Installation Guide

ManualsBrandsA.O. Smith ManualsGas Water HeatersG6-DMH4032NV

For Your Safety

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

• Safety Instructions

• Installation

• Operation

October 2016

DO NOT RETURN THIS UNIT TO THE STORE. To obtain technical, warranty, or service assistance during or after the

installation of this water heater, visit our website at:

http:// www.AOSmithAtLowes.com or call toll free 1-877-817-6750

— 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.

— Installation and service must be

performed by a qualified installer,

service agency or the gas supplier.

WARNING: If the information in these

instructions is not followed exactly, a fire

or explosion may result causing property

damage, personal injury or death.

RESIDENTIAL DIRECT VENT GAS WATER HEATERS

Installation Instructions and Use & Care Guide

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.

WARNING: Gas leaks can not always be detected by

smell.

Gas suppliers recommend that you use a gas detector

approved by UL or CSA.

For more information, contact your gas supplier.

If a gas leak is detected, follow the “WHAT TO DO IF YOU

SMELL GAS” instructions.

• Care and Maintenance

• Troubleshooting

• Parts List

LOW LEAD

NTENT

• SHIPPED SET FOR NATURAL GAS AND CONVERTIBLE

TO L.P. (PROPANE) GAS. ALL PARTS INCLUDED.

• FOR POTABLE WATER HEATING ONLY. NOT SUITABLE

FOR SPACE HEATING.

• FOR DIRECT VENT INSTALLATION IN A MANUFACTURED

HOME (MOBILE HOME) ONLY.

• FOR USE ONLY WITH VENTING SYSTEMS SUPPLIED

WITH THE WATER HEATER, WHETHER A NEW

INSTALLATION OR A REPLACEMENT INSTALLATION.

2000536053 (VER 00) 100277328 (REV A)

Summary of content (40 pages)

