Instruction Manual RESIDENTIAL GAS WATER HEATERS POWER VENT/POWER DIRECT VENT GAS MODELS WITH DIRECT SPARK IGNITION MODELS VG6250T100/VGD6275T100 SERIES 130/131 www.americanwaterheater.com American Water Heater Johnson City, TN 37605 • For Your Safety • AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER. Thank you for buying this energy efficient water heater. We appreciate your confidence in our products.
TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE.................................3 APPROVALS..................................................................................3 GENERAL SAFETY INFORMATION..............................................4 Precautions...............................................................................4 Grounding Instructions..............................................................4 Hydrogen Gas Flammable........................................................
SAFE INSTALLATION, USE AND SERVICE The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual.
GENERAL SAFETY INFORMATION PRECAUTIONS HYDROGEN GAS FLAMMABLE DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN UNDER WATER. Immediately call a qualified service agency to inspect the water heater and to make a determination on what steps should be taken next. Explosion Hazard If the unit is exposed to the following, do not operate heater until all corrective steps have been made by a qualified service agency. Flammable hydrogen gases may be present. 1. External fire.
GENERAL SAFETY INFORMATION 5
GENERAL SAFETY INFORMATION Fire or Explosion Hazard Fire Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. For continued protection against risk of fire: Avoid all ignition sources if you smell gas. Do not expose water heater controls to excessive gas pressure. Do not install water heater on carpeted floor. Do not operate water heater if flood damaged. Use only the gas shown on the water heater rating plate.
INTRODUCTION Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service. See the Installation Checklist and Troubleshooting on Page 51. By using this checklist the user may be able to make minor operational adjustments and avoid unnecessary service calls. However, service and diagnostic procedures should only be performed by a Qualified Service Agency.
DIMENSIONS AND CAPACITY DATA ROUGH IN DIMENSIONS: 50 GALLON UNIT Figure 1: DIMENSIONS FOR 50 GALLON UNIT ROUGH IN DIMENSIONS: 75 GALLON UNIT Figure 1A: DIMENSIONS FOR 75 GALLON UNIT Table 1 – ROUGH-IN-DIMENSIONS 50G 75G Units A B C D E F G H I Inches 66.75 49.25 22.00 15.75 3.00 8.00 8.00 62.00 65.00 cm 169.5 125.09 55.88 40.00 7.62 20.32 20.32 157.48 165.1 Inches 64.71 45.64 27.75 16.00 3.71 8.00 7.93 57.36 58.98 cm 164.4 115.9 70.5 40.6 9.4 20.3 20.
DIMENSIONS AND CAPACITY DATA Table 2 – CAPACITY, GAS AND ELECTRICAL CHARACTERISTICS Approximate Capacity Manifold Pressure Electrical Characteristics U.S. Gals. Liters Gas Type “WC kPA Volts/Hz Amperes 50 189 Nat./LP 0 75 284 Nat/LP 0 0 120/60 <5 0 120/60 <5 All models - Maximum Supply Pressure: 14 inches W.C. (3.48kPa) Minimum Supply Pressure for Natural Gas: 3.50” (.87kPa) Minimum Supply Pressure for Propane Gas: 8.00” (1.
FEATURES AND COMPONENTS 50 GALLON UNIT **29 20 23 21 5 **14 22 1 12 18 **15 21 16 25 11 ACCESS PANEL 17 24 33 18 35 Caution: This access panel covers 13 32 a 2” NPT plug that was required during the manufacturing of this water heater. This 2” NPT flange is not a cleanout fitting, removing the 2” NPT plug and using this fitting as a cleanout could void your warranty.
FEATURES AND COMPONENTS (CONT.) 75 GALLON UNIT **29 **14 20 21 23 22 **15 5 18 21 12 11 17 25 13 1 24 18 3 16 2 26, 27 31 4 35 33 19 32 34 30 VACUUM RELIEF VALVE 28 *INSTALL PER LOCAL CODES * CAUTION HARNESS HAS 120 VAC. IN OPERATION. ** See Planning the Vent System, Installation of Vent System and Condensate Piping for more information.
FEATURES AND COMPONENTS (CONT.
