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American Water Heater 30 Gallon 30000 BTU Flame Guard Standard Mobile Home Natural Gas Water Heater MFG6130T303N0V user manual
American Water Heater 30 Gallon 30000 BTU Flame Guard Standard Mobile Home Natural Gas Water Heater MFG6130T303N0V user manual
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11 ROOF JACK INSTALLATION ROOF JACK KIT MODELS VENT KIT- 12 INCH (9002964), VENT KIT - 32 INCH (9002965), VENT KIT - 60 INCH (9002966) AND VENT KIT - 95 INCH (9002967) FIGURE 13. 1. Cut 5 1/2” diameter holes through the roof and ceiling directly in line with the flue connection on top of the water heater. For a sloped roof, the roof hole may have to be enlarged to allow the roof jack to be installed vertically. 2. Telescope down the flue pipe in the roof jack assembly to a length that will project at least 6” below the finished ceiling before installing the roof jack assembly. NOTE: Flue pipe joints have silicone seals that must remain in place. A soapy water solution sprayed around the seal area will enable the flue pipe and outer pipe below to telescope more freely. 3. Telescope down the outer pipe of the roof jack assembly to a length that will project at least 2” below the finished ceiling before installing the roof jack assembly, see Figure 14. FIGURE 14.4. Ease the roof jack assembly through the roof and ceiling openings. The roof jack flashing tilts up to 22.6° degrees for use on a sloping roof. 5. Use sealant or caulk on the roof to seal under flashing of the roof jack assembly. Use roof nails or screws on wood construction or sheet metal screws on metal roofs (nails and screws not provided), see Figure 15. FIGURE 15. NOTE: An optional Roof jack Extension Pipe (9002588) is required when the roof pitch is 5 1/2” or greater, or where local codes require the roof jack cap (outlet) terminate above the peak of the roof. 6. Remove the paper backing from the 1 1/2” x 9 3/4” woven tape seal (found attached to the heater top) and apply the seal around the flue collar of the water heater, see Figure 16 on page 12.
12 FIGURE 16. 7. Extend the flue pipe down close to the water heater flue collar, see Figure 17. FIGURE 17. 8. Slide the securing clamp over the bottom of the flue pipe and pull the pipe down over the flue collar. Locate vent securing clamp in top and secure clamp with sheet metal screw. Tighten nut and bolt clamp until flue pipe is tight in clamp, see Figure 18. FIGURE 18. NOTE: All joints for vent piping between roof jack and water heater are sealed from the manufacturer. No additional sealing of vent pipe is necessary. MANUFACTURED HOME INSTALLED OVER BASEMENT OR CRAWLSPACE - AIR INTAKE THROUGH AN OUTSIDE WALL ALL 30 AND 40 GALLON MODELS 3” PVC Schedule 40 intake air vent piping: Optional Kit No. 9002986 contains a 3” PVC Schedule 40-45° vent cap with screen and two 3” wall collars. ALL 50 GALLON MODELS 4” PVC Schedule 40 intake air vent piping: Optional Kit no. 9002987 contains a 4” PVC Schedule 40-45° vent cap with screen and two 4” wall collars.ALL MODELS 1. PVC, ABS or CPVC Schedule 40 piping and fittings are acceptable materials for the intake air vent system. 2. The intake air vent system must terminate horizontally to the outdoors. 3. Remove the screws which attach the wind baffle to the existing metal air intake vent pipe underneath the home. Discard the wind baffle and screws, see Figure 19. FIGURE 19. 4. Attach a 3” or 4” PVC street elbow to the metal air intake vent using 3 sheet screws. Continue PVC piping to outside wall and terminate with vent cap and screen, see Figure 20. 3” size - 30 and 40 gallon models. 4” size - 50 gallon models. See pages 13 and 14 for cementing instructions FIGURE 20.
