American Water Heater Water Heater Commercial Ultra Low NOx Gas water Heater, homeappliance

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Commercial Gas Water Heater Installation Instructions and Use & Care Guide for models with prefix DCG and ADCG To obtain technical, warranty or service assistance during or after the installation of this water heater, call toll free: 1-800-456-9805 When calling for assistance, please have the following information ready: 1. Model number 2. 7 digit product number 3. Serial number 4. Date of installation 5. Place of purchase Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2 71681 REV.A 03-09 what can happen if the instructions are not followed. Table of Contents Water Heater Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Unpacking the Water Heater . . . . . . . . . . . . . . . . . . . . . . 3 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . ..4 Site Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Clearances and Accessibility . . . . . . . . . . . . . . . . . . . . . . 5 Combustion Air Supply and Ventilation . . . . . . . . . . . . . . . . . . . . . 6-9 Water System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Gas Supply and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Operating Your Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Maintenance of Your Water Heater . . . . . . . . . . . . . . . . . . . . . . . 22-23 Trouble Shooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25 Repair Parts Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2 INSTALLATION INSTRUCTIONS Consumer Information This water heater is design-certified by CSA International as a Category I, non-direct vented water heater which takes its combustion air either from the installation area or from air ducted to the unit from the outside. This water heater must be installed according to all local and state codes, or in the absence of local and state codes, with the "National Fuel Gas Code", ANSI Z223.1(NFPA 54)- latest edition. Canadian installations must be performed in accordance with CAN/ CSA-B149.1. This is available from the following: American Gas Association 1515 Wilson Boulevard Arlington, VA 22209 National Fire Protection Agency 1 Batterymarch Park Quincy, MA 02269 Canadian Standards Association 5060 Spectrum Way Mississauga, ON L4W 5N6 Check the phone listings for the local authorities having jurisdiction over this installation. Installer and Owner Responsibilities This manual has been prepared to acquaint you with the installation, operation and maintenance of this gas water heater and provide important safety information in these areas. Read all of the instructions thoroughly before attempting the installation or operation of this water heater. Keep this manual for future reference. Do not discard this manual. You or future users of this water heater will need it for future reference. The manufacturer and seller of this water heater will not be liable for any damages, injuries or deaths caused by failure to comply with the installation and operating instructions outlined in this manual. The manufacturer of this water heater recommends that it be professionally installed by qualified service technicians. Examples of qualified service technicians include: those trained in the plumbing and heating industry, local gas utility personnel or an authorized service person. Massachusetts code requires this water heater to be installed in accordance with Massachusetts Plumbing and Fuel Gas Code 248 CMR Sections 2.00 and 5.00. A data plate identifying this water heater can be found on the front of the water heater. When referring to this water heater always have the information listed on the data plate readily available. Retain your original receipt as proof of purchase.Unpacking the Water Heater Excessive Weight Hazard Use two or more people to move and install water heater unless proper handling equipment is utilized. Failure to do so can result in back or other injury. Removing Packaging Materials Important: Do not remove any permanent instructions, labels, or the data label from outside of the water heater or on the inside of panels. • Remove exterior packaging and place installation components aside. • Inspect all parts for damage prior to installation and start-up. • Completely read all instructions before attempting to assemble and install this product. • After installation, dispose of packaging material in the proper manner. 3 FLAMMABLES FLAMMABLE VAPORS Site Location • Select a location near the center of the water piping system. The water heater must be installed indoors and in a vertical position on a level surface. DO NOT install in bathrooms, bedrooms, or any occupied room normally kept closed. • Locate the water heater as close to the gas vent as practical. Consider the vent system piping and combustion air supply requirements when selecting the water heater location. The venting system must be able to run from the water heater to termination with minimal length Vapors from flammable liquids will explode and catch fire causing death or severe burns. Do not use or store flammable products such as gasoline, solvents or adhesives in the same room or area near the water heater. Keep flammable products: 1. far away from heater 2. in approved containers, 3. tightly closed and 4. out of children's reach. This water heater has a main burner and an automatic ignition system. The ignition system: 1. can come on at any time and 2. will ignite flammable vapors. Vapors: 1. cannot be seen, 2. are heavier than air, 3. go a long way on the floor and 4. can be carried from other rooms to the water heater by air currents. Do not install this water heater where flammable products will be stored. Installation Requirements The water heater must be installed according to all local and state codes, or in the absence of local and state codes, the "National Fuel Gas Code", ANSI Z223.1 (NFPA 54)-latest edition. Canadian installations must be performed in accordance with CAN/CSA-B149.1. Note: In the State of California, the water heater must be braced, anchored, or strapped to avoid moving dur ing an earthquake. Contact local utilities for code requirements in your area or call 1-800-456-9805 and request instructions. and elbows. • Locate the water heater near the existing gas piping. If installing a new gas line, locate the water heater to minimize the pipe length and elbows. • The water heater should be located in an area not subject to freezing temperatures. Water heaters located in unconditioned spaces (i.e., attics, basements, etc.) may require insulation of the water piping and drain piping to protect against freezing. The drain and controls must be easily accessible for operation and service. Maintain proper clearances as specified on the data plate. • The operation of air-moving devices such as exhaust fans, ventilation systems, clothes dryers, fire-places, etc., can affect the proper operation of the water heater. Note: Special attention must be given to the location of these devices and the conditions they may create. Flow reversal of flue gases may cause an increase of carbon monoxide inside of the dwelling. Important: Air for combustion and ventilation must not come from a corrosive atmosphere. Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage. The following types of installation (but not limited to the following) will require outdoor air for combustion due to chemical exposure, and may reduce but not eliminate the presence of corrosive chemicals in the air: • Beauty shops • Photo processing labs • Buildings with indoor pools • Water heaters installed in laundry, hobby or craft rooms • Water heaters installed near chemical storage areas 4 Figure1: Minimum Clearance Locations Important: The water heater should be located in an area where leakage of the tank or connections will not result in dam age to the area adjacent to the water heater or to lower floors of the structure. Due to the normal corrosive action of the water, the tank will eventually leak after an extended period of time. A suitable metal drain pan should be installed under the water heater as shown below, to help protect the property from damage which may occur from leaks in the piping connections or tank. The pan must limit the water level to a maximum depth of 1 3/4 inches (45mm) and be 2 inches (51mm) wider than the water heater and piped to an adequate drain. The pan must not restrict combustion airflow. Locate the water heater near a suitable indoor drain. Outside drains are subject to freezing temperatures which can obstruct the drain line. The piping should be at least 3/4" (19mm) Back Top View Sides Front 24" min. for service ID and pitched for proper drainage. Under no circum stances will the manufacturer or seller of this water heater be held liable for any water damage which is caused by your failure to follow these instructions. Pipe to Vent Top to ceiling adequate drain 1 3/4" Max At least 2" greater than the diameter of the water heater Clearances and Accessibility Notice: Minimum clearances from combustible materials are stated on the data plate located on the front of the water heater. • If the water heater is installed in a restaurant or food service location where the floor is cleaned frequently, NSF International requires the water heater to maintain 6 inches (150mm) of clearance above the floor. To comply with the NSF International requirement, install leg extension kit. For availability contact 1-800-456-9805 • The water heater is certified for installation on a combustible floor. Important: If installing over carpeting, the carpeting Sides must be protected by a metal or wood panel beneath the water heater. The protective panel must extend beyond the full width and depth of the water heater by at least 3 inches (76mm) in any direction, or if in an alcove the entire floor must be covered by the panel. The panel must be strong enough to carry the weight of the water heater when full of water. Figure 1 may be used as a reference guide to locate the specific clearance locations. A minimum of 24 inches (610mm) of front clearance and 4 inches (102mm) on each side should be provided for inspection and service. Front View 5 COMBUSTION/VENT PIPE SYSTEM Carbon Monoxide Hazard Follow all instructions to locate and install the vent pipe system. Instructions can be found in this manual, in state or local codes (or the authority having jurisdiction), or in the absence of such, the National Fuel Gas Code, ANSI Z223.1, NFPA 54, Latest Edition. Canadian installations must be performed in accordance with CAN/CSA-B149.1 Failure to properly locate and install the vent pipe system can result in death, explosion, or carbon monoxide poisoning. Combustion Combustion air must be free of acid-forming chemicals. These chemicals are found in aerosol sprays, deter gents, bleaches, cleaning solvents, air freshener, paint and varnish removers, refrigerant, and many other com mercial products. When burned, vapors from these products form highly corrosive acid compounds. These products should not be stored or used near the water heater or air inlet. Venting Vent pipe installation must be installed according to all state and local codes, or in the absence of local and state codes, the National Fuel Gas Code, NFPA 54, ANSI Z223.1-latest edition. Canadian installations must be performed in accordance with CAN/CSA-B149.1 It is the responsibility of the installing contractor to provide a vent adequate in capacity and in good usable condition. Btu/hr capacity limitations are governed by the style and height of the vent/chimney. For installa tions in the United States, capacity tables are available in the National Fuel Gas Code (ANSI Z223.1- latest edi tion). Canadian installation information can be found in CAN/CSA-B149.1 U.L. recognized fuel gas and carbon monoxide (CO) detectors are recommended in all applications and should be installed using the manufacturer's instructions and local codes, rules, or regulations. Important: Check to make sure the vent pipe is not blocked in any way. • Venting should be as direct as possible with a minimum number of pipe fittings. • Exhaust gas vents must be installed with U.L. listed type B vent pipe according to the vent manufacturer's instructions and the terms of its listing. • Single wall vent connectors must have 6" (152mm) of clearance from unprotected com bustible surfaces. • If sidewall venting is necessary, a power vent kit is required. For availability contact 1-800- 456-9805. • Vents that run through unconditioned spaces where below freezing temperatures are expect ed should be properly insulated to prevent freezing. • Existing vent systems must be inspected for obstructions, corrosion and proper installation. • Vents must be connected to the water heater's drafthood by a certified vent connector or by directly originating at the drafthood opening. • Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer's instructions. • Horizontal vent connections must have an upward slope of at least 1/4" (6mm) per foot (305mm). • Gas vents must be supported to prevent damage, joint separation, and maintain clearances to combustible materials. • Vent connection joints should be fastened by sheet metal screws or by other approved methods. • Vent and vent connectors should have adequate support to keep weight off the draft hood. All pipe, fittings, and procedures must conform to American National Standard Institute and American Society for Testing and Materials (ANSI/ASTM) stan dards in the United States. Important: If you lack the necessary skills required to properly install this venting system, you should not proceed, but get help from a qualified service technician. 6 Air Requirements For buildings that are not well sealed (do not have tight fitting doors and windows) natural air infiltration may provide sufficient air required for combustion and venti lation. For buildings using tight construction (newer and An adequate air supply shall be provided for combustion and ventilation of this water heater. An insufficient supply can result in poor combustion and possible sooting of the burner, combustion chamber or flue passageway. This may present a potential fire hazard or could create a serious health hazard by producing carbon monoxide. General Where an exhaust fan or any other air consuming appliance (Eg. Clothes dryer, furnace, etc.) is installed in the same space as the water heater, sufficient air openings must be available to provide fresh air when all appliances are operating simultaneously. The area in which the heater is located is classified as either "an unconfined space" or "a confined space." An unconfined space is defined as a space having a volume not less than 50 cubic feet per 1000 BTU/hour (4.8 cubic meters per kilowatt) of combined input rating of all appliances using the space. Adjacent open rooms may be included as part of the unconfined space. There shall be no closeable