American Water Heater 316888-004 Installation And Operating Manual Download Page 1

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Installation and Operating Manual

0710

316888-004 Rev. 00

KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE

WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

POWER VENT GAS MODELS

ALL TECHNICAL AND WARRANTY QUESTIONS:

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

PURCHASED.

HYBRID GAS WATER HEATERS

•

For Your Safety

•

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

ANSI Z21.10.3b-2008

www.americanwaterheater.com

Summary of Contents for 316888-004

Page 1: ...MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED POWER VENT GAS MODELS ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED HYBRID GAS WATER HEATERS For Your Safety AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER ANSI Z21 10 3b 2008 www americanwaterheater com ...

Page 2: ...al Connections 32 CALIBRATION 32 OPERATING INSTRUCTIONS 33 Display Panel 33 Wiring Diagram 35 Lighting Instructions 36 Heat Cycle Definitions 37 Temperature Regulation 38 Unique Hybrid Features 39 Temperature Regulation 41 Constant Output Temperature Control 42 Start Up Conditions 42 Operational Conditions 42 MAINTENANCE 43 Housekeeping 43 Venting System Inspection 43 Burner Operation And Inspecti...

Page 3: ...arm This appliance can cause low level exposure to some of the substances listed IMPORTANT DEFINITIONS Qualified Installer or Service Agency Installation and service of this water heater requires ability equivalent to that of a Qualified Agency as defined by ANSI below in the field involved Installation skills such as plumbing air supply venting gas supply electrical supply are required in additio...

Page 4: ...4 www americanwaterheater com GENERAL SAFETY ...

Page 5: ...low through the hose The condensate lines must be able to flow freely to an appropriate drain Do not allow condensate lines to become crimped closed Analyze the entire vent system to make sure that condensate will not become trapped in a section of vent pipe and therefore reduce the open cross sectional area of the vent Breathing Hazard Carbon Monoxide Gas WARNING Installation Do not install the w...

Page 6: ...the National Fuel Gas Code ANSI Z223 1 NFPA 54 and the National Electrical Code NFPA 70 Documents are available from Canadian Standards Association 5060 Spectrum Way Mississauga Ontario Canada L4W 5N6 NFPA documents are also available from National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 The water heater when installed must be grounded in accordance with the local codes or ...

Page 7: ...www americanwaterheater com 7 ...

Page 8: ...alve E Cold Water Inlet F Expansion Tank G Vent Termination Elbow H Access Door Heat Engine I Earthquake Strap J Power Cord K Main Manual Gas Shutoff Valve L Gas Supply M Sediment Pocket N Condensate Tube O Drain Pan P Drain Valve Q Heat Engine Hose Cold In R Casing Door Plastic S Display Enclosure Plastic T Heat Engine Hose Hot Out U Side Casing Plastic V Top Casing Enclosure Plastic W Exhaust El...

Page 9: ...upply is acidic or otherwise impure the water supply must be treated with approved methods in order to ensure full warranty coverage Problems resulting from the forma tion of scale are not covered by the warranty Minimum Clearance To Combustibles Service Clearance Test Pressure P S I Top Front Vent Back Sides Floor Front Sides 0 0 0 0 0 0 21 53 3 cm 12 30 5 cm 300 This appliance must be installed ...

Page 10: ...ally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signa...

Page 11: ...f valve Tampering voids all warranties Only qualified service technicians should service these components DO NOT use with piping that has been treated with chromates boiler seal or other chemicals DO NOT add any chemicals to the system piping which will contaminate the potable water supply HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which wi...

Page 12: ... connected correctly in the receptacle box Failure to connect correctly will prevent the unit from functioning properly Installation of the water heater must be accomplished in 1 2 3 4 5 such a manner that if the tank or any connections should leak the flow will not cause damage to the structure For this reason it is not advisable to install the water heater in an attic or upper floor When such lo...

Page 13: ...vents or adhe sives 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 Water heater has a main burner and spark generator The spark generator 1 can be triggered at any time and 2 the spark will ignite flammable vapors Vapors 1 cannot be seen 2 are heavier than air 3 go a long way on t...

