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American Water Heater 40 Gallon 42000 BTU UltraLow Nox Power Vent Natural Gas Water Heater PVUG6240T42NV User Manual
American Water Heater 40 Gallon 42000 BTU UltraLow Nox Power Vent Natural Gas Water Heater PVUG6240T42NV User Manual
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21 Operational Conditions CondensationMoisture 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 “sizzling” 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 effi cient 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. CAUTION - PROPERTY DAMAGE HAZARD IMPORTANT: It is always recommended that a suitable metal 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. Refer to “Location Requirements” section Water Heater SoundsDuring 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 fl ush the tank as directed under “Draining and Flushing”. Smoke/OdorThe 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-offThis water heater is designed to automatically shut-off in the event of the following: 1. The water temperature exceeds 180°F (83°C.) 2. A blockage occurs in the combustion chamber air inlet, the fl ue gas exhaust outlet, or both the inlet and outlet. 3. The blower fails to operate or operates improperly. 4. The ignition of fl ammable vapors. A high temperature limit switch or ECO (Energy Cut Off) in the tank is used to shut off the unit if the water temperature exceeds 180°F (83°C.) The ECO is a single use switch and requires complete replacement of the entire thermostat. If the ECO should actuate, the water heater cannot be used until the thermostat is replaced by a quali fi ed person. Contact your local dealer for service information. Anode Rod/Water OdorEach 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. Once the anode is depleted, the tank will start to corrode, eventually developing a leak. Certain water conditions will cause a reaction between this rod and the water. The most common complaint associated with the anode rod is a “rotten egg smell” produced from the presence of hydrogen sulfide gas dissolved in the water . IMPORTANT: Do not remove this rod permanently as it will void any warranties. The parts list includes a special anode that can be ordered if water odor or discoloration occurs. NOTE: This rod may reduce but not eliminate water odor problems. The water supply system may require special aeration or chlorination equipment from a water conditioning company to successfully eliminate all water odor problems. The use of a water softener may decrease the life of the water heater tank. The anode rod should be inspected after a maximum of three years and annually thereafter until the condition of the anode rod dictates its replacement. NOTE: Artifi cially softened water requires the anode rod to be inspected annually. The following are typical (but not all) signs of a depleted anode rod: • The majority of the rods diameter is less than 3/8”. • Signifi cant sections of the support wire (approx. 1/3 or more of the anode rod’s length) are visible. If the anode rod show signs of either or both it should be replaced. NOTE: Whether re-installing or replacing the anode rod, check for any leaks and immediately correct if found. In replacing the anode: 1. Turn off gas supply 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 of water from tank (Refer to the “Draining and Flushing” section for proper procedures). Close drain valve. 4. Remove old anode rod. 5. Use Tefl on ® tape or approved pipe sealant on threads and install new anode rod. 6. Turn on water supply and open a nearby hot water faucet to purge air from water system. Check for any leaks and correct immediately if found. 7. Restart the water heater as directed under the “Operating Your Water Heater” section. See the “Repair Parts Illustration” section for anode rod location. TEFLON® is a registered trademark of E.I. Du Pont De Nemours and Company. 30 seconds if no further buttons are pressed. After 30 seconds the control will go back to “Sleep” mode. 2. Release both of the temperature adjustment buttons. A. To decrease the temperature press and release the “COOLER” button until the desired setting is reached. B. To increase the temperature press and release the “HOTTER” button until the desired setting is reached. NOTE: Holding down the button will not continue to lower or raise the temperature setting. The button must be pressed and released for each temperature change desired. Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance. NOTE: During low demand periods when hot water is not being used, a lower thermostat setting will reduce energy losses and may satisfy your normal hot water needs. If hot water use is expected to be more than normal, a higher thermostat setting may be required to meet the increased demand. When leaving your home for extended periods (vacations, etc.) turn the temperature dial to its lowest setting. This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather. Figure 18 Anode Rod Depletion Pitted Anode Rod Exposed Support Wire Exposed Support Wire Temperature Setting Display A B C C - Flashing = approx. 160°F C = approx. 150°F B = approx. 140°F A = approx. 130°F = approx. 120°F WARM = approx. 80°F Figure 17 Gas Valve/ Thermostat Settings