doors between these rooms. An example of this is an open basement. A confined space is one smaller than described above. Air shall be supplied through permanent openings as described in Figure 2. At no time shall an air opening have a dimension of less than 3" (75 mm) and at no time shall any top opening be lower than the top of the water heater. renovated structures), the air supply shall be introduced from the outdoors, regardless of whether the space is confined or unconfined. Combustion Air "Supply" Ducts Air supply ducts shall be of galvanized steel or equiva lent corrosion resistant material. A single air duct may not be substituted when required for upper and lower air openings. Horizontal upper combustion air ducts shall not slope downward toward the air inlet. Louvers and Grills Openings for air supply ducts must provide free unob structed air movement. Louver and grill openings must be sized to ensure that the FREE OPEN AREA is never less than the area of the air duct. LOCATION: The location for top and bottom openings are as fol lows; For U.S. installations:The top opening shall com mence within 12" (300 m) of the top of space and the bottom opening shall commence within 12" (300mm) of the bottom of the enclosure. For Canadian installations:The top opening shall be located as close to the ceiling as practical but never lower than the relief opening of the lowest draft control device. The bottom opening shall be located neither more than 18 inches (450 mm), nor less than 6 inches (150 mm), above floor level. 7 Air Opening Requirements (a) EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM INSIDE THE BUILDING. Two permanent openings (top and bottom) shall be provided connecting the confined space (e.g., closet/small room) with the unconfined space. Each opening shall have a free area of one square inch per 1,000 BTU/hour (22 cm²/kW) input of all appliances in the confined space, but not less than 100 square inches (645 cm²). b) BASEMENT INSTALLATION, EQUIPMENT LOCATED IN CON FINED SPACES; ALL AIR FROM OUTDOORS. Outside air inlets shall be a minimum of 12" (300mm) above the grade (snow) line. When supplying air directly from the outdoors: For American installations: Two openings (top and bottom) shall be provided with each opening having a minimum free area of one square inch per 4,000 BTU/hour input (5.5 cm²/kW) of total input rating of all appliances in the confined space. For Canadian installations: Canadian codes specify single air supply source. Canadian customers and authorities having jurisdiction may use the sizing listed in Table 1. When using a single air supply, the duct shall terminate within 1 foot (300 mm) above and within 2 feet (600 mm) hori Figure: 2 Equipment Location and Combustion/Ventilation Air Requirements (a) zontally from the burner level of the appliance having the largest input. Table 1 Combined input of all appliances in confined space Required free area of duct Acceptable Equivalent duct diameter A1 B2 BTU/hr(kW) in2(mm2) in(mm) in(mm) 75,000(23) 11(7,000) 4(100) 5(125) 100,000(30) 14(9,000) 4(100) 5(125) 125,000(37) 18(12,000) 5(125) 6(150) 150,000(45) 22(14,000) 5(125) 6(150) 175,000(53) 25(16,000) 6(150) 7(175) 200,000(60) 29(19,000) 6(150) 7(175) 225,000(68) 32(21,000) 6(150) 7(175) 250,000(75) 36(23,000) 7(175) 8(200) 275,000(83) 40(26,000) 7(175) 8(200) 300,000(90) 43(28,000) 7(175) 8(200) 325,000(98) 47(30,000) 8(200) 9(225) 350,000(105) 50(32,000) 8(200) 9(225) 375,000(113) 54(35,000) 8(200) 9(225) 400,000(120) 58(37,000) 9(225) 10(250) Notes: 1.Maximum lenght of ducts in column A is 20 equivalent feet(6.1 meters). 2.Maximum lenght of ducts in column B is 50 equivalent feet(15.2 meters). (c) EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM OUTDOORS. For American installations: When supplying air directly from the out doors using horizontal ducting, each opening shall have a free minimum area of one square inch per 2,000 BTU/hour (11 cm²/kW) of total input rating of all appliances in the confined space. For Canadian installations: Refer to Table 1 of part (b). (d) EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC. For American installations: When supplying air directly through vertical ducting, each opening shall have a free minimum area of one square inch per 4,000 BTU/hour (5.5 cm²/kW) of total input rating of all appli ances in the confined space. Permanent Ventilation Air Combustion Air Duct (b) Venting Outdoor Air Ducts Combustion (c) Outlet Air Inlet Air Ducts (d) 12" Grade 12" *U.S. installations require a dual duct system. 8 Draft Hood/Damper Installation Flue Outlet Reducer Some units are shipped with a flue outlet reducer (See Figure 3B). Use only the flue outlet reducer supplied Do not operate water heater with damper in closed position, it must be in the open position during water heater operation. Do not negate the action of any existing safety or operational controls. Install the supplied draft hood and damper on the flue outlet collar. Use only the supplied draft hood and damper, DO NOT use any substitute or alter the components in any way. Place the damper on the water heater (see figure 3A). Align the four pilot holes on top of the water heater with the 4 corresponding holes on the damper bracket and secure with the supplied screws. Next, align the draft hood legs with the 4 corresponding pilot holes on top of the water heater and attach securely with the supplied screws. Locate the wiring from the ECO, and attach it to the wiring harness on the damper (see Figure 3A). Once damper is installed, ensure that the damper posi tion indicator is visible (See figure 3A). Figure 3A: Flue Damper Assembly with this unit. The flue outlet reducer should be connected to the top of the flue damper and sealed by high temperature silicon. 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)-latest edition. Figure 3B: Flue Outlet Reducer Bracket screws Draft hood screws Draft hood High Flue outlet reducer temperature silicon sealant Damper motor Damper wiring harness Damper in OPEN position Damper motor Damper wiring harness ECO wiring harness Damper position indicator Damper motor Damper wiring harness Damper in OPEN position 9 9 WATER SYSTEM PIPING Piping Installation Piping, fittings, and valves should be installed according to the installation drawing (Figure 4). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation. Water supply pressure should not exceed 80% of the work ing pressure of the water heater. The working pressure is stated on the water heater's data plate. If this occurs, a pressure reducing valve with a bypass should be installed in the cold water inlet line to the entire system. This should be placed on the supply to the entire structure in order to maintain equal hot and cold water pressures. Note: Water supplied to the unit that exceeds 12 grains (205 mg/l) total hardness may reduce the life and perform ance of the water heater. Depending on the degree of hard ness, it is recommended that either a water pre-treatment system or a water softener be installed and properly main tained. Important: Heat cannot be applied to the water fittings on the water heater as they may contain nonmetallic parts. If solder connections are used, solder the pipe to the adapter Space Heating If this unit is to be used to supply both space heating and domestic potable (drinking) water then the following instructions must be followed: 1. All piping and components used must be suitable for use with domestic (potable) drinking water. 