Page 14: ...when handling any kind of sheet metal product Tabs have been provided on each side of the rear portion of the shroud The top and bottom of each tab must be cut and gently bent inwards thus allowing the straps to exit the shroud see Figure 9 In order to access the tabs and install the earthquake straps it is necessary to remove the top front and side panels of the shroud as follows see Figures 6 8 ...

Page 15: ...anwaterheater com 15 Screws Screws Top Casing Front FIGURE 7 Screws FIGURE 8 FIGURE 9 After the heater has been positioned and the earthquake straps have been installed re assemble the shroud in the reverse order ...

Page 16: ...apor barrier etc additional air may need to be provided using the methods described in Appliances in Confined Space that follows APPLIANCES IN CONFINED SPACES CONFINED SPACE is a space whose volume is less than 50 cubic feet per 1 000 Btu per hour 4 8cm per kW of the aggregate input rating of all appliances installed in that space When drawing combustion air from inside a building to a confined sp...

Page 17: ...area of 1 square inch per 4 000 Btu per hour 5 5 cm2 kW of total input rating of all equipment in the enclosure see Figure 13 3 When communicating with the outdoors through horizontal ducts each opening should have a minimum free area of 1 square inch per 2 000 Btu per hour 11 cm2 kW of total input rating of all equipment in the enclosure see Figure 14 FIGURE 13 4 When ducts are used they should b...

Page 18: ...swashing dishwashing cleaningandothersanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the physically or developmentally disabled If anyone using hot water fits into one of these groups or if there is a local code or state law requiring a certain temperature water at t...

Page 19: ...stem or a water softener before the water heater system If you are installing a water filtering system use a 5 micron filter to reduce particles that can potentially cause nuisance shutdown problems and prolong the maintenance of the water heater s inlet filter A water softener can affect the life of the anode installed in this water heater Refer to Anode Rod Inspection section in this manual Clea...

Page 20: ...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 Shall terminate a maximum of 6 in 15cm above a floor drain or external to the building In cold climates it is recommended that the discharge line be terminated at an adequate drain inside the building Shall not have any valv...

Page 21: ... its gas connections must be leak tested before placing the appliance in operation Use a leak test solution not a match or open flame NOTE An alternate location for the gas line entry is possible Drill a suitable hole centered on the crosshairs on the left side panel Use pipe joint compound or Teflon tape marked as being resistant to the action of petroleum Propane L P gases The appliance and its ...

Page 22: ...3 352 9007441005 Rated inputs are suitable up to 11 000 ft 3 352m elevation Consult the factory for installation at altitudes over 11 000 ft 3 352m WARNING THIS HIGH EFFICIENCY WATER HEATER IS CERTIFIED FOR USE AT AN ALTITUDE OF 11 000 Ft 3 352 METERS HOWEVER FOR USE AT ALTITUDES OVER 3 500 Ft 1 067m THE PCB MUST BE CHANGED Some gas utility companies derate their gas for altitude making it unneces...

Page 23: ...pipe and elbows 2 This water heater is capable of venting flue gases a maximum distance equivalent to 50 ft 15 2m of 2 in pipe or 100 ft 30 5m of 3 in pipe The use of elbows reduces the maximum distance see Table 1 NOTE The lengths of pipe listed are exclusive of the termination The termination elbow with an installed screen is required and uses the equivalent of 7 ft 2 1m of vent pipe length Ther...

Page 24: ...luding joining the pipe to Termination PVC Material If local codes do not allow the use of the PVC termination when a material other than PVC is used for venting then an equivalent fitting of that material may be substituted if the screen in the PVC terminal is removed and inserted into the new fitting This water heater is supplied with a 45 degree termination elbow that is a special fitting that ...

Page 25: ...EXHAUST OUTLET WHICH WILL CAUSE IMPROPER OPERATION WITH SOME INSTALLATIONS IT IS RECOMMEND TO INSTALL A CONDENSATE PUMP NOTE Barbed fitting not required if hard piping is used to drain condensate CONDENSATE TUBE SLOPE TO SUITABLE DRAIN CONDENSATE TRAP VENTING DRAIN PAN ROUTE TO SUITABLE DRAIN EXHAUST ELBOW NOTE THE CONDENSATE TUBE MUST BE BELOW EXHAUST ELBOW BARBED FITTING FIGURE 22 INSTALLATION O...

