maintain

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Vent

 

 

 

Specified

 

 

 

 

 

 

 

 

 

 

Connector

 

 

 

Clearance

 

 

 

 

 

 

 

 

 

 

Slope Up

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1/4 Inch

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Per Foot

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Minimum

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Venting Gas Vent System With Type B Double Wall Vent Pipe.

Figure 9.

Consult the table found in the “National Fuel Gas Code”, NFPA 54, ANSI Z223.1-current edition to determine the minimum height from roof to lowest discharge opening.

Listed Vent Cap

Maintain Manufacturer’s

Specified Minimum Clearance

Support Strap

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

**Maintain

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Specified

Maintain

 

 

 

 

 

 

 

 

 

Seal

 

 

 

 

 

 

 

 

 

 

 

 

 

Clearance

Clearance*

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Vent Connector

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Vent

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Connector

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Slope Up

 

 

 

 

 

 

 

 

 

Unused Chimney

 

 

 

 

 

 

 

 

 

 

 

 

 

1/4 Inch

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Flue Or Masonry

 

 

 

 

 

 

 

 

 

 

 

 

 

Per Foot

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Enclosure

 

 

 

 

 

 

 

 

 

 

 

 

 

Minimum

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Venting Through Chimney With Type B Double Wall Vent Pipe.

Figure 10.

*Maintain vent pipe clearance requirements to local, state and/or the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition.

**NFPA 211, Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances states that these chimneys are intended to be installed in accordance with the installation instructions provided with each chimney support assembly. Minimum air space clearance to combustible materials should be maintained as marked on the chimney sections.

10

KNOW THE WATER HEATER’S COMPONENT PARTS

Electronic Control Display (Upper Control)

The Electronic Control Display panel used on this water heater provides an easy-to-read, eye level display for temperature adjustment, fault code diagnostics and recall, powered anode rod operation and setting the temperature scale for either Fahrenheit (°F) or Celsius (°C).

Figure 11.

Electronic Control Display

(Upper Control)

Gas Control Valve/Thermostat (Lower Control)

The gas control valve/thermostat is where the incoming gas supply is connected to the water heater. It is used in conjunction with the electronic control display to start or stop main burner operation. There is an On/Off switch located on the right-hand side of the control. The gas control valve/thermostat is energized by a 24 VAC power supply transformer and uses a temperature sensing probe to open or close the flow of gas to the main burner. The gas control valve has an inlet filter built into its body to prevent impurities in the gas system from contaminating the internal valves and a LED diagnostic light located in the lower right hand corner of the valve to display any micro-computer fault experienced by the control. On the bottom of the control is where electrical connections to the other component parts are attached along with the gas supply (manifold tube) to the main burner. The gas control/valve thermostat of this water heater is suitable for use on Natural gas only.

Figure 12.

Gas Control Valve/ Thermostat

On/Off Switch

located on Bottom View

the right side.

Gas SupplyInlet

Temperature Probe

/High Limit Probe

 

 

 

1 8 Pin Systems

 

 

 

Connector

 

 

 

2 5 Pin Communications

Manifold Tube

 

 

Connector

 

 

 

3 3 Pin Ignitor

Power Supply

4

Pressure

Connector

4 2 Pin Power

Transformer

 

1 Switch / Fan,

Connector

3

FV Sensor

Connector

 

Igniter/Flame

Connector

 

 

2

 

 

Sense

 

 

Control Display,

 

 

Connector

 

 

Anode Rod

 

 

 

 

 

 

Connector

 

11

KNOW THE WATER HEATER’S COMPONENT PARTS

Burner/Manifold Door Assembly

The burner/manifold door assembly consists of several components such as: main burner, burner orifice, manifold tube and flame sense / hot surface igniter. See figure below for the complete list of components (Figure 13).

Figure 13.

Main Burner

 

Manifold

 

 

 

Tube

 

 

Manifold

 

 

Door

Scoop side to be placed

 

View

Flame Sense / Hot Surface

on the same side as

Port

View Port.

Igniter Assembly

 

Burner Orifice*

 

Flame Sense/

Hot Surface

Igniter Assembly

Burner Screws

Door Gasket

*DO NOT operate the water heater without the burner orifices installed.

Figure 14.

Air intake

Chamber

Screen

Air intake

Chamber

Fan

Air intake

Chamber

Air Intake Chamber Fan

The small fan at the top of the air intake chamber on the side of the water heater is used to draw in necessary combustion air for the efficient operation of the main burner. The fan pressurizes the sealed combustion chamber which in turn allows the flue baffle inside the center flue tube to slow down the hot exhaust gases so heat can be extracted into the water before exiting into the vent system. The air intake chamber fan runs for about 5 seconds to prepurge the combustion chamber before the beginning of an ignition sequence when there is a call for heat. The fan will continue to operate while the main burner is in operation and for about 5 seconds after the temperature set point has been achieved. The air intake chamber screen covering the fan should be inspected and cleaned periodically to assure it is not limiting air flow into the chamber (Figure 14).