2. Do not use piping or components that have been connected to a nonpotable system or treated with chromates or other toxic chemicals. Do not add any chemicals to the water heater piping. 3. If system requires temperatures in excess of 120°F (49°C) install a tempering valve, per the manufacturers instructions, in the domestic (potable) hot water line to limit the risk of scalding (See Figure 5). 4. Be sure to follow the manual(s) shipped with the heating system. Also follow any state or local codes. Figure: 4 Water Piping Installation In a closed system use a Thermal Expansion Tank Cold Water before attaching the adapter to the hot and cold water fit Hot Water Supply to Fixtures tings. Outlet Main Water Supply 1. The water heater may have three water piping connec Pressure Reducing Valve with Bypass tion points. The top and front are 1 1/2" NPT and the Unions Cold Water connections on the back of some heaters are 2" NPT. When using front or back connections a nipple inlet tube combination is required. For availability contact 1-800-456-9805. Note: Inlet and outlet piping connections cannot be mixed. For example, a top inlet connection must use a top outlet connection. 2. The installation of unions in both the hot and cold water supply lines is recommended for ease of removing the water heater for service or Metal drain pan 1 3/4" depth max. Inlet Valve Temperature and Pressure Relief Valve Discharge line 6" max. above drain Drain line 3/4" ID min. Massachusetts: Install a vacuum relief in cold water line per replacement. 3. Since most commercial installations utilize higher Drain section 19MGL 142 temperatures, the use of a tempering valve is strongly recommended in all domestic hot water lines (i.e. public restroom sinks, etc). 4. If installing the water heater in a closed water system, install an expansion tank in the cold water line as specified under "Closed System/Thermal Expansion" (Page 12). 5. Install a shut-off valve in the cold water inlet line. It should be located close to the water heater and be easily accessible. Know the location of this valve and how to shut off the water to the heater. 6. The water heater is shipped with a factory-installed Temperature and Pressure Relief Valve. Install a discharge line in the opening in the T & P valve (see instructions on Page 13). 7. After piping has been properly connected to the water heater, remove the aerator at the nearest hot water faucet. Open the hot water faucet and allow the tank to completely fill with water. To purge the lines of any excess air, keep the hot water faucet open for 3 minutes after a constant flow of water is obtained. Close the faucet and check all connections for leaks. Tempering Valve Installation A Tempering Valve should be installed per the manufac turer's instructions in the hot water line. See Figure 5 (below) for sample tempering valve installation. Figure 5: Tempering Valve Cold Water Inlet Follow the tempering valve manufacturer's instructions. Hot Water Outlet Tempered water to fixturesTempering valve (Set to 120°F) 10 Outlet Boosted Temperature Figure 6: Commercial Unit with Auxiliary Booster Heater - Two Temperature (With or Without Building Recirculation) Hot Water to Fixtures Shut-off valve Thermometer Shut-off valve Thermometer Temperature and Pressure Relief Valve Typical Booster Heater Shut-off valve Check Valve Temperature and Pressure Relief Valve Pre-Heater Thermal Expansion Tank Shut-off valve 1 1/2" Cold water supply Pre-Heated Water to the Booster Pressure Reducing Valve Note: Install a vacuum relief valve if required by local codes. Figure 7: Commercial Unit with Auxiliary Storage Heater - Forced Circulation With or Without Building Recirculation - Front Inlet/Outlet Connections Thermometer Shut-off valve Hot Water Outlet Shut-off valve Storage Tank Pressure Relief Valve Thermal Expansion Tank PressureReducingValve Temperature and Pressure Relief Valve 1 1/2" Coldwater supply Heater Temperature and Shut-off valve Plug Cock Check Valve Circulating Pump Note: Install a vacuum relief valve if required by local codes. 11 11 Figure 8: Commercial Unit with Auxiliary Storage Heater - Forced Circulation With or Without Building Recirculation - Top Inlet/Outlet Connections Thermometer Outlet Boosted Temperature Thermometer Hot Water to Fixtures Thermal Expansion Tank Pressure Reducing Valve 1 1/2" Cold Pre-Heated Water to the Booster water supply Shut-off valve Check valve Temperature and Shut-off valve Typical Booster Heater Temperature and Pressure Relief Valve Pressure Relief Valve Pre-Heater Note: Install a vacuum relief valve if required by local codes. Please note the following: DO NOT install this water heater with iron piping. The system should be installed only with piping that is suit able for potable (drinkable) water such as copper, CPVC, or polybutylene. DO NOT use PVC water piping. DO NOT use any pumps, valves, or fittings that are not compatible with potable water. DO NOT use valves that may cause excessive restric tion to water flow. Use full flow ball or gate valves only. DO NOT use 50/50 tin-lead solder (or any lead based solder) in potable water lines. Use 95/5 tin-antimony or other equivalent material. DO NOT tamper with the gas valve/thermostat, igniter, or temperature and pressure relief 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. Closed System/Thermal Expansion Periodic discharge of the temperature and pressure relief valve may be due to thermal expansion in a closed water supply system. The water utility supply meter may contain a check valve, backflow preventer or water pressure reducing valve. This will create a closed water system. During the heating cycle of the water heater, the water expands causing pressure inside the water heater to increase. This may cause the temperature and pressure relief valve to discharge small quantities of hot water. To prevent this, it is recommended that a diaphragm-type expansion tank (suitable for potable water) be installed on the cold water supply line. The expansion tank must be properly sized for the application. Contact the local water suppli er or plumbing inspector for information on other meth ods to control this situation. Important: Do not plug or remove the temperature and pressure relief valve. 12 Temperature and Pressure Relief Valve Explosion Hazard If the temperature and pressure relief valve is dripping or leaking, have a qualified service technician replace it. • Do not plug valve. • Do not remove valve. Failure to follow these instructions can result in death or explosion. Figure 9: T&P Relief Valve must not exceed the working pressure of the water heater as stated on the data plate. Important: Only a new temperature and pressure relief valve should be used with this water heater. Do not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater. Do not place any valve or piping between the relief valve and the tank. The Temperature & Pressure Relief Valve: • Must not be in contact with any electrical part. • Must be connected to an adequate discharge line. • Must not be rated higher than the working pressure shown on the data plate of the water heater. • The BTUH rating of the T & P valve must be greater than, or equal to, the input rating of the water heater. The Discharge Line: • Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line. • Must not be capped, blocked, plugged or contain any valve between the relief valve and the end of the discharge