PAGE 1
Installation Instructions and Use & Care Guide RESIDENTIAL DIRECT VENT GAS WATER HEATERS • SHIPPED SET FOR NATURAL GAS AND CONVERTIBLE TO L.P. (PROPANE) GAS. ALL PARTS INCLUDED. • FOR POTABLE WATER HEATING ONLY. NOT SUITABLE FOR SPACE HEATING. • FOR DIRECT VENT INSTALLATION IN A MANUFACTURED HOME (MOBILE HOME) ONLY. • FOR USE ONLY WITH VENTING SYSTEMS SUPPLIED WITH THE WATER HEATER, WHETHER A NEW INSTALLATION OR A REPLACEMENT INSTALLATION.
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SAFE INSTALLATION, USE AND SERVICE This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.
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Water temperature over 125°F (52°C) can cause servere burns instantly resulting in severe injury or death. Children, the elderly, and the physically or mentally disabled are at highest risk for scald injury. Feel water before bathing or showering. Temperature available. limiting valves are Read instruction manual for safe temperature setting. Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
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TABLE OF CONTENTS INSTALLATION CHECKLIST .......................................................21 GAS CONVERSION ................................................................21-22 LIGHTING INSTRUCTIONS.........................................................23 TEMPERATURE REGULATION ..................................................24 FOR YOUR INFORMATION ....................................................25-26 Start Up Conditions ............................................................
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TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER - GAS MODELS A B C D E F G H I Flue Reducer Anode Hot Water Outlet Insulation Gas Supply Piping Manual Gas Shut-off Valve Ground Joint Union Sediment Trap Inner Door J K L M N O P Q R Outer Door Union Inlet Water Shut-off Valve Cold Water Inlet Inlet Dip Tube (Not Shown) Temperature-Pressure Relief Valve Rating Plate Flue Baffle Gas Control Valve/Thermostat S T U V W Drain Valve Manifold/Burner Assembly Flue Metal Drain Pan Piezo Igniter (bottom, Left-
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TYPICAL INSTALLATION * MIXING VALVE USAGE Figure 2. HOTTER WATER CAN SCALD: This appliance has been design certified as complying with American National Standard/CSA Standard ANSI Z21.10.1 • CSA 4. 1 for water heaters and is considered suitable for: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy clothes washing, dish washing, and other sanitizing needs can scald and permanently injure you upon contact.
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LOCATING THE NEW WATER HEATER home. The combustion air intake piping can be 3” (76 mm) PVC for 30 and 40 gallon models and 4” (102 mm) PVC for 50 Gallon models. The air intake piping cannot exceed the lengths shown in Table 1 (page 12), including vertical and horizontal runs, or have more than 3 elbows. All horizontal runs require adequate support at 3-1/2 foot (106.68 cm) intervals. See Figure 4.
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the environment in which the water heater is installed. Water heaters are sometimes installed in locations where leakage may result in property damage, even with the use of a metal drain pan piped to a drain. However, unanticipated damage can be reduced or prevented by a leak detector or water shut-off device used in conjunction with a piped drain pan.
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INSULATION BLANKETS Should you choose to apply an insulation blanket to this heater, you should follow these instructions (For identification of components mentioned below, see Figure 1). Failure to follow these instructions can restrict the air flow required for proper combustion, potentially resulting in fire, asphyxiation, serious personal injury or death. • Do not apply insulation to the top of the water heater, as this will interfere with safe operation of the draft hood.
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4. Set the water heater in place against the lip of the duct assembly as shown in Figure 11. FIGURE 11. FIGURE 7. 5. Secure the water heater to the duct assembly using the screw provided. 9” (22.86 cm) MIN. - 30 GAL. 10” (25.4 cm) MIN. - 40 GAL. 11” (27.9 cm) MIN. - 50 GAL. 9” (22.86 cm) MIN. - 30 GAL. 10” (25.4 cm) MIN. - 40 GAL. 11” (27.9 cm) MIN. - 50 GAL. 4” (10.16 cm) MIN. - 30 GAL. 0” MIN. - 40 & 50 GAL. 0” MIN.
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ROOF JACK INSTALLATION ROOF JACK KIT MODELS VENT KIT- 12 INCH (9002964005), VENT KIT - 32 INCH (9002965005), VENT KIT - 60 INCH (9002966005) AND VENT KIT - 95 INCH (9002967005) VENT KIT / 95” (241.3 cm) ROOF JACK: SURFACE OF OUTER PIPE HAS A MINIMUM CLEARANCE OF 0” (0 CM). VENT KIT / 60” (152.4 cm) VENT KIT / 32” (81.28 cm) 95” (241.3 cm) MAX. 36” (91.4 cm) MIN. 60” (152.4 cm) MAX. 32” (81.28 cm) MIN. VENT KIT / 12” (30.48 cm) 32” (81.28 cm) MAX. 18” (45.72 cm) MIN. 12” (30.48 cm) MAX. 136” (345.