Pressure Switch

A pressure switch in the control string of this water heater is used to verify there is an adequate flow of combustion air into the combustion chamber before and during main burner operation. It is electrically connected to the gas control valve/thermostat and controls the opening and closing of the gas valve. If there is an insufficient air supply being delivered to the combustion chamber the pressure switch will not allow the water heater to operate (Figure 15).

Figure 15

Pressure

Switch

12

A.O. Smith PCG6240T403NOV, PCG250T403NOV, PCG2J5040T3NOV, PCG2J4040T3NOV, 12 40GPC T 100 User Manual

KNOW THE WATER HEATER’S COMPONENT PARTS

Flammable Vapor Cut Off Switch (FV Sensor)

Figure 16.

The water heater is equipped with a FV sensor, for

 

detecting the presence of flammable vapors (e.g.

 

spilled gasoline). When the sensor detects those

 

vapors, the heater will shut down and not operate.

 

If flammable vapors are detected or the sensor

 

is inoperative, an icon will flash on the electronic

 

control display and the heater will go into a lockout

 

mode. The water heater will not function again until

 

the flammable vapors have been eliminated and the

 

control is manually reset using a special Flammable

FV Sensor

Vapor sensor reset sequence. (Figure 16).

Figure 17.

Powered

Anode

Rod

Power Anode Rod

To protect the glass-lined water tank from corrosion through electrolysis, this water heater is equipped with a non sacrificial powered anode rod. Unlike conventional magnesium or aluminum anode rods used in water heaters, the powered anode does not deteriorate and is less likely to contribute to the occurrence of “Smelly (Rotten Egg) Water” (Figure 17).

HOW THE WATER HEATER’S COMPONENT PARTS ARE CONNECTED

Figure 18.

Air Intake

Gas Control

Valve / Thermostat

Chamber Fan

 

Pressure

Switch

Igniter/Flame

Sense Connector

FV Sensor

CAUTION:

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION.

VERIFY PROPER OPERATION AFTER SERVICING.

Anode

Rod

Control Display

CAUTION:

DO NOT USE AN EXTENSION CORD TO CONNECT THE TRANSFORMER TO AN ELECTRICAL OUTLET.

Power Supply

Transformer

13

WATER HEATER OPERATION

The figure below shows the water heater’s sequence of operation when a call for heat is initiated. The gas control valve/thermostat will attempt to light the burner three times. If the flame sense rod in the burner/ manifold assembly does not detect ignition, the control will enter lockout mode indicated by the electronic control display’s flashing of the appropriate status code.

SEQUENCE OF OPERATION

Call for heat indicated by flashing of display screen status codes.

Gas valve/thermostat will do a relay check (relay clicks will be heard).

Display will show temperature set point during call for heat.

Draft Blower is energized.

System will verify pressure switch operation and start a 5 second pre-purge, then air intake fan will turn off.

Ignitor will start a 12 second warm up period. “IGN” will show on display.

Gas valve/thermostat will open for 4 second trial for ignition and fan will turn on.

Main burner flame is detected by flame sense rod. Air intake fan and main burner will continue to operate until water temperature inside the tank reaches temperature set point.

Gas valve/thermostat is deenergized and air intake fan continues for a post purge time of approximately 5 seconds.

Water heater returns to standby mode.

14

FILLING, DRAINING AND FLUSHING THE WATER HEATER TANK

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. To drain the tank, perform the following steps:

1.Turn off the gas to the water heater at the manual gas shut-off valve and turn off the electrical power to the gas control/thermostat valve.

2.Open a nearby hot water faucet until the water is no longer hot.

3.Close the cold water inlet valve.

4.Remove the outer door and connect a hose to the drain valve and terminate it to an adequate drain or external to the building (Figure 19).

5.Open the water heater drain valve and allow all the water to drain from the tank. Flush the tank with water as needed to remove sediment.

6.Close the drain valve, refill the tank, and restart the heater as directed in the lighting instructions on the front of the heater.

IMPORTANT: Condensation may occur when refilling the tank and should not be confused with a tank leak.

NOTE: If the water heater is going to be shut down for an extended period, the drain valve should be left open.

Figure 19.

Hose

Outer Door

Adequate Drain

15

LIGHTING INSTRUCTIONS

Read and understand these directions thoroughly before attempting to operate the water heater. Make sure the view port is not missing or damaged. Make sure the tank is completely filled with water before operating the water heater. The gas control valve/thermostat has an “On/Off Switch” and needs to be turned on before the water heater is operational. Check the label on the front of the water heater near the gas control valve/thermostat for the correct gas. Do not start this water heater with any gas other than the one listed on the label. If you have any questions or doubts, consult the gas supplier or gas utility company. The following Lighting Instruction label appears on the front of the water heater.