line. • Must terminate a maximum of 6 inches (152mm) above a floor drain or external to the building. • Must be capable of withstanding 250°F (121°C) without distortion. • Must be installed to allow complete drainage of both the valve and discharge line. For protection against excessive pressures and temperatures, a temperature and pressure relief valve must be installed in the opening marked "T & P RELIEF VALVE" (See Figure 9). This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or materials as meeting the requirements for Relief Valves and Automatic Shut-off Devices for Hot Water Supply Systems, ANSI Z21.22. (CSA4.4, Temperature, Pressure, Temperature and Pressure Relief Valves and Vacuum Relief Valves in Canada). The function of the temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure devel oping in the water heater. The valve's relief pressure 13 13 GAS SUPPLY AND PIPING how to turn off the gas to this unit. Explosion Hazard Use a new AGA or CSA approved gas supply line. Install a shut-off valve. Do not connect a natural gas water 2. Install a drip leg as shown. The drip leg must be no less than 3 inches (76mm) long for the accumula tion of dirt,foreign material and water droplets. 3. Install a ground joint union between the water heater and the manual shut-off valve. This is to allow easy servicing. 4. Turn the gas supply on and check for leaks. Use a chloride-free soap and water solution (bubbles forming indicate a leak) or other approved method. Figure 10: Gas Piping Manual Gas heater to a L.P. gas supply. Do not connect a L.P. gas water heater to a natural gas supply. Failure to follow these instructions can result in death, explosion, or carbon monoxide poisoning. Gas Requirements Shut-off Valve Ground Joint Union Check with local utility for min. height Read the data plate to be sure the water heater is made for the type of gas being used. This information will be found on the data plate located on the front of the water heater. If the information does not agree with Drip leg the type of gas available, do not install or operate the water heater. Call your dealer. Gas Pressure Note: An odorant may be added by the gas supplier to the gas used by this water heater. This odorant may fade over an extended period of time. Do not depend upon this odorant as an indication of leaking gas. Gas Piping The gas piping must be installed according to all local and state codes, or in absence of local and state codes, with the "National Fuel Gas Code", ANSI Z223.1 (NFPA 54)-latest edition. Canadian installations must be per formed in accordance with CAN/CSA-B149.1. Note: If using a flexible gas connector, make sure its rating tag matches or exceeds the input of the water heater. Tables 2, 3A, and 3B on page 15 provide a sizing reference for commonly used gas pipe materials. Consult the "National Fuel Gas Code" or "Natural Gas and Propane Installation Code" for the recommended gas pipe size of other materials. Follow the instructions below and reference Figure 10 for gas piping installa tion. 1. Install a readily accessible manual shut-off valve in the gas supply line as recommended by the local utility. Know the location of this valve and Important: The gas supply pressure must not exceed the maximum supply pressure as stated on the water heater's data plate. Minimum supply pressure should also be maintained per the data plate. 14 Gas Pressure Testing Important: This water heater and its gas connection must be leak tested before placing the appliance in operation. • If the code requires the gas lines to be tested at a pressure of 14" W.C. or greater, the water heater and its manual shut-off valve must be disconnected from the gas supply piping system and the line capped. • If the gas lines are to be tested at a pressure less than 14" W.C., the water heater must be isolated from the gas supply piping system by closing its manual shut-off valve. U.L. recognized fuel gas and carbon monoxide(CO) detectors are recommended in all applications and should be installed using the manufacturer's instruc tions and local codes, rules, or regulations. Note: Air may be present in the gas lines and could prevent the burner from lighting on initial start-up. The gas lines should be purged of air by a qualified service technician after installation of the gas piping system. Explosion Hazard Have a qualified service technician make sure L.P. gas pressure does not exceed 13" water column. Failure to do so can result in death, explosion, or fire. 15 15 ELECTRICAL CONNECTIONS Electrical Installation 1. Shut off the power at the electrical service box. 2. Loosen the screws securing the access panel to the electrical compartment. (The electrical wiring diagram can be found on the inside of the access panel.) Set the access panel aside. 3. Connect the electrical supply to the water heater in accordance with local utility requirements and codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70 and/or the CSA C22.1, Electrical Code. Use only a dedicated If you lack the necessary skills required to properly install the electrical wiring to this water heater, do not proceed but have a qualified service technician perform the installation. When making the electrical connections, always make sure: • The voltage and frequency correspond to that specified on the water heater data plate on the front of the water heater. • The electrical supply has the proper overload fuse or breaker protection. The water heater draws less than 7 amps. • Wire sizes and connections comply with all applicable codes. • Wiring is enclosed in approved conduit (if required by local codes). • The water heater and electrical supply are properly grounded. • This water heater must be "hard-wired" do not use an extension cord to supply electrical power to this water heater. Note: The wiring diagram can be found on page 17. Always reference the wiring diagram(s) for the correct electrical connections. Caution: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. electrical circuit containing a properly sized fuse or circuit breaker. Maximum overload protection should not exceed 15 Amperes. 4. Connect this circuit (directly from the electrical service box) to an electrical disconnect switch. 5. Ground the water heater by connecting the electrical service ground wire to the green ground wire (provided). Note: The power supply to this water heater must be properly polarized, [120 volts from the hot lead (black) to ground and 0 volts from the neutral lead (white) to ground] otherwise, the unit will not operate. 