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6. Extend the flue pipe downward until it is close to the flue reducer. See Figure 16. FIGURE 16. 7. Fit the bottom opening of the pipe over the top opening of the flue reducer. See Figure 17. Ensure that there is no gap and that the seal is complete. 8. Secure the flue pipe to the reducer with three (3) evenly-spaced sheet metal screws (Figure 17). Do not leave any open holes in the flue reducer or flue pipe.
PAGE 13
INSTALLATION SHOWING USE OF PVC, ABS OR CPVC PIPE 5. Vertical and horizontal runs must be securely supported at 3-1/2 foot (1.06 m) intervals. See Figure 20. SLOPE INLET PIPING DOWNWARD TOWARD VENT CAP TO PREVENT CONDENSATION BUILDUP. FIGURE 22. FIGURE 20. NOTE: Wall collars are for aesthetic purposes and are not required for the heater to operate. 6. The intake air vent piping can be installed with no more than 3 elbows. See Figure 21.
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to excessive pressure build up. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This condition is not covered under the limited warranty. TABLE 2: APPROX. SETTING TIME FOR 2-1/2” (63.5mm) TO 4” (102mm) PIPE JOINTS MOVEMENT OF JOINT COMPLETE SET 90°F (32.2°C) TO 150°F (65.6°C) 3/4HR. 8 HRS. 50°F (10°C) TO 90°F (32.2°C) 1 HR. 15 HRS. 0°F (-17.77°C) TO 50°F (10°C) 1-1/3 HR. 18 HRS.
PAGE 15
WATER PIPING PRESSURE TEST TEMPERATURE-PRESSURE RELIEF VALVE Explosion Hazard Temperature-pressure relief valve must comply with ANSI Z21.22-CSA 4.4 and ASME code. ,I ZDWHU SLSLQJ V\VWHP LV WR EH DLU SUHVVXUH WHVWHG WKH ZDWHU KHDWHU PXVW EH GLVFRQQHFWHG IURP WKH ZDWHU SLSLQJ V\VWHP Properly sized temperaturepressure relief valve must be installed in opening provided.
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The Discharge Pipe: • Shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions. • Shall not be plugged or blocked. • Shall be of material listed for hot water distribution. • Shall be installed so as to allow complete drainage of both the temperature-pressure relief valve, and the discharge pipe. • FIGURE 25. Shall pass through the structural floor and terminate external to the building.
PAGE 17
WARNING MANUAL GAS SHUT-OFF VALVE GROUND JOINT UNION CHECK WITH LOCAL UTILITY FOR MINIMUM HEIGHT Explosion Hazard • Use a new CSA approved gas supply line. • Install a shut-off valve. • Do not connect a natural gas water heater to an L.P. gas supply. • Do not connect an L.P. gas water heater to a natural gas supply. • Failure to follow these instructions can result in death, explosion, or carbon monoxide poisoning. 3” (7.62cm) MINIMUM SEDIMENT TRAP FIGURE 27.
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LP GAS ONLY Liquefied petroleum gas is over 50% heavier than air and in the occurrence of a leak in the system, the gas will settle at floor level. Basements, crawl spaces, skirted areas under mobile homes (even when ventilated), closets and areas below ground level will serve as pockets for the accumulation of gas. Before lighting an L.P. gas water heater, smell all around the appliance at floor level. If you smell gas, follow the instructions as given in the warning on the front page. When your L.P.
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3 4 19
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INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above ¿nished grade in the area of the venting, including but not limited to decks and porche
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INSTALLATION CHECKLIST This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. The new technology used in meeting these standards makes this product more sensitive to installation errors. Please review the following checklist and make any required installation upgrades or changes. Questions? Contact Residential Technical Assistance.
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A. Remove the Manifold/Burner Assembly 1. 2. 3. 4. 5. 6. 7. 8. 9. 3. Insert the replacement manifold/burner assembly into the burner compartment, making sure that the tip of the manifold tube engages in the slot of the bracket inside the combustion chamber. See Figure 43. 4. Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion chamber. 5.
PAGE 23
LIGHTING INSTRUCTIONS Read and understand these directions thoroughly before attempting to light or re-light the pilot. Make sure that the view port (sight glass) is not missing or damaged. (See Figure 40.) Make sure the tank is completely filled with water before lighting the pilot. Check the rating plate near the gas control valve/thermostat for the correct gas. Do not use this water heater with any gas other than the one listed on the rating plate unless the water heater has been properly converted.
PAGE 24
TEMPERATURE REGULATION Water temperature over 125°F (52°C) can cause servere burns instantly resulting in severe injury or death. NOTE: • If the knob is set to a higher temperature setting than 120°F (48.9°C), a mixing valve should be installed to limit the temperature of the water to 120°F (48.9°C) at the fixtures. Children, the elderly, and the physically or mentally disabled are at highest risk for scald injury. • Temperatures shown on the gas control valve/thermostat are approximates.
PAGE 25