13 NOTE: Vent cap must be located a minimum of 12” above the ground. 5. Vertical and horizontal runs must be securely supported at 3 1/2 Foot intervals, see Figure 21. FIGURE 21. 6. The intake air vent piping can be installed with no more than 3 elbows, see Figure 22. FIGURE 22. CUTTING OPENING THROUGH AN OUTSIDE WALL AND COLLAR INSTALLATION Determine the location of the opening in the wall and cut a 3 3/4” hole (30 & 40 Gallon) or 4 3/4” hole (50 Gallon) through an outside wall. The 3” or 4” PVC, ABS or CPVC Schedule 40 vent pipe can be run from the water heater through the wall or from the wall to the water heater, whichever is most convenient. The vent pipe must extend a minimum of 1 1/2” through the exterior wall. Note that the inside collar must be slipped over the vent piping before locating the pipe through the wall. Before securing the inside and outside collars to the wall, use a silicone sealer between pipe and opening to insure a water and air tight seal, see Figure 23. INSTALLATION SHOWING USE OF PVC, ABS OR CPVC PIPE FIGURE 23. NOTE: Wall collars are for aesthetic purposes and are not required for the heater to operate. CEMENTING PVC, ABS OR CPVC PIPE AND FITTINGS Read and observe all safety information printed on primer, cleaner, and cement containers. Primer, cleaner, and cements are extremely flammable. They are harmful or fatal if swallowed. The vapors are harmful. They may irritate eyes and skin and can be absorbed through the skin. Always store primer, cleaner, and cements in cool, dry, well ventilated places. Keep containers closed. Use them in well ventilated areas. Wear impervious clothing while handling. Do not smoke, eat, or drink while handling. Wash thoroughly after handling and before eating. Wear eye protection when handling. If swallowed, drink water, do not induce vomitting, and call a physician or poison control center immediately. If inhaled, get fresh air and seek medical attention if ill feelings persist. In case of eye and skin contact, immediately flush with plenty of water for 15 minuttes and seek medical attention if irritation persists. KEEP OUT OF REACH OF CHILDREN. All primers, cleaners, and cements must meet all local codes and applicable standards of the American Society For Testing Materials Standards. Before using primers, cleaners and cements, stir or shake, making sure contents are liquid. Do not use if found to be lumpy or jelly-like. 1. Cut pipe ends squarely removing all burrs and dirt. 2. Dry fit pipe and fittings to be connected for proper fit. 3. Clean pipe and fitting with primer/cleaner. 4. Apply a thin coat of cement to fitting, avoiding puddling inside. 5. Apply a liberal coat of cement to pipe leaving no voids. 6. QUICKLY assemble parts while cement is fluid! If you wait too long, recoat pipes. 7. Push pipe completely into socket of fitting, turning as it goes until it bottoms. 8. Hold pipe and fitting together for 30 seconds. Then carefully clean off excess with a cloth. Allow connections a sufficient time to cure before distrurbing. 9. Remember that vent pipes must be adequately and securely supported.