CONTROLS AND SWITCHES BLOCKED EXHAUST SWITCH The Blocked Exhaust Switch is set up to shut the unit off when a buildup of positive pressure in the exhaust vent pipe occurs. This switch is a positive pressure switch that requires an increase in pressure to change the electrical contacts from normally closed to open. When this switch prevents the unit from igniting, most likely the exhaust is blocked by some means.
INSTALLATION CONSIDERATIONS LOCATING THE WATER HEATER Also, the water heater must be located and/or protected so it is not subject to physical damage by a moving vehicle. Carefully choose a location for the new water heater. The placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the water heater. CAUTION Property Damage Hazard • All water heaters eventually leak. • Do not install without adequate drainage.
• Do not apply insulation to the top of the water heater, as this will interfere with safe operation of the blower assembly. • Do not cover the control system LCD on top of the water heater. • Do not cover the outer door, thermostat or temperature & pressure relief valve. • Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.
FRESH AIR OPENINGS FOR CONFINED SPACES UNCONFINED SPACE The following instructions shall be used to calculate the size, number and placement of openings providing fresh air for combustion, ventilation and dilution in confined spaces. The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only. DO NOT refer to these illustrations for the purpose of vent installation.
AIR FROM OTHER INDOOR SPACES Alternatively a single permanent opening, commencing within 12 inches (300 mm) of the top of the enclosure, shall be provided. See Figure 6. The water heater shall have clearances of at least 1 inch (25 mm) from the sides and back and 6 inches (150 mm) from the front of the appliance.
INSTALLATION REQUIREMENTS CHEMICAL VAPOR CORROSION Corrosion of the flueways and vent system may occur if air for combustion contains certain chemical vapors. Such corrosion may result in failure and risk of asphyxiation. Spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride (water softener salt), waxes, and process chemicals are typical compounds which are potentially corrosive.
MIXING VALVES GAS PIPING Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death. Children, the elderly and the physically or mentally disabled are at highest risk for scald injury. Make sure gas supplied is same type listed on model rating plate. The inlet gas pressure must not exceed 14 inch water column (3.5 kPa) for natural and propane gas (L.P.). The minimum inlet gas pressure shown on rating plate is that which will permit firing at rated input.
GAS SUPPLY SYSTEMS All gas piping must comply with local codes and ordinances or with the current editions National Fuel Gas Code (ANSI Z223.1/ NFPA54). Copper or brass tubing and fittings (except tin lined copper tubing) shall not be used. Low pressure building gas supply systems are defined as those systems that cannot under any circumstances exceed 14” W.C. (1/2 PSI Gauge). These systems do not require pressure regulation.
SPACE HEATING AND POTABLE WATER SYSTEM THERMAL EXPANSION Your water heater is equipped with inlet/outlet connections for use in space heating applications (see Figure 9). If this water heater is to be used to supply both space heating and potable (drinking) water, the instructions listed below must be followed: As water is heated, it expands (thermal expansion). In a closed system the volume of water will grow when it is heated.
TEMPERATURE-PRESSURE RELIEF VALVE CAUTION This water heater is provided with a properly rated/sized and certified combination Temperature-Pressure Relief Valve (T&P relief valve) by the manufacturer. The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA 4.4, and the code requirements of ASME.
CONDENSATE PIPING • Slope the condensate drain toward the inside floor drain or condensate pump. This water heater is a condensing unit and requires a drain to be located in close proximity to allow the condensate to drain safely. The condensate drains from the unit at the exhaust tee located at the bottom of the unit (see Figure 11). Condensate from this water heater is mildly acidic. Please note that some local codes require that condensate is treated by using a pH neutralizing filter prior to disposal.
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 finished grade in the area of the venting, including but not limited to decks and porch
VENTING INSTALLATION NOTE: This unit can be vented with PVC pipe materials (DWV ASTM-D2665 or CSA B181.2; Schedule 40, 80, 120 ASTM-D1785 or CSA B137.3; or SDR Series ASTM-D2241 or CSA B137.3), CPVC pipe materials (CPVC41 ASTM-D2846 or CSA B137.6; Schedule 40, 80 ASTM-F441 or CSA B137.6; or SDR Series ASTM-F442), ABS pipe materials (Schedule 40 DWV ASTM-D2661 or CSA B181.1) and Centrotherm ECO Systems and DuraVent Polypropylene listed vent systems.