FOR YOUR INFORMATION START UP CONDITIONS CONDENSATE thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent temperaturepressure relief valve operation: water discharged from the valve due to excessive pressure build up. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This condition is not covered under the limited warranty.
PAGE 26
“AIR” IN HOT WATER FAUCETS SAFETY SHUT OFF SYSTEM This water heater is designed to automatically shut off in the event of the following: 1. When the pilot flame is extinguished for any reason. A thermocouple is used to determine if a pilot flame is present and will shut off the gas supply to the main burner and pilot if the flame is absent. 2. When the water temperature in the tank exceeds 189°F (87°C).
PAGE 27
MAINTENANCE OF YOUR WATER HEATER IMPORTANT: If you do not have the skills and training to perform a maintenance procedure, do not attempt it. Get help from a qualified technician. Anode Rod Depletion BURNER FLAME INSPECTION Inspect the burner flames through the viewport and compare them to the drawing in Figure 36. A properly operating burner should produce a soft blue flame. Blue tips with yellow inner cones are satisfactory. The tips of the flame may have a slight yellow tint.
PAGE 28
TEMPERATURE-PRESSURE RELIEF VALVE OPERATION Explosion Hazard 7HPSHUDWXUH SUHVVXUH UHOLHI YDOYH PXVW FRPSO\ ZLWK $16, = &6$ DQG $60( FRGH 3URSHUO\ VL]HG WHPSHUDWXUH SUHVVXUH UHOLHI YDOYH PXVW EH LQVWDOOHG LQ RSHQLQJ SURYLGHG 1. Turn off the gas to the water heater at the manual gas shut-off valve. 2. Open a nearby hot water faucet until the water is no longer hot. 3. Close the cold water inlet valve. 4.
PAGE 29
REMOVING THE BURNER FROM THE MANIFOLD/BURNER ASSEMBLY the old one. Make only the bends closest to the pilot before going to the next step. 1. Take off the burner by removing the two (2) screws located underneath the burner. 2. Check the burner to see if it is dirty or clogged. The burner may be cleaned with soap and hot water (Figure 41).
PAGE 30
combustion chamber (Figure 45). COMBUSTION CHAMBER 5. DOOR GASKET Tighten the two screws that secure the manifold/burner assembly to the combustion chamber. (Use a 1/4” SAE nut driver.) There should be no space between the gasket part of the manifold door and combustion chamber. IMPORTANT: Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber. 6.
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TESTING THE IGNITER SYSTEM • Turn off the gas to the water heater at the manual gas shut-off valve. Watch the electrode tip while activating the igniter. A visible spark should jump from the electrode. To avoid shock, do not touch the burner or any metal part on the pilot or pilot assembly. If no spark is visible, check the wire connections and make sure the electrode is not broken. Replace the igniter if defective. Dirt and rust on the pilot or electrode tip can prevent the igniter spark.
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LEAKAGE CHECKPOINTS Use this guide to check a “Leaking” water heater. Many suspected “Leakers” are not leaking tanks. Often the source of the water can be found and corrected. Read this manual first. Then before checking the water heater make sure the gas supply has been turned “OFF”, and never turn the gas “ON” before the tank is completely full of water.
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TROUBLESHOOTING GUIDELINES PROBLEM BURNER WILL NOT IGNITE POSSIBLE CAUSE(S) 1. 2. 3. 4. 5. 6. 7. 8. 9. CORRECTIVE ACTION Pilot not lit Thermostat set too low No gas Dirt in the gas lines Pilot line clogged Main burner line clogged Non-functioning thermocouple Non-functioning thermostat Heater installed in a confined area 1. 2. 3. 4. 5. 6. 7. 8. 9. Light pilot Turn temp.
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TROUBLESHOOTING GUIDELINES PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION DRIP FROM RELIEF VALVE 1. 2. 3. Excessive water pressure Heater stacking Closed water system 1. 2. 3. Use a pressure reducing valve and relief valve Lower the thermostat setting See “Closed System/Thermal Expansion” THERMOSTAT FAILS TO SHUT-OFF 1. 2. Thermostat not functioning properly Improper calibration 1. 2. Replace thermostat Replace thermostat COMBUSTION ODORS 1. Insufficient secondary air 1. 2. 3.
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PILOT LIGHT TROUBLESHOOTING CHART Section B: Pilot light repeatedly goes out. Section A: Pilot light will not light (new installation). Is the manual gas shut-off valve, located in the supply line to the water heater, in the on position? YES Have you bled all the air from the pilot tube and gas supply line? NO YES Is the igniter producing a spark? NO Turn the manual gas shut-off valve to the on position and follow the lighting instructions on the front of the water heater.
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REPAIR PARTS LIST Key No. 1 2 3 4 5 6 7 7 8 9 10 11 12 13 13 14 15 #16 #16 17 18 *19 20 20 20 20 21 *22 23 * # Part Description 19 10” Extension Pipe (Optional) Air Duct Assembly (14.5” to 24” [36.8cm to 61cm] Long) Angle Bracket Angle Bracket (2 Required) Anode Rod Burner Burner Orifice (Natural Gas) Gas) Burner Orifice (Propane [L.P.
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NOTES 37
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NOTES 38
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NOTES 39