14 APPROXIMATE SETTING TIME FOR 2 1/2” TO 4” PIPE JOINTS MOVEMENTCOMPLETE OF JOINT SET 90°F TO 150°F3/4HR. 8 HRS. 50°F TO 90°F 1 HR. 15 HRS. 0°f TO 50°F 1 1/3 HR. 18 HRS. WATER PIPING HOTTER WATER CAN SCALD: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, cleaning and other sanitizing 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 infirm, or physically/mentally handicapped. If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfies your hot water needs, a means such as a *mixing valve, shall be used at the hot water taps used by these people or at the water heater, see Figure 2. Valves for reducing point of use temperature by mixing cold and hot water are also available. Consult a Qualified Installer or Service Agency. Follow manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual. This water heater shall not be connected to any heating systems or component(s) used with a non-potable water heating appliance. Toxic chemicals, such as those used for boiler treatment shall not be introduced into this system. Water supply systems may, because of such events as high line pressure, frequent cut-offs, the effects of water hammer among others, have installed devices such as pressure reducing valves, check valves, back flow preventers, etc. to control these types of problems. When these devices are not equipped with an internal by-pass, and no other measures are taken, the devices cause the water system to be closed. As water is heated, it expands (thermal expansion) and closed systems do not allow for the expansion of heated water.The water within the water heater tank expands as it is heated and increases the pressure of the water system. If the relieving point of the water heater’s temperature-pressure relief valve is reached, the valve will relieve the excess pressure. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This is an unacceptable condition and must be corrected. It is recommended that any devices installed which could create a closed system have a by-pass and/or the system have an expansion tank to relieve the pressure built by thermal expansion in the water system. Expansion tanks are available for ordering through a local plumbing contractor. Contact the local water supplier and/or a service agency for assistance in controlling these situations. NOTE: To protect against untimely corrosion of hot and cold water fittings, it is strongly recommended that di-electric unions or couplings be installed on this water heater when connected to copper pipe. Figure 24 shows the typical attachment of the water piping to the water heater. The water heater is equipped with 3/4 inch NPT water connections. FIGURE 24. T & P VALVE AND PIPE INSULATION Remove insulation for T&P Valve and pipe connections from carton. Fit pipe insulation over the hot water line. Make sure that the insulation is against the top cover of the heater. Fit T&P Valve insulation over valve. Make sure that the insulation does not interfere with the lever of the T&P valve.
15 Secure all insulation using tape. FIGURE 25. WATER PIPING PRESSURE TEST This section is only for the manufacturer installing the water heater when the installation is to comply with H.U.D. Standards. When testing the water ways, H.U.D. Standards state: “Water distribution system. All water piping in the water distribution system shall be subjected to a pressure test. The test shall be made by subjecting the system to air or water at 100 psi for 15 minutes without loss of pressure. When air pressure is used, the water heater shall not be connected during the test”. NOTE: If water piping system is to be air pressure tested, the water heater must be disconnected from the water piping system. Failure to disconnect the water heater during air pressure testing of water piping system could result IN DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. FIGURE 26. TEMPERATURE-PRESSURE RELIEF VALVE This heater is provided with a properly certified combination temperature - pressure 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 and Automatic Gas Shut-off Devices for Hot Water Supply Systems, ANSI Z21.22 • CSA 4.4, and the code requirements of ASME. If replaced, the valve must meet the requirements of local codes, but not less than a combination temperature and pressure relief valve certified as indicated in the above paragraph. The valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (150 psi = 1,035 kPa) and a discharge capacity not less than the water heater input rate as shown on the model rating plate. For safe operation of the water heater, the relief valve must not be removed from its designated opening nor plugged. The temperature-pressure relief valve must be installed directly into the fitting of the water heater designed for the relief valve. Position the valve downward and provide tubing so that any discharge will exit only at any distance below the structural floor. Be certain that no contact is made with any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstances. Excessive length, over 30 feet (9.14 m), or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve, see Figure 27. No valve or other obstruction is to be placed between the relief valve and the tank. Do not connect tubing directly to discharge drain unless a 6 inch air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water flow may cause property damage. The Discharge Pipe: • Shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions. • If water piping system is to be air pressure tested, the water heater must be disconnected from the water piping system. • Failure to disconnect the water heater during air pressure testing of the water system could result in DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. • Temperature-pressure relief valve must comply with ANSI Z21.22 and ASME code. • Properly sized temperature-relief valve must be installed in opening provided. • Can result in overheating and excessive tank pressure. • Can cause serious injury or death.