Page 26: ...erminals are being installed on the outside of a finished wall it may be easier to mark both the inside and outside wall Align the holes by drilling a hole through the center of the template from the inside through to the outside The template can now be positioned on the outside wall using the drilled holes as a centering point for the template A MASONRY SIDE WALLS Chisel an opening approximately ...

Page 27: ...ANCE TO PREVENT BLOCKAGE OR ICE BUILDUP BRACKET EQUIVALENT VENT LENGTH MEASURED FROM THIS POSITION FIGURE 27 Before completing the installation of the venting system be sure to read the sections of this manual discussing the proper method of cutting and cementing PVC pipe and fittings in the Vent Pipe Preparation section It is recommended that the completion of the venting system start at the rubb...

Page 28: ...VC piping materials that you are about to use C Know the reputation of your manufacturer and their products D Know your own qualifications or those of your contractor The solvent welding technique of joining PVC and CPVC pipe is a specialized skill just as any other pipe fitting technique E Closely supervise the installation and inspect the finished job before start up F Contact the manufacturer s...

Page 29: ...cm USE ONLY NATURAL BRISTLE 3 MAKING THE JOINT A Cutting Pipe must be squarely cut to allow for the proper interfacing of the pipe end and the fitting socket bottom This can be accomplished with a miter box saw or wheel type cutter Wheel type cutters are not generally recommended for larger diameters since they tend to flare the corner of the pipe end If this type of cutter is used the flare on th...

Page 30: ...joint will have sufficient cement to make a bead all the way around the outside of the fitting hub The fitting will have a tendency to slide back while the cement is still wet so hold the joint together for about 15 seconds STEP F G Cleanup and joint movement Remove all excess cement from around the pipe and fitting with a dry cotton rag This must be done while the cement is still soft The joint s...

Page 31: ...ARNING VENT HOOD S MAY BE EXTREMELY HOT DURING OPERATION FIGURE 31 CAUTION TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE IN WINDY COLD AREAS THE MAXIMUM PRACTICAL DISTANCE BETWEEN THESE TWO TERMINALS IS RECOMMENDED ...

Page 32: ...this procedure once it has started After a successful calibration the heater will go into standby mode During the calibration if the call for heat ends the calibration was not completed and the E36 error message will be shown on the display If this occurs unplug the power cord and repeat steps 1 and 2 1 2 3 To put the heater into service after a successful calibration Unplug the power cord from th...

Page 33: ...ts the base a locked and an unlocked arc Operating Modes Operating modes are Boost for peak demand Energy Saver and Vacation Three LEDs are used to indicate the Operating Mode Vacation Mode Yellow LED Energy Saver Mode Green LED Boost Mode Orange LED The Operating Modes have the following characteristics Vacation mode Fixed temperature setting of 90 F 32 C Set point Difference is 14 F 8 C Tank Set...

Page 34: ...rease the set point and pressing the Down button will decrease the set point NOTE The Temperature Set point cannot be adjusted beyond the limits of the current Mode selected Burner in Operation When the burners are in operation and flame is detected by the flame sensor the flame symbol is illuminated Switching Between Units of Measure Switching between temperature units of measure F C Two yellow L...

Page 35: ...6 J6 Programing J1 Flame J5 Water Valve Water Flow J8 Thermistors J9 RS 485 J10 UIM Setting J11 High Temp SW Water Valve Water Flow Sensor BROWN YELLOW BLACK WHITE Flame Sense Rod YELLOW BLACK BLACK BLACK BROWN BROWN RED RED BLUE BLUE Thermistors J12 Gas Valves ECO J13 Pump J15 Auxiliary Out Igniter J16 XFMR Pr Transformer J7 Power 120Vac J4 XFMR Sec J3 Thermal Fuse J2 Blower Blower BROWN BROWN BL...