22 MAINTENANCE OF YOUR WATER HEATER Draining and Flushing It is recommended that the tank be drained and fl ushed every 6 months to remove sediment which may build up during operation. 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. 2. Turn off the electrical supply to the water heater. 3. Open a nearby hot water faucet until the water is no longer hot. 4. Close the cold water inlet valve. 5. Connect a hose to the drain valve and terminate it to an adequate drain or external to the building. 6. Open the water heater drain valve and allow all the water to drain from the tank. Flush the tank with water as needed to remove sediment. 7. Close the drain valve, re fi ll the tank, and restart the heater as directed under “Operating Your Water Heater.” If the water heater is going to be shut down for an extended period, the drain valve should be left open. IMPORTANT: Condensation may occur when re fi lling the tank and should not be confused with a tank leak. Routine Preventive Maintenance At least annually, a visual inspection should be made of the venting and air supply system, piping systems, main burner, and fl ame sense/hot surface igniter. 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. Check for a soft blue fl ame. Discoloration is normal. Clean the burner as described in “Natural Gas Burner (Ultra Low Nox).” Also, to clean the combustion chamber, follow these steps: 1.) Remove the burner door assembly as described in this manual; 2.) Remove loose debris from the combustion chamber with a vacuum cleaner/shop vac; 3.) Replace the burner door assembly as described in this manual. • Dust or debris on the fl ame arrestor at the bottom of the combustion chamber. If needed, use compressed air to clear dust and debris from the fl ame arrestor. • Leaking or damaged water and gas piping. • Presence of fl ammable 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 properly perform this visual inspection, you should not proceed, but get help from a quali fi ed person. Temperature and Pressure Relief Valve Explosion Hazard If the temperature and pressure relief valve is dripping or leaking, have a qualified person replace it. Examples of a qualified person include: licensed plumbers, authorized gas company personnel, and authorized service personnel. Do not plug valve. Do not remove valve. Failure to follow these instructions can result in death, or explosion. WARNING Manually operate the temperature and pressure relief valve at least once a year to make sure it is working properly (see Figure 19.) To prevent water damage, the valve must be properly connected to a discharge line which terminates 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 continues to release water, immediately shut off the manual gas shut-off valve and the cold water inlet valve and call a quali fi ed person. Figure 19 Temperature & Pressure Relief Valve Temperature and Pressure Relief Valve Manual Relief Valve Discharge line to drain
23 Replacement Parts Replacement parts may be ordered through your plumber or the local distributor. Parts will be shipped at prevailing prices and billed accordingly. When ordering replacement parts, always have the following information ready: 1. model, serial, and product number 2. type of gas 3. item number 4. parts description See “Repair Parts” section. IMPORTANT: If you lack the necessary skills to perform the procedures in this section, you should not proceed. Get help from a qualifi ed person. Removing the Burner Door Assembly 1. Turn off the gas to the water heater at the manual gas shut-off valve (See figure 2) and disconnect power to the water heater. 2. Remove the outer door. 3. Remove the two screws securing the burner door assembly to the skirt. 4. Disconnect the hot surface igniter/flame sense wires and manifold tube at the gas control valve/thermostat. See Figure 20A. 5. Remove both wire terminals from the FV sensor (Figure 20B). Keep the FV sensor for later use. NOTE: The FV sensor bracket is located at the bottom edge of the water heater (front). To remove the sensor from the bracket, simply open the bracket door and slide the assembly out. Figure 20B FV Sensor Terminals (2) FV Sensor Bracket 6. Grasp the manifold tube and push down slightly to free the manifold from the gas control valve/thermostat. 7. Carefully remove the burner door assembly from the burner compartment. Be sure not to damage internal parts. 8. Check the burner to see if it is dirty or clogged. See “Natural Gas Burner (Ultra Low Nox).” FIGURE 20A Gas Valve/Thermostat Manifold Tube Hot Surface Igniter/Flame Sense Connector Natural Gas Burner (Ultra Low Nox) Check the burner to see if it is dirty or clogged. The burner may be cleaned with soft paint brush (Figure 21). Do not use a wire brush or any tool that may damage the burner screen. IMPORTANT: Do not use the burner if the burner screen is damaged. Damage may be rips or holes in the burner screen. Discoloration is normal. See also “Routine Preventive Maintenance.” FIGURE 21 Burner Cleaning Use a soft brush on this surface. FIGURE 20C Burner Door Assembly Burner Door AssemblyBurner Door Gasket Flame Sense/ Hot Surface Igniter Wires Manifold Tube Hot Surface Igniter and Flame Sense Rod Burner Burner Viewport Manifold Component Block