16 • Shall not be plugged or blocked. • Shall be of material listed for hot water distribution. • Shall be installed so as to allow complete drainage of both the temperature-pressure relief valve, and the discharge pipe. • Shall terminate at an adequate drain. • Shall not have any valve between the relief valve and tank. The temperature-pressure relief valve must be manually operated at least once a year. Caution should be taken to ensure that (1) no one is in front of or around the outlet of the temperature-pressure relief valve discharge line, and (2) the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot. If after manually operating the valve, 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. FIGURE 27. FILLING THE WATER HEATER Never use this water heater unless it is completely full of 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. To fill the water heater with water: 1. Close the water heater drain valve by turning the handle to the right (clockwise). The drain valve is on the lower front of the water heater. 2. Open the cold water supply valve to the water heater. NOTE: The cold water supply valve must be left open when the water heater is in use. 3. To insure complete filling of the tank, allow air to exit by opening the nearest hot water faucet. Allow water to run until a constant flow is obtained. This will let air out of the water heater and the piping. 4. Check all water piping and connections for leaks. Repair as needed. GAS PIPING Make sure the gas supplied is the same type listed on the model rating plate. The inlet gas pressure must not exceed 10.5” W.C. for natural gas and 13” W.C. for propane (L.P.) gas. The minimum inlet gas pressure shown on the rating plate is that which will permit firing at rated input. If the gas control valve is subjected to pressures exceeding 1/2 pound per square inch (3.5 kPa), the damage to the gas control valve could result in a fire or explosion from leaking gas. If the main gas line Shut-off serving all gas appliances is used, also turn “off” the gas at each appliance. Leave all gas appliances shut “off” until the water heater installation is complete. A gas line of sufficient size must be run to the water heater. Consult the current edition of National Fuel Gas Code ANSI Z223.1/NFPA 54 and your gas supplier concerning pipe size.
17 There must be: • A readily accessible manual shut off valve in the gas supply line serving the water heater, and • A drip leg (sediment trap) ahead of the gas control valve to help prevent dirt and foreign materials from entering the gas control valve. • A flexible gas connector or a ground joint union between the shut off valve and control valve to permit servicing of the unit. Be sure to check all the gas piping for leaks before lighting the water heater. Use a soapy water solution, not a match or open flame. Rinse off soapy solution and wipe dry. When installed at elevations above 5,000 feet (1524 m), input rating should be reduced at the rate of 4 percent for each 1,000 feet (305 m) above sea level which requires replacement of the burner orifice in accordance with National Fuel Gas Code ANSI Z223.1/NFPA 54. Contact your local gas supplier for further information. Failure to replace the standard orifice with a high altitude orifice when installed could result in improper and inefficient operation of the appliance, producing carbon monoxide gas in excess of safe limits, which could result in serious injury or death. Contact your gas supplier for any specific changes which may be required in your area. Use pipe joint compound or teflon tape marked as being resistant to the action of petroleum [Propane (L.P.)] gases. The appliance and its gas connection must be leak tested before placing the appliance in operation. The appliance and its individual Shut-off valve shall be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 pound per square inch (3.5 kPa). It shall be isolated from the gas supply piping system by closing its individual manual Shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 pound per square inch (3.5 kPa). Connecting the gas piping to the gas control valve of the water heater can be accomplished by either of the two methods shown in Figures 28, 29 and 30. SEDIMENT TRAPS A sediment trap shall