Page 36: ...re 8 If the appliance will not operate follow the instructions TO TURN OFF GAS TO APPLIANCE and call your technician or gas supplier DANGER Hotter water increases the risk of scald injury Consult the instruction manual before changing temperature DANGER OPERATING INSTRUCTIONS A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do NOT ...

Page 37: ... during the first stage of the post purge mode high speed fan operation conditions for a new call for heat are met then the system will allow the state change to Initial call for heat only after the first stage of the post purge mode is complete Standby Mode After successful completion of post purge the fan is turned off and the control will wait until the determined conditions for a call for heat...

Page 38: ...OSTAT TO CONTROL WATER TEMPERATURE HOT WATER TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHER AND LAUNDRYUSECANCAUSESCALDBURNSRESULTING IN SERIOUS PERSONAL INJURY AND OR DEATH THE TEMPERATURE AT WHICH INJURY OCCURS VARIES WITH THE PERSON S AGE AND THE TIME OF THE EXPOSURE THE SLOWER RESPONSE TIME OF CHILDREN AGED OR DISABLED PERSONS INCREASES THE HAZARDS TO THEM NEVERALLOW SMALL CHILDREN TO USE A HO...

Page 39: ...40 F 60 C Energy Saver Mode is selected for all other Temperature set point values Three LED s are used to indicate the Operating Mode Selection Vacation Mode Yellow LED Energy Saver Mode Green LED Boost Mode Orange LED The Operating Modes have the following characteristics Vacation mode Fixed temperature setting of 90 F 32 C Energy Saver mode Temperature range from 100 F to 135 F 38 C to 57 C in ...

Page 40: ...en the temperature reaches the maximum design temperature for the venting used This switch should reset to the closed position when the vent pipe temperature cools sufficiently Opening Temperature is approximately 165 F 74 C 5 F 2 8 C Closing Temperature is approximately 135 F 57 C 5 F 2 8 C The power for the main gas valve is to be routed through the Exhaust Vent High Temperature Switch causing t...

Page 41: ... temperature If a power outage occurs or the unit is energized de energized by the STANDBY symbol for re booting the controller resets to the last temperature setting After clearing a continuous lockout error code the unit will always go back to the factory default temp setting and mode Storage Tank Set point The control is required to maintain a storage tank set point differential temperature Sto...

Page 42: ...us conditions Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal See CONDENSATE section OPERATIONAL CONDITIONS Smelly Water In each water heater there is installed at least one anode rod see parts section for corrosion protection of the tank Certain water conditions will cause a reaction between this rod and the water ...

Page 43: ...ir the unit It must be replaced At least once a year a visual inspection should be made of the main burner and spark generator assembly for proper flame characteristics and ignition sequences You should also check for sooting Soot is not normal and will impair proper combustion Soot build up indicates a problem that requires correction before further use Turn OFF gas to water heater and leave off ...

Page 44: ...of the valve is required Turn off the cold water inlet heater and call a qualified service man If after manually operating the valve see Figure 36 it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions and replace the temperature pressure relief valve with a new one 1 2 3 4 5 6 7 1 2 3 If the temperatu...

Page 45: ...ade the paint FLUSHING THE HEAT EXCHANGER LIME BUILD UP The heat exchanger must be cleaned on a regular basis to reduce lime build up The frequency of this cleaning is dependent on the quality of your local water supply Failure to flush the appliance will cause damage to the heat exchanger Damage caused by lime build up is not covered by the unit s warranty Disconnect electrical power to the water...

Page 46: ... during freezing temperatures Also periodic draining and cleaning of sediment from the tank may be necessary Set the power switch to the OFF position OPEN a nearby hot water faucet and let the water run until it is no longer hot CLOSE the cold water inlet valve to the water heater Connect a hose to the drain valve and terminate to an adequate drain OPEN the water heater drain valve to allow for ta...