24 Replacing the Burner Door Assembly 1. Check the door gasket for damage or imbedded debris prior to installation. 2. Inspect the viewport for damage and replace as required. 3. Insert the burner assembly into the burner compartment, making sure that the burner assembly sits firmly against the bracket inside the combustion chamber. See Figure 22. FIGURE 22 Close-up inside view of the combustion chamber Bracket 4. Inspect the door gasket and make sure there is no fiberglass insulation between the door gasket and the combustion chamber. 5. Replace the two screws that secure the burner door assembly to the combustion chamber and tighten them securely. Once the burner door assembly is secured, visually inspect the gasket between the door and the combustion chamber for spaces or gaps that would prevent a seal. IMPORTANT: Do not operate the water heater if the burner door gasket does not create a seal between the door and the combustion chamber. 6. Reconnect the manifold tubing to the gas control Tighten both burner door screws securely. valve/thermostat. Do not cross-thread or apply any thread sealant to the manifold tubing. 7. Reconnect the Flame Sense/Hot Surface Igniter wires to the thermostat (Figure 20A). 8. Connect both wire terminals to the FV sensor as shown in Figure 20B, then place the sensor inside the bracket. Ensure that the terminals are secure and that the bracket door is closed securely. 9. Turn gas supply on and refer to the Lighting Instructions. 10. Check for leaks by brushing on an approved noncorrosive leak detection solution. If such a solution is not available, use a mixture of dish washing soap and water (one part soap to 15 parts water) or children’s soap bubble solution. Bubbles will show a leak. Correct any leak found. 11. Replace the outer door, then verify correct operation. Removing and Replacing the Gas Control Valve/Thermostat IMPORTANT: Use only factory authorized replacement parts. Removing the Gas Control Valve/Thermostat: 1. Set the gas control valve/thermostat to its lowest setting by first depressing the COOLER and HOTTER buttons together and hold for 1 second. Then press the COOLER button until the WARM indicator light appears. (Figure 17). 2. Unplug the water heater from the wall outlet. 3. Turn off the gas at the manual shut-off valve on the gas supply pipe (Figure 2). 4. Drain the water heater. Refer to the “Draining and Flushing” section and follow the procedure. 5. Disconnect the flame sense/hot surface igniter wire from the thermostat. Disconnect the manifold tube at the gas control valve/thermostat (Figure 20A). 6. Refer to “Gas Piping” (Figure 2) and disconnect the ground joint union in the gas piping. Disconnect the remaining pipe from the gas control valve/thermostat. 7. To remove the gas control valve/thermostat, thread a correctly sized pipe into the inlet and use it to turn the gas control valve/thermostat (counterclockwise.) Do not use pipe wrench or equivalent to grip body. Damage may result, causing leaks. Do not insert any sharp objects into the inlet or outlet connections. Damage to the gas control valve/thermostat may result. Replacing the Gas Control Valve/Thermostat: To replace the gas control valve/thermostat, reassemble in reverse order. Use only factory authorized replacement parts. • Be sure to use approved Teflon ® tape or pipe joint compound on the gas piping connections and fitting on the back of the gas control valve/thermostat that screws into tank. • Turn gas supply on and check for leaks. Use a chloride-free soap and water solution (bubbles forming indicate a leak) or other approved method. • Be sure tank is completely filled with water before lighting and activating the water heater. Follow the Lighting Instructions. • If additional information is required, contact Residential Technical Assistance. TEFLON ® is a registered trademark of E.I. Du Pont De Nemours and Company. Explosion Hazard Remove any fiberglass between gasket and combustion chamber. Replace viewport if glass is missing or damaged. Replace door gasket if damaged. Failure to follow these instructions can result in death, explosion, or fire. WARNING Replace manifold component block if missing or removed.