POLYPROPYLENE INSTALLATIONS Polypropylene vent systems do not use cement to connect the pipe and elbow sections but use a push together gasket seal method. Do not attempt to connect Polypropylene with sealant cement. All vent connections MUST be secured by the vent manufacturer’s joint connector. The installer must use a specific vent starter adapter at the flue connection. The adapter is supplied by the vent manufacturer to adapt to its vent system.
VENT PIPE TERMINATION INSTALLATION OF HORIZONTAL THROUGH THE WALL VENT SYSTEM The first step is to determine where the vent pipe will terminate. See Figures 12, “Figure: 13A”, and “Figure: 14”. The vent may terminate through a sidewall as shown in Figure 12 and “Figure: 14” or through the roof as shown in “Figure: 15” and “Figure: 16”. If you are installing your system so that it vents through roof, please refer to section titled VERTICAL VENT TERMINAL INSTALLATION.
DIRECT VENT TERMINAL INSTALLATION B.) WOODEN SIDE WALLS Drill a pilot hole approximately one quarter inch outside of the marked circle. This pilot hole is used as a starting point for a saws-all or sabre saw blade. Cut around the marked circle staying approximately one quarter inch outside of the line. (This will allow the vent pipe to easily slide through the opening. The resulting gap will be covered by the vent terminal cover plates.
TERMINATION CLEARANCES SIDEWALL POWER VENT POWER VENT (using room air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION G V D H A v E L v B FI XE D CLOSED V F B B C OPERABLE V OPERABLE V B B FI XE D CLOSED M X V A V X V K J B V VENT TERMINAL X AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED Figure: 15 Vent terminal clearances for “Power Vent” installations. Power Vent configurations use room air for combustion.
TERMINATION CLEARANCES SIDEWALL DIRECT VENT DIRECT VENT (using outdoor air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION G V D H A v E L v B FI XE D CLOSED V F OPERABLE V B B C OPERABLE V B FI XE D CLOSED M X V B V X V K J A B V VENT TERMINAL X AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED Figure: 16 Vent terminal clearances for “Direct Vent” installations. Direct Vent configurations use outdoor air for combustion.
VERTICAL VENT TERMINAL INSTALLATION WHEN TERMINATING THROUGH A ROOF, THE FOLLOWING SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE FOLLOWED. 1. Proper support must be provided for all pipe protruding through the roof. 2. The vertical roof terminations should be sealed with a plumbing roof boot or equivalent flashing. 3. The air intake termination and the exhaust vent termination must penetrate the same side of roof. 4.
DIRECT VENT DIAGRAM 12” MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL 12” MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL Figure: 20 Figure: 21 24” MINIMUM SEPARATION. EXHAUST MUST BE AT SAME LEVEL OR ABOVE INTAKE TERMINAL.
CONCENTRIC VENT INSTALLATION INSTALLATION VERTICAL ROOF TERMINATION This water heater is certified for concentric venting with concentric vent kit #9006328005. Follow instructions below for proper installations. 1. Determine best location for termination kit. NOTE: Roof termination is preferred since it is less susceptible to damage, has reduced chances to intake contaminants, and less visible vent vapors. Table 8 – KIT COMPONENTS 2. Cut 1 hole (5 in. diameter) 3.
NOTE: Do not allow insulation or other materials to accumulate inside pipe assembly when installing through hole. INSTALLATION SIDE WALL TERMINATION 5. Secure assembly to roof structure as shown in “Figure: 27” using field supplied metal strapping or equivalent support material. NOTE: Ensure termination height is above the roof surface or anticipated snow level as shown in “Figure: 27”. 6.
5. Install rain cap and small diameter pipe assembly in Y concentric fitting and large pipe assembly. Ensure small diameter pipe is bottomed and cemented in Y concentric fitting. MULTI-CONCENTRIC VENT TERMINATIONS When two or more water heaters are direct vented with concentric vent terminations near each other, each water heater must be individually vented. NEVER common vent this water heater.
LOW PROFILE TERMINATION INSTALLATION This water heater is certified for sidewall direct venting with IPEX System 636 Low Profile Vent Kit. Follow instructions below for proper installations. To Boiler Intake Air Connection All termination kits must be located and installed in accordance with local codes or the current editions of the National Fuel Gas Code (ANSI Z223.1/NFPA 54). From Boiler Vent Pipe Connection 1.