6. After making all electrical connections, completely fill the tank with water and check all connections for leaks. Open the nearest hot water faucet and let it run for 3 minutes to purge the water lines of air and sediment and to ensure complete filling of the tank. The electrical power may then be turned on. 16 WIRING DIAGRAM 17 17 INSTALLATION CHECKLIST Water Heater Location Requirements • Centrally located with the water piping system. Located as close to the gas piping and vent pipe system as possible. • Located indoors and in a vertical position. Protected from freezing temperatures. • Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor. Sufficient room to service the water heater. • Provisions made to protect the area from water damage. Properly sized drain pan installed and piped to an adequate drain. • Installation area free of corrosive elements and flammable materials. Vent Pipe System • Draft hood and damper properly installed • Vent connectors securely fastened with screws and supported properly to maintain 6" (152mm) clearance. • Vent pipe and fittings of approved material. • Acceptable size, length, and number of elbows on exhaust outlet pipe. • Installed in accordance with prevailing provisions of local codes, or in the absence of such, National Fuel Gas Code, NFPA 54, ANSI Z223.1-Latest Edition. Canadian Installations must be performed in accordance with CAN/CSA-B149.1. • Drafthood or vent pipe should not be obstructed in any way. Vent Termination Vertical • Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer's instructions. Water System Piping • Temperature and pressure relief valve properly installed with a discharge line run to an open drain and protected from freezing. • All piping properly installed and free of leaks. • Water heater completely filled with water. • A properly sized expansion tank must be installed on all closed systems. • A tempering valve should be installed per the manufacturer's instructions. Gas Supply and Piping • If using a flexible gas connector, make sure its rating tag matches or exceeds the input of the water heater. • Adequate pipe size and of approved material. • Gas supply is the same type as listed on the water heater data plate. • Gas line equipped with full opening shut-off valve, union and drip leg. • Approved pipe joint compound used. • Chloride-free soap and water solution or other approved means used to check all connections and fittings for possible gas leaks. Electrical Connections • Unit must be "hard-wired" to a dedicated 120V power supply • Proper polarity. • Water heater properly grounded. • Installed in accordance with prevailing provisions of local codes, or in the absence of such, National Electrical Code, ANSI/NFPA 70 and/or the CSA C22.1, Electrical Code. 18 OPERATING YOUR WATER HEATER Read and understand these directions thoroughly before attempting to operate the water heater (see Lighting Instructions on page 20). Check the data plate on the front of the water heater for the correct gas. Do not use this water heater with any gas other than the one listed on the data plate. If you have any questions or doubts, consult your gas supplier or gas utility com pany. L.P. (Propane) Models Propane gas is heavier than air and in the occurrence of a leak in the system, the gas will settle on the floor Water Heater Operation When the thermostat calls for heat, it will signal the damper to open. Once the damper fully opens, it will signal the igniter to light the pilot. The pilot will then ignite the main burners. The water heater will operate until the call for heat ends. At this time the main burners and pilot will shut-off and the damper will close. See Figure 12 below for a sequence of operation flowchart. Figure 12: Sequence of Operation 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 a propane 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 propane tank runs out of fuel, turn off the gas at all gas appliances including pilot lights. After the tank is refilled, all appliances must be re-lit according to their manufacturer's instructions. ELECTRICAL POWER APPLIED TO UNIT THERMOSTAT CALLS FOR HEAT DAMPER OPENS PILOT IGNITES PILOT IGNITES BURNER WATER HEATER OPERATES TILL CALL FOR HEAT ENDS THERMOSTAT SATISFIES BURNER & PILOT SHUT OFF DAMPER CLOSES 19 19 OPERATING INSTRUCTIONS 7. Turn gas control knob counterclockwise to "ON". 1. STOP! Read the safety information above on this label. 2. Turn off all electric power to the appliance. 3. Set the thermostat to the lowest setting. 4. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to 8. Set thermostat to desired setting. 9. Turn on all electric power to the appliance. light the pilot by hand. 5. Turn the gas control knob clockwise to the "OFF" position. Do not force. 6. Wait ten (10) minutes to clear 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. 10.If the appliance will not operate after three automatic tries, follow these instructions once more. If the appliance still refuses to light, follow the instruc tions "To Turn Off Gas To Appliance" and call a qual ified service technician. TO TURN OFF GAS TO APPLIANCE 1.Turn off all electric power to the appliance if service is to be performed. 2.Set the thermostat to lowest setting. Stacking Stacking occurs when a series of short draws of hot water are taken from the water heater tank. This causes increased cycling of the burner and can result in increased water temperatures at the hot water outlet. A tempering valve should be installed in the hot water supply line to reduce the risk of scald injury. Water Temperature Regulation 3.Turn the gas control knob clockwise to the off position. Do not force. The thermostat is adjusted to its lowest temperature setting when it is shipped from the factory. Water tem perature can be regulated by moving the temperature dial to the preferred setting. The preferred starting point is 120°F(49°C). Important: Since most commercial installations utilize higher temperatures, the use of a tempering valve is strongly recommended in all domestic hot water lines (i.e. public restroom sinks, etc). Auxiliary commercial equipment (i.e. dishwashers, laundry equipment, etc.) may require higher temperature settings. Refer to instruction manuals supplied with this type equipment for recommended temperature settings. Important: Adjusting the thermostat past the 120°F (49°C) setting on the temperature dial (see Figure 13) will increase the risk of scald injury. Hot water can pro duce first degree burns within: Figure 13: Temperature Dial Water temperature over 125°F can cause 120°F (49°C) more than 5 min utes 130°F (54°C) at 20 seconds 140°F (60°C) at 3 seconds severe burns instantly or death from scalds. Children, disabled and elderly are at highest risk of being scalded. Feel water before bathing or showering. Temperature limiting valves are recommended. 20 150°F (66°C) at 1-1/2 seconds 160°F (71°C) at less than 1 sec ond Each water heater consists of a mechanical tempera ture stop set to 140°F (60°C). To set to a different set ting remove the temperature dial knob, loosen the shaft nut and re-position the mechanical temperature stop. Tighten the shaft nut and replace the temperature dial knob. Emergency Shut Down Important: If overheating occurs or the gas supply fails to shut off, close the manual gas supply valve and turn the gas control knob to the off position. Turn off the electrical supply to the unit and close the cold water supply valve. Do not operate the water heater again until it has been thoroughly checked by a qualified service technician. Checking the Draft Burn Hazard Do not touch vent. Doing so can result in burns. After successfully lighting the water heater, allow the unit to operate for 15 minutes and check the drafthood relief opening for proper draft. Pass a match flame around the relief opening of the drafthood (See Figure 14). A steady flame drawn into the opening indicates proper draft. If the flame flutters or is blown out, combustion products are escaping from the relief opening. If this occurs, do not operate the water heater until proper adjustments or repairs are made to the vent pipe system. Figure 14: Vent Draft Test Burner Flames Inspect the burner flames through the viewport and compare them to the drawings in Figure 15. A properly operating burner should produce a soft blue flame and be about 2"(51mm) to 2 -1/2"(64mm) in height. Blue