be installed as close to the inlet of the water heater as practical at the time of water heater installation. The sediment trap shall be either a tee fitting with a capped nipple in the bottom outlet or other device recognized as an effective sediment trap. If a tee fitting is used, it shall be installed in conformance with one of the methods of installation shown in Figures 28,29 and 30. FIGURE 28. GAS PIPING WITH FLEXIBLE CONNECTOR. FIGURE 29. GAS PIPING WITH ALL BLACK IRON PIPE TO GAS CONTROL. ALTERNATIVE SEDIMENT TRAP LOCATION FIGURE 30. Contaminants in the gas lines may cause improper operation of the gas control valve that may result in fire or explosion. Before attaching the gas line be sure that all gas pipe is clean on the inside. To trap any dirt or foreign material in the gas supply line, a drip leg (sometimes called a sediment trap) must be incorporated in the piping. The drip leg must be readily accessible. Install in accordance with the “Gas Piping” section. Refer to the current edition of the National Fuel Gas Code, ANSI Z223.1/ NFPA 54. FUEL CONVERSION INSTRUCTIONS FROM NATURAL GAS TO PROPANE (L.P.) GAS This water heater has been factory equipped to operate with the type gas indicated in the “EQUIPPED FOR” area of the model rating plate located near the gas control valve. The indicated gas may be either Natural or Propane (L.P.). By following the conversion instructions in this manual or the instructions near the gas control valve, the water heater must be converted if it is to be used with the opposite gas. DO NOT USE THIS WATER HEATER WITH ANY GAS OTHER THAN THE ONE LISTED ON THE MODEL RATING PLATE. Failure to use the correct gas can cause problems which can result in DEATH, SERIOUS BODILY
18 INJURY, OR PROPERTY DAMAGE. If you have any questions or doubts consult your gas supplier or gas company. Read and follow detailed conversion instructions located on the water heater and also in the instruction manual in their entirety before starting the conversion. Conversion kit with necessary parts are in a bag attached to the drain valve. FOR 30 GALLON HEATER: Orifice size: #40 for Natural / #52 for Propane (L.P.), if converted - Propane Rate: 30,000 BTU. FOR 40 GALLON HEATER: Orifice size: #38 for Natural / #51 for Propane (L.P.), if converted - Propane Rate: 32,000 BTU. FOR 50 GALLON HEATER: Orifice size: #35 for Natural / #51 for Propane (L.P.), if converted - Propane Rate: 38,000 BTU. Step 1.Turn gas control knob “A” to “PILOT”. Depress and turn “OFF”, see Figure 31 page 19. Step 2.Remove outer and inner access doors from water heater. Step 3.Remove burner assembly from water heater control by first removing 6 screws holding inner door to heater, then loosening 3/4” nut “H” holding burner assembly to control, see figures 32 and 33. Loosen pilot tube nut “J” and thermocouple nut “K” at control. Disconnect wire to Piezo Igniter. Step 4.Remove screws “D” disengaging manifold from burner, see Figure 34 page 19. Step 5. Remove orifice “E”, see Figure 34 page 19 using 3/8” wrench. Install orifice marked “L.P.” found in the bag into manifold. Tighten securely. Secure burner to manifold with screws “D”. Step 6.Loosen pilot tube nut “F”, see Figure 35 page 19. Remove orifice “G” and replace with red colored orifice found in bag. Reinstall nut “F” and tighten securely. Step 7. Make sure all connections are tightened securely, and reinstall burner assembly into water heater. Position end of manifold inside bracket as shown in Figure 34 page 19. Reinstall manifold into control and tighten 3/4” nut (“H”) securely. Recheck to see that end of manifold is still inside bracket as shown in Figure 34 page 19. Reinstall pilot tubing and thermocouple into control, see Figure 32 page 15. Connect wire to Piezo Igniter. Reinstall inner door using the 6 screws removed in Step 3. Step 8.Place screwdriver in slot “B”, see Figure 31 page 19. Depress and turn counterclockwise ( ) to stop. Control screw must be in “IN” position for propane (L.P.) gas and in “OUT” position for natural gas. STOP! Read label “For Your Safety” located on your water heater. Step 9.Set the thermostat to lowest setting by turning the water temperature dial clockwise, ( ) to its lowest temperature setting (with arrow on dial) as shown. Step 10.Turn