LIGHTING AND OPERATION LABELS 37
TEMPERATURE REGULATION It is recommended that lower water temperatures be used to avoid the risk of scalding. It is further recommended, in all cases, that the water temperatures be set for the lowest temperature which satisfies your hot water needs. This will also provide the most energy efficient operation of the water heater. Valves for reducing the point-of-use temperature by mixing cold and hot water are available.
CONTROL SYSTEM OPERATION OVERVIEW THE DESKTOP SCREEN The water heaters covered in this manual are equipped with an electronic control system that regulates water temperature inside the storage tank. Heating cycles and ignition are managed by the control system. The ECO (energy cut out), Flame Sensor, pressure switches and Temperature Probe is monitored by the control system. The Combustion Blower, Igniter and the 24 Volt Gas Control Valve are all energized by the control system.
STATUS ICONS The Status Icons are displayed on the Desktop screen and convey operational and diagnostic information. The icons are described in the table below. Table 12 – STATUS ICONS Icon Description Water temperature in the tank has fallen. Shaded area of the animated thermometer icon will rise and fall in response to water temperature in the storage tank as sensed from the Temperature Probe. Water temperature in the tank has reached the Operating Set Point. The control system enters the Standby mode.
OPERATING STATES The current operational state of the water heater is displayed on the Desktop screen as the Status. The common operational states are described in the table below. Table 13 – OPERATING STATES State Description Standby The water heater is not in an active heating cycle. IE: the Tank Temperature is at or above the Operating Set Point minus temperature differential. Input Verification The control system is conducting a diagnostic check at the beginning of a heating cycle.
USER SETTINGS & CONTROL SYSTEM MENUS TEMPERATURES OPERATING SET POINT AND DIFFERENTIAL ADJUSTMENT The Operating Set Point is adjustable from 90°F (42°C) to 160°F (71°C). The factory setting is 120°F (49°C). The Differential is adjustable from 2° to 20°. The factory setting is 8°. These user settings are accessed from the Temperatures menu. These instructions explain how to adjust these settings and navigate the control system.
TEMPERATURES (CONT) DESCRIPTION/ACTION DISPLAY • Tank Probe Offset - adjustable user setting, range -5° to +5°F (factory setting 0°F). The Tank Probe Offset is used to calibrate control system temperature sensing. This offsets to more effectively read point of use temperature in the tank. This feature can also be used to compensate for building recirculation loops (hot water returning to the storage tank) that may cause the heating cycles to terminate prematurely.
DISPLAY SETTINGS DESCRIPTION/ACTION DISPLAY Select Display Settings from the Main Menu and press the Operational Button under "SELECT" to enter this menu. This menu contains adjustable display options for viewing information on the LCD screen. Use the Up & Down Buttons to navigate the menu. Display Settings • Temperature Units - Adjustable user setting that changes temperature units display to Celsius °C or Fahrenheit °F.
CURRENT FAULT DESCRIPTION/ACTION DISPLAY Select Current Fault from the Main Menu and press the Operational Button under "SELECT" to enter this menu. This menu contains non adjustable operational information. Use the Up & Down Buttons to navigate the menu. Blocked Exhaust Fault occurred 2 mins ago The exhaust is blocked or restricted. Ensure condensate hose is draining. This menu contains the current Fault or Alert error message. The time the Fault or Alert message occurred appears directly below.
SERVICE CONTACT INFORMATION The control system has a discrete menu that Installing contractors and/or qualified service technician can access to enter contact information for their customers. This contact information will be displayed with all Fault and Alert messages. DESCRIPTION/ACTION DISPLAY From the Desktop Screen press and hold down the middle (unmarked) Operational Button for 30 seconds and then release it.
FOR YOUR INFORMATION START UP CONDITIONS complaint associated with the anode rod is one of a rotten egg smell in the hot water. The smell is a result of four factors which must all be present for the odor to develop: SMOKE/ODOR It is not uncommon to experience a small amount of smoke and odor during the initial start-up. This is due to burning off of oil from metal parts, and will disappear in a short while. a. A concentration of sulfate in the supply water. b. Little or no dissolved oxygen in the water.