Page 47: ...05 41ºC or 105ºF ºC LED or ºF LED turned ON H03 Storage tank temperature H03 xxx ºC or ºF 041 or 105 41ºC or 105ºF ºC LED or ºF LED turned ON H04 Heat engine water flow rate H04 xxx litres minute 056 5 6 litres minute 1 48 Gallons minute 1 litre 0 264 Gallons 1 gallon 3 78 litres H05 Fan Speed H05 __x xxx rpm 006_511 6511 rpm rpm rotations per minute H06 Fan Current H06 __x xxx mA 001_456 1456 mA ...

Page 48: ...to the Main Valve Continuous Measure the water temperature ECO switch open temperature is 85 5ºC 185 14ºF and close temperature is 65 5ºC 149 14ºF Check the ECO switch Check the ECO wire harness Change the board 1 2 3 4 E09 High temperature Vent Switch Open Control detects that the High Temperature Vent Switch is open preventing power to the Main Valve Continuous Measure the water temperature High...

Page 49: ...emperature Probe is Short circuit Outlet Temperature is maximum defined temperature E24 Inlet Temperature Probe is Open circuit Inlet Temperature is minimum defined temperature E25 Inlet Temperature Probe is Short circuit Inlet Temperature is maximum defined temperature E26 Tank Temperature Probe is Open circuit Tank Temperature is minimum defined temperature E27 Tank Temperature Probe is Short ci...

Page 50: ...ul but DIP switch 4 not set to normal Soft Unplug the power cord check the DIP switch 4 position and put it in ON position Increase the set point so that a call for heat occurs Drain the tank in order to lower the water temperature so that a call for heat is generated Set DIP switch 4 to OFF position Recalibrate the unit Change the board 1 2 3 4 5 6 E37 No Water Flow The heater could not start bec...

Page 51: ...l thermal expansion tank Do not plug T P valve Improperly sealed valve Check relief valve for proper operation Do not plug T P valve HOT WATER ODORS refer to cathodic protection High sulfate or mineral content in water supply Drain and flush heater thoroughly then refill Bacteria in water supply Chlorinate water supply HOT WATER TOO HOT Thermostat set too high Refer to TEMPERATURE REGULATION secti...

Page 52: ... line d Improper sized dip tube e Water heater disconnected from electrical power Check if there is any error code on the display THE WATER IS NOT HOT ENOUGH The temperature is set too low a Check unit s temperature setting b Check for cross plumbing between cold and hot water lines THE WATER IS TOO HOT The temperature set too high Check unit s temperature setting CANNOT OPEN DOOR Door pins locked...

Page 53: ...er or pipe connections may be leaking B Small amounts of water from temperature pressure relief valve may be due to thermal expansion or high water pressure in your area C The temperature pressure relief valve may be leaking at the tank fitting D Water from a drain valve may be due to the valve being slightly opened E The drain valve may be leaking at the tank fitting F Water in the water heater b...

Page 54: ...Engine Cold In N Drain Valve O Tank Thermistor Probe P Front Door Lock Hook Cam Q Shroud Right Side Tank Assembly Door R Display Subassembly S Heat Engine T Cover Front Flue Gas Return U Hi Limit Temperature Switch V Air Inlet Cover Direct Vent W Air Inlet Cover Gasket Direct Vent X ECO Switch Y Transformer Z PCB Circuit Board Assembly w Base 1 Power Cord Assembly 2 Flame Sensor 3 Spark Generator ...

Page 55: ...www americanwaterheater com 55 R O N M L K J I H G F E D C B A T Q S P 12 U 10 7 6 5 4 3 2 1 Z Y X W V 11 9 8 13 ...

Page 56: ...O 9007179015 Drain trap assembly condensate 9007205005 Heat engine assy 9007206005 Gas valve 9007207005 Diptube J 3 4 return 9007208005 Transformer 9007209005 Hi limit Fuse 9007210015 Switch High Temp 9007211015 Inlet water filter 9007423015 Water valve assembly 9007424005 Display assembly with label English 9007425005 Display assembly with label Bilingual 9007426005 PCB fuse 9007427015 Flame sens...

Page 57: ...www americanwaterheater com 57 NOTES ...

Page 58: ...58 www americanwaterheater com NOTES ...

Page 59: ...www americanwaterheater com 59 NOTES ...

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