tips with yellow inner cones are satisfactory. The tips of the flame may have a slight yellow tint. The flame should not be all yellow or have a sharp blue-orange color. Contaminated air may cause an orange colored flame. Contact a qualified service technician if the flame is not satisfactory. Figure 15: Pilot/Burner Flame 2 - 2 1/2" Operational Conditions Condensation Moisture from the products of combustion condenses on the tank surface and the outside jacket of the water heater and forms drops of water which may fall onto the burner or other hot surfaces. This will produce a "siz zling" or "frying" noise. This condensation is normal and should not be confused with a leaking tank. Condensation may increase or decrease at different times of the year. High efficient energy saver water heaters will produce larger amounts of condensation on initial start up or when a large amount of hot water is being used. Do not confuse this with a "tank leak". Once the water reaches a temperature of 120°F (49°C) and the tank warms up (usually 1-2 hours), the condensation will stop. Important: It is always recommended that a suitable drain pan be installed under the water heater to protect the area from water damage resulting from normal condensation production, a leaking tank or piping connections. Under no circumstances is the manufac turer to be held responsible for any water damage in connection with this water heater. Water Heater Sounds During the normal operation of the water heater sounds or noises may be heard. These noises are common and may result from the following: 1. Normal expansion and contraction of metal parts during periods of heat-up and cool-down. 2. Condensation causes sizzling and popping within the burner area and should be considered normal. 3. Sediment buildup in the tank bottom will create varying amounts of noise and may cause premature tank failure. Drain and flush the tank as directed under "Draining and Flushing". Smoke/Odor The water heater may give off a small amount of smoke and odor during the initial start-up of the unit. This is due to the burning off of oil from metal parts of a new unit and will disappear after a few minutes of operation. Safety Shut-off This water heater is designed to automatically shut-off in the event of the following: 1. The pilot flame is extinguished for any reason. 2. The water temperature exceeds 205°F (96°C). 21 21 MAINTENANCE OF YOUR WATER HEATER Draining and Flushing It is recommended that the tank be drained and flushed every 6 months to remove sediment which may buildup during operation. Note: Warranty is null and void in the event lime & scale deposits are allowed to exceed two inches in depth. 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 electricity. 2. Close the cold water inlet valve. 3. Open a nearby hot water faucet. 4. Connect a hose to the drain valve and terminate it to an adequate drain. Note: The drain hose should be rated for at least 200°F (49°C). If the drain hose does not have this rating, open the cold water inlet valve and a nearby hot faucet until the water is no longer hot. 5. Open the water heater drain valve and allow all the water to drain from the tank. 6. Remove the screws holding the cleanout plate, then remove the plate for access. 7. Remove any lime, sediment, or scale from the tank. Be careful not to damage the glass lining. 8. Flush the tank with water as needed to remove any remaining sediment. 9. Check gasket on cleanout plate, replace if necessary. 10. Replace the cleanout plate and screws, tighten sufficiently. 11. Close the drain valve, refill the tank, and restart the water heater as directed under "Operating Your Water Heater". If the water heater is going to be shut down for an extend ed period, the drain valve should be left open. Important: Condensation may occur when refilling the tank and should not be confused with a tank leak. Routine Preventative Maintenance At least annually, a visual inspection should be made of the venting and air supply system, piping systems, main burner, and pilot burner. Check the water heater for the following: • Obstructions, damage, or deterioration in the venting system. Make sure the ventilation and combustion air supplies are not obstructed. • Build-up of soot and carbon on the main burner and pilot burner. Check for a soft blue flame. • Leaking or damaged water and gas piping. • Presence of flammable or corrosive materials in the installation area. • Presence of combustible materials near the water heater. • Verify proper operation after servicing this water heater Important: If you lack the necessary skills required to prop erly perform this visual inspection, you should not proceed, but get help from a qualified service technician. Temperature and Pressure Relief Valve Explosion Hazard If the temperature and pressure relief valve is dripping or leaking, have a qualified service technician replace it. • Do not plug valve. • Do not remove valve. Failure to follow these instructions can result in death or explosion. Manually operate the temperature and pressure relief valve at least once a year to make sure it is working prop erly (See Figure 16). To prevent water damage, the valve must be properly connected to a discharge line which ter minates at an adequate drain. Standing clear of the outlet (discharged water may be hot), slowly lift and release the lever handle on the temperature and pressure relief valve to allow the valve to operate freely and return to its closed position. If the valve fails to completely reset and contin ues to release water, immediately shut off the manual gas valve, electric power and the cold water inlet valve and call a qualified service technician. Figure 16: T&P Valve Test 22 Pilot Burner and Main Burner Assembly Inspection To access the pilot burner and main burner for inspec tion: 1. Turn off gas at main shutoff valve and turn off electrical power. 2. Disconnect the gas supply line from the gas valve. 3. Remove the 2 screws holding the Pilot & Main Burner Assembly in place. See Figure 17 for location of screws. Figure 17: Pilot/Burner Assembly Removal 4. Carefully slide the assembly out of the water heater. 5. If needed, use a brush or vacuum to clean any soot or debris from the burners. 6. Check for correct alignment of burners before sliding assembly back into the water heater. 7. Carefully slide Pilot/Burner Assembly back into the water heater. 8. Replace and sufficiently tighten the two screws holding the Pilot/Burner Assembly in place. 9. Reconnect the gas supply line to the gas valve. 10. Turn on gas at main shutoff valve. 11. Check for gas leaks and proper operation on the unit after servicing. Gas Valve Removal and Replacement It is recommended that this maintenance be performed by a qualified service technician. 1. Turn the thermostat to its lowest setting. 2. Turn off gas at manual gas shut-off valve (see figure 10 for reference) and disconnect electrical power from water heater. 2. Unplug the 4 wires located on the gas valve. Label wire position for correct reattachment. 3. Disconnect pilot tube from the gas valve. 4. Disconnect the main gas line from the gas valve. Use care not to crack the gas valve housing. 5. Carefully unscrew the gas valve from the burner assembly. Important: When removing gas control valve do not use a pipe wrench or vise to grip the body. 6. When replacing the gas valve, use an approved Teflon® or pipe joint compound on the pipe threads. 