FOR YOUR SAFETY READ BEFORE OPERATING

 

WARNING: If you do not follow these instructions exactly, a fire or

 

explosion may result causing property damage, personal injury

 

or loss of life.

 

FLAMMABLE

BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.

A. This appliance does not have a pilot. It is equipped with

 

If you cannot reach your gas supplier, call the

an ignition device that will automatically light the

 

fire department.

burner. Do not try to light the burner by hand.

C. Use only your hand to push in the electronic display

B. BEFORE OPERATING smell all around the appliance

 

buttons and gas control switch. Never use tools.

area for gas. Be sure to smell next to the floor because

 

If the control buttons will not push in, don't try to

some gas is heavier than air and will settle on the floor.

 

repair them, call a qualified service technician. Force

WHAT TO DO IF YOU SMELL GAS:

 

or attempted repair may result in a fire or explosion.

Do not try to light any appliance.

D. Do not use this appliance if any part has been

Do not touch any electric switch;

 

under water. Immediately contact a qualified

do not use any phone in your building.

 

installer or service agency to replace a flooded

Immediately call your gas supplier from a neighbor’s

water heater. Do not attempt to repair the unit.

phone. Follow the gas supplier’s instructions.

 

It must be replaced!

OPERATING INSTRUCTIONS

ON

OFF

ON/OFF

SWITCH

"GAS CONTROL"

1.STOP! Read the safety information

above on the label.

2.Turn on all electrical power to the appliance.

3.Set the ON/OFF switch on the gas control to the "ON" position.

4.Set the Electronic Display to the lowest setting by first pressing the COOLER and HOTTER buttons together and holding for 1 second. Then press the COOLER button to the lowest setting.

5.Set the ON/OFF switch on the gas control to the "OFF" position.

6.This appliance is equipped with a device which automatically lights the burner.

DO NOT TRY TO LIGHT THE BURNER BY HAND.

7. Wait five (5) minutes to

clear out any gas.

If you then smell gas,

STOP! Follow "B" in

the safety information above on this label. If you don't smell gas, go to the next step.

"ELECTRONIC DISPLAY"

8.Set the ON/OFF switch on the gas control to the "ON" postition.

9.Set the Electronic Display to the desired setting by first pressing the COOLER and HOTTER buttons together and holding for 1 second. Then press the HOTTER button until the desired setting is reached.

DANGER: Hotter water increases the risk of scald injury. Consult the instruction manual before changing temperature.

10.If the appliance will not operate, follow the instructions "TO TURN OFF GAS TO APPLIANCE" and call your technician or gas supplier.

WARNING: TURN OFF ALL ELECTRIC POWER BEFORE SERVICING.

TO TURN OFF GAS TO APPLIANCE

1.Set the Electronic Display to the lowest setting by first pressing the COOLER and HOTTER buttons together and holding for 1 second. Then press the COOLER button to the lowest setting.

2.Set the ON/OFF switch on the gas control to the "OFF" postition.

3.Turn off all electrical power to the appliance if service is to be performed.

185741-000

Figure 20.

16

ADJUSTING THE TEMPERATURE ON THE

ELECTRONIC CONTROL DISPLAY

Adjusting the Temperature Set Point - The thermostat of this water heater has been factory set at its lowest position. It is adjustable and must be reset to the desired temperature setting to reduce the risk of scald injury. The electronic control display temperature should be set at approximately 120°F (49°C) and this is the preferred starting point, see Figure 21 Some states have a requirement for a lower setting. If you need hotter water, follow directions for temperature adjustment, but beware of the warnings in this section.

Pressing the “COOLER”button decreases temperature and pressing the “HOTTER” button increases the temperature.

To avoid any unintentional changes in water temperature settings, the control has a tamper resistant feature for changing the temperature setting. To change the temperature setting follow these instructions:

1.“Unlock” the temperature indicators by holding down both “COOLER” and “HOTTER” temperature adjustment buttons at the same time for one second (See Figure 21). The temperature indicators will light up and will only remain on for 30 seconds if no further buttons are pressed. After 30 seconds the control will go back to “Lock” mode (“Lock” mode indicates a temperature setting is locked into the control memory).

2.Release both of the temperature adjustment buttons.

A.To decrease the temperature press and release the “COOLER” button until the desired setting is reached.

B.To increase the temperature press and release the “HOTTER” button until the desired setting is reached.

NOTE: Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the heater.

Figure 21.

Gas Control Valve/Thermostat Settings

HOTTER COOLER

Electronic Control Display

Water

Time for 1st

Time for Permanent Burns

Temperature

Degree Burn

2nd & 3rd Degree

°F

(Less Severe Burns)

(Most Severe Burns)

110

(normal shower temp.)

 

116

(pain threshold)

 

116

35 minutes

45 minutes

122

1 minute

5 minutes

131

5 seconds

25 seconds

140

2 seconds

5 seconds

149

1 second

2 seconds

154

instantaneous

1 second

(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978)

Table 2

17

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