gas control knob clockwise to “OFF” position. Knob cannot be turned from “PILOT” to “OFF” unless knob is depressed slightly. DO NOT FORCE. Step 11.Wait five minutes to clear out any gas. If you then smell gas, STOP! Follow “B” in the safety information on “For Your Safety” label. If you don’t smell gas, got to the next step. Step 12.The pilot is located in front of the burner, see Figure 33 on page 19. Step 13. I f you don’t smell gas, turn knob on gas control counterclockwise to “PILOT” position. Step 14. Push in control knob all the way and hold down. Immediately light the pilot using the Piezo Igniter. Continue to hold control knob in for about one (1) minute after the pilot is lit. Release knob and it will pop back up. Pilot should remain lit. If it goes out, repeat Steps 9 through 12. • If knob does not pop up when released, stop and immediately call the local gas supplier. • If the pilot will not stay lit after several tries, depress and turn the gas control knob clockwise to “OFF” and call the gas supplier. Step 15. Check for gas leaks with only pilot flame burning using soapy water solution, not a match or open flame. Check for gas leaks at fittings “F” and “G”, see Figure 35 page 19 and at fittings “J”, see Figure 32 page 19. Step 16.Make sure temperature adjustment dial is turned clockwise ( ) in its lowest position, see Figure 31 page 19. Step 17. Replace outer door. Step 18. At arm’s length away turn gas control knob to the full “ON” position. WARNING: D o not use gas control knob to regulate gas flow. Turn temperature adjustment dial counterclockwise ( ) until gas flows to main burner and ignites. Step 19. With a soapy water solution, not a match or open flame, check for gas leaks at gas connection “H”, see Figure 32 page 19. If gas leak occurs, turn off immediately by shutting off gas cock at inlet to control, or by turning gas control knob to “PILOT” pushing down and turning to “OFF”. Repair gas leak as necessary, and repeat Steps 9 through 19. Step 20. At arm’s length away, set the thermostat to desired setting. The mark ( ) HOT indicative of approx. 120°F (49°C) is preferred starting point. Some local laws may require a lower starting point. If hotter water is desired see the “Temperature Regulation” section in this manual.
19 Step 21.Replace the outer door if not replaced in Step 17. Step 22.Remove adhesive label found in conversion kit and place next to rating plate. Mark label indicating for which type gas the water heater is now equipped. FUEL CONVERSION INSTRUCTIONS FROM PROPANE (L.P.) GAS TO NATURAL GAS This water heater has been factory equipped to operate with the type gas indicated in the “EQUIPPED FOR” area of the model rating plate located near the gas control valve. The indicated gas may be either Natural or Propane (L.P.). By following the conversion instructions in this manual or the instructions near the gas control valve, the water heater must be converted if it is to be used with the opposite gas. DO NOT USE THIS WATER HEATER WITH ANY GAS OTHER THAN THE ONE LISTED ON THE MODEL RATING PLATE. Failure to use the correct gas can cause problems which can result in DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. If you have any questions or doubts consult your gas supplier or gas company. To convert from Propane (L.P.) gas to Natural gas, follow the “Fuel” Conversion Instructions “From Natural Gas to Propane (L.P.) Gas” section except in Step 5, use orifice “E”, marked “NAT.”. In Step 6 use pilot orifice “G”, brass color and in Step 8 turn control screw “B” in Figure 12 clockwise ( ) to stop. Screw must be in “OUT” position for Natural Gas. See “Instruction Label” for orifice sizes and information below. FOR 30 GALLON HEATER: Orifice size: #52 Propane (L.P.) / #40 for Natural , if converted - Natural Rate: 30,000 BTU. FOR 40 GALLON HEATER: Orifice size: #51 for Propane (L.P.) / #38 for Natural, if converted - Natural Rate: 32,000 BTU. FOR 50 GALLON HEATER: Orifice size: #51 for Propane (L.P.) / #35 for Natural, if converted - Natural Rate: 38,000 BTU. Maximum Supply Pressure: 10.5” W.C. for Natural Gas. 13” W.C. for Propane (L.P.) Gas. Minimum Supply Pressure: 5” W.C. for Natural Gas. 11” W.C. for Propane (L.P.) Gas.FIGURE 33. FIGURE 34. FIGURE 35. FIGURE 31. FIGURE 32.