7. Screw the new gas valve onto the burner assembly. 8. Reconnect the pilot tube to the gas valve. 9. Reconnect the main gas line to the gas valve. 10. Turn the gas supply on and check for leaks. Use a chlorine-free soap and water solution (bubbles forming indicate a leak) or other approved method. 11. Reconnect the 4 wires to their proper location and restore electrical power to the unit. 11. Verify proper operation after servicing this water heater. 12. If additional information is required, contact the Product Service and Support Group at 1-800-456- 9805. Anode Rod Inspection Each water heater contains at least one anode rod, which will slowly deplete while protecting the glass-lined tank from corrosion and prolonging the life of the water heater. Certain water conditions will cause a reaction between the rods and the water. Once the anodes are depleted, the tank will start to corrode, eventually developing a leak. The most common complaint asso ciated with the anode rod is a "rotten egg smell" pro duced from the presence of hydrogen sulfide gas dis solved in the water. Do not remove this rod permanently as it will void any warranties, stated or implied. A spe cial anode is available for this complaint. This rod may reduce but not eliminate water odor problems. The water supply system may require special filtration equipment from a water conditioning company to suc cessfully eliminate all water odor problems. Artificially softened water is exceedingly corrosive because the process substitutes sodium ions for mag nesium and calcium ions. The use of a water softener may decrease the life of the water heater tank. The anode rods should be removed from the water heater tank every 3 years for inspection. If the rods are more than 50% depleted, the anode rods should be replaced. In replacing the anodes: 1. Turn off gas supply and electrical power to the water heater. 2. Shut off the water supply and open a nearby hot water faucet to depressurize the water tank. 3. Drain approximately 5 gallons (19 l) of water from tank (Refer to "Draining and Flushing" for proper procedures). Close drain valve. 4. Remove old anode rods. 5. Use Teflon® tape or approved pipe sealant on threads and install new anode rods. 6. Turn on water supply and open nearby hot water faucet to purge air from water system. 7. Restart the water heater as directed under "Operating Your Water Heater." See the "Repair Parts Illustration" for anode rod location. 23 23 DCG3 SERIES COMMERCIAL GAS DAMPERED WATER HEATERS No Hot Water NO High water temp. YES Will ECO light reset once temp. in tank cools? Power to heater? Check continuity across ECO NO OPEN CLOSED Is ECO light on? Replace ECO Go to thermostat troubleshooting Repair YES NO YES flow chart Check for 24V YES power problem Check for 24V between PV & PV/MV terminals on gas valve NO When thermostat is turned up does pilot spark? YES Does pilot light? YES NO NO between purple and white wires on the ignition control module (ICM) YES Check for 24V NO Is ground good from control module to incoming ground? YES NO Repair Ground NO Replace gas valve Check for 24V between PV & Does sparking stop? NO Clean flame sensor - check YES Replace ICM between PV & MV/PV terminals ignition control module (ICM) YES Check spark wire Check for 24V between orange & white wires on damper harness NO YES Bypass damper, PV/MV terminals ignition control module (ICM) ground. If still problem, see below FOUND DAMAGE for damage & continuity. Also check spark ALL OK orange & purple wires, if heater fires then NO Replace ICM YES Bad spark assembly or assembly for cracks in ceramic or wrong spark gap replace damper Go to Check gas supply OK wiring between spark assembly & ICM Replace faulty component Replace ICM thermostat troubleshooting flow chart Repair gas supply ALL SHOULD BE OK Go to thermostat troubleshooting flow chart YES NO Does main burner fire? YES Does main burner stay lit until thermostat satisfies? NO Does pilot light shrink or go out when main burner fires? NO YES Is there 24V between MV & PV/MV terminals at gas valve? YES Check for blockage in burner or orifice, also check incoming gas supply Is gas flex being used, or other small pipe? NO NO NO Is there 24V between MV & PV/MV terminals at the ICM? Check & adjust gas pressure NO Replace ICM Replace gas valve OK FCG3-0805 Copyright© by American Water Heater Company 2005. All rights reserved. DCG3 SERIES THERMOSTAT TROUBLESHOOTING FLOW CHART No voltage or low voltage from purple wire between thermostat board & ECO board Replace With an ohm meter set at X1, check orange wires on set pot. (3,000 ohms at lowest setting and 0 ohms at highest setting) Replace set pot When slowly turning NO bad sensor(s) OHMS READING NO GOOD Take ohm reading from upper sensor and lowest sensor and compare reading with Check ECO and ICM NO HAS BAD SPOT Replace ECO board NO set pot dial from low to high, ohm reading should be a smooth transition with no skips, jumps or glitches Check orange wire OK chart below. (A temperature reading from a water sample taken from T&P valve is also needed for this test) OHMS OK Check purple wire Replace Will ECO board YES NO YES NO thermostat reset? YES High water temperature Is ECO light on? Check damper from ECO board to damper for 24V YES Sensor Resistance vs. TemperatureResistance (K ohms) from thermostat for 24V circuit board 0 1 2 3 4 5 6 7 8 32648 31026 29495 28049 26682 25389 24166 23010 21915 19898 18968 18088 17253 16461 15710 14998 14322 13680 12492 11942 11419 10922 10450 10000 9572 9165 8778 8057 7722 7403 7099 6808 8532 6268 6016 5775 5327 5117 4917 4726 4543 4368 4201 4042 3889 3602 3468 3340 3217 3099 2986 2878 2774 2675 2488 2400 2316 2235 2157 2083 2011 1942 1876 1752 1693 1637 1582 1530 1480 1432 1385 1340 1256 1216 1177 1140 1105 1070 1037 1005 974 916 888 861 835 810 786 763 741 719 26109 25400 24712 24045 23399 22771 22163 21573 21000 19906 19383 18876 18383 17905 17440 16990 16553 16128 11884 11592 11308 11032 10763 10502 10248 10000 9760 7333 7165 7000 6839 6683 6531 6383 6238 6098 5827 5697 5570 5446 5326 5208 5094 4982 4873 3758 3679 3602 3527 3453 3382 3312 3244 3177 2488 2439 2391 2344 2298 2253 2209 2166 2124 1688 1656 1625 1595 1566 1537 1509 1481 1454 1170 1150 1129 1110 1090 1071 1053 1035 1017 982 965 949 933 917 901 886 871 857 Temp. 9 0°C 20879 10°C 13071 20°C 8409 30°C 5546 40°C 3742 50°C 2579 60°C 1813 70°C 1297 80°C 944 90°C 698 40°F 20445 50°F 15715 70°F 9526 90°F 5961 100°F 4767 120°F 3112 140°F 2083 160°F 1427 180°F 999 190°F 842 200°F 828 814 801 788 775 762 749 737 725 713 FCG3-0805 Copyright© by American Water Heater Company 2005. All rights reserved. REPAIR PARTS ILLUSTRATION When ordering repair parts always give the following information: 1. Model, serial, and product number 2. Type of gas 3. Item number 4. Parts description Repair Parts List No. Part Name and Description No. Part Name and Description 1 Drafthood 15 Main Burner Orifice(s) 2 Diptube (Top) 16 Control Box Cover 3 Diptube (Front) (Optional not pictured) 17 Transformer 4 Diptube (Back) (Optional not pictured) 18 Ignition Control Module 5 Flue Baffles 19 Thermostat board 6 Clean Out Gasket 20 ECO Reset Board 7 Clean Out Cover 21 Control Box 8 Clean Out Cover Jacket 22 Wiring Harness 9 Drain Valve 23 Anode Rod(s) 10 Main Burner Tube(s) 24 T&P Valve 11 Burner Tray 25 Temp. Control Potentiometer 12 Pilot Burner Assembly 26 Upper Temperature Sensor/ECO 13 Main Burner Manifold 27 Lower Temperature Sensor 14 Gas Valve 28 Flue Damper 26