PERIODIC MAINTENANCE VENTING SYSTEM INSPECTION Certain water conditions will cause a reaction between the anode rod and the water. The most common complaint associated with the anode rod is a “rotten egg smell” produced from the presence of hydrogen sulfide gas dissolved in the water. IMPORTANT: Do not remove this rod permanently as it will void any warranties. A special anode rod may be available if water odor or discoloration occurs. NOTE: This rod may reduce but not eliminate water odor problems.
NOTE: Excessive water pressure is the most common cause of Temperature-Pressure Relief Valve leakage. Excessive water system pressure is most often caused by “thermal expansion” in a “closed system.” See Closed Water Systems and Thermal Expansion on Page 21. The Temperature-Pressure Relief Valve is not intended for the constant relief of thermal expansion.
6. Open the water heater drain valve to flush the storage tank. 7. Flush the water heater storage tank to remove sediment and allow the water to flow until it runs clean. 8. Close the water heater drain valve when flushing is completed. 9. Remove the drain hose. 10. Fill the water heater - see Filling The Water Heater in this manual. 11. Turn on the electrical supply to place the water heater back in operation. 12. Allow the water heater to complete several heating cycles to ensure it is operating properly.
LEAKAGE CHECKPOINTS Never use this water heater unless it is completely filled with water. To prevent damage to the tank, the tank must be filled with water. Water must flow from the hot water faucet before turning “ON” gas to the water heater. B:Anode Rod Connection A:Inlet & Outlet A *Condensation may be seen on pipes in humid weather or pipe connections may be leaking. G:Recirculation Connection B. *The anode rod fitting may be leaking. C:T & P Connection C.
TROUBLESHOOTING INSTALLATION CHECKLIST SEQUENCE OF OPERATION The list below represents some of the most critical installation requirements that, when overlooked, often result in operational problems, down time and needless parts replacement. This is not a complete list. Before performing any troubleshooting procedures use the list below to check for installation errors. Costs to correct installation errors are not covered under the limited warranty.
SEQUENCE OF OPERATION FLOW CHART If tank temperature drops below Operating Set Point minus Differential setting a heating cycle is activated Control System performs diagnostic checks Normal State of all pressure switches and ECO are checked Blower Prover pressure switch verified open All other pressure switches and ECO are verified closed NO Control System Locks Out Displays Fault Msg Combustion Blower is energized Pre-Purge cycle Blower Prover switch contacts confirmed closed by control system NO Ig
OPERATIONAL PROBLEMS If the Main Burner ignites momentarily but does not sustain ignition allow the water heater to try to ignite up to two more times until control system locks out and the Ignition Failure Fault message is displayed on the control system's LCD. If the water heater is experiencing rough starts - see Rough Starting, Rough Operation on this page.
FAULT AND ALERT CONDITIONS FAULT CONDITIONS Only qualified service technician, as defined in Qualifications using appropriate test equipment, should perform any service procedures on the water heater. When the control system declares a Fault condition it will display a Fault message on the control system's LCD with an exclamation "!" mark. The control system will lock out and disable heating operation until the condition is corrected.
FAULT AND ALERT MESSAGES Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualified service technician in your area. POSSIBLE CAUSES - CHECK/REPAIR DISPLAYED FAULT/ALERT MESSAGE • The control system has failed to ignite the Main Burner. • Water heater is not properly grounded, loose or open ground wire to the Main Burner. • Dirty/corroded flame sensor, clean flame sensor with fine steel wool (replace if damaged).
FAULT AND ALERT MESSAGES (CONT) Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualified service technician in your area. POSSIBLE CAUSES - CHECK/REPAIR DISPLAYED FAULT/ALERT MESSAGE • The control system has detected the Blower Prover Switch contacts are closed when they should be open at the beginning of a heating cycle. • Pinched/shorted Blower Prover Switch wiring.
WIRING DIAGRAM CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.
LIMITED RESIDENTIAL GAS WARRANTY THIS WARRANTY IS APPLICABLE TO THE ORIGINAL OWNER ONLY.
Technical Support and Parts: 800-456-98055 Copyright © 2014 American Water Heaters. All rights reserved.