25 TROUBLESHOOTING Please check the guidelines below. For your safety, water heater service should be performed only by a qualifi ed person. # LED STATUS PROBLEM SOLUTION 1 Inadequate or no earth ground. 1 Ensure the wall outlet (power supply) is properly grounded. 2 Ensure all ground connections/wires on the water heater are securely connected. 2 High resistance to earth ground or reversed polarity in the 120 VAC power supply. 1 Ensure that the water heater is securely connected to earth ground. 2 Ensure that the wall outlet/power supply is properly wired. Also, ensure that internal 120 VAC wiring connections and the wiring harness have no reversed wires. 120 VAC hot wire must connect to the on/off switch. 3 Pressure switch circuit remaining closed for more than 5 seconds after heating cycle begins. Blower may not start in this condition. 1 Ensure air pressure switch circuit wiring is correct and the air pressure switch is not jumpered. 2 Replace the air pressure switch. 4 Pressure switch circuit remains open longer than 5 seconds after the blower is energized. Blower may run continuously in this condition. 1 Ensure the air pressure switch sensing tube is properly connected at both ends and is not kinked or damaged. 2 Ensure the correct size of vent and intake air pipe (direct vent products) was used per the installation instructions that came with the water heater. 3 Ensure the maximum number of elbows or maximum equivalent feet of vent or intake air pipe have not been exceeded per the installation instructions that came with the water heater. 4 Ensure there are no obstructions in the vent or intake air pipe. 5 Open hot surface igniter circuit. 1 Check wiring to the hot surface igniter assembly - replace igniter assembly if wiring is damaged or worn. 2 Check resistance of the igniter at igniter assembly plug - should be between 11 and 18 ohms at room temperature (77° F at plug end) - replace igniter if open or shorted. 3 Check igniter assembly plug and the socket on the gas control valve/thermostat for good connection. Replace igniter assembly if the plug is worn or damaged. 4 Replace the gas control valve/thermostat if the igniter assembly socket on the bottom of the control is worn or damaged. 6 Ignition/fl ame failure. The gas control valve/thermostat has reached the maximum number of retries (3) for ignition and is currently locked out for one hour. Cycle the power to the water heater off and on to reset. 1 Ensure fl ame sensor is making good contact with the burner fl ame and ensure fl ame is steady. Also ensure supply and manifold gas pressures are within the requirements in the installation manual. 2 Gas supply is turned off or gas pressure is too low. For low gas pressure, consult with your gas utility. 3 Ensure the fl ame sensor is clean - use fi ne steel wool to clean the fl ame sensor. 4 Check igniter assembly plug and the socket on the bottom of the gas control valve /thermostat for good connection. Replace igniter assembly if the plug is worn or damaged. Replace the gas control valve /thermostat if socket is worn or damaged. 5 Replace igniter assembly. Continued on the next page.
26 TROUBLESHOOTING cont. #LED STATUS PROBLEM SOLUTION 7 8 9 Self diagnostic check has detected a problem with the gas valve driver circuit, internal microprocessor, or other internal circuits. 1 Turn the power off for 10-20 seconds, then on again to clear these error codes. 2 If any of these error codes persist or cannot be cleared, replace the gas control valve/thermostat. 10 Flame signal sensed out of proper sequence. 1 Turn the power off for 10-20 seconds, then on again to clear these error codes. 2 Replace the gas control valve/thermostat if this error code persists. 11 Water in the tank has exceeded the maximum allowable temperature, activating the ECO (energy cut off). 1 Turn the power off for 10-20 seconds, then on again to clear these error codes. 2 Replace the gas control valve/thermostat if the error code persists. 12 One or both of the temperature adjust buttons are stuck. 1 Press and release both temperature adjust buttons several times - cycle water heater power off and on. 2 Replace the gas control valve/thermostat if the error code persists. 13 The water temperature sensor (located in the control valves immersion probe) is either open or shorted. 1 Turn the power off for 10-20 seconds, then on again to clear these error codes. 2 Replace the gas control valve/thermostat if the error code persists. 14 The FV (fl ammable vapor) sensor is either open or shorted. 1 Turn off power to the water heater. Ensure all FV sensor wiring, the ignitor assembly plug, and the ignitor assembly socket on the bottom of the Intelli-Vent control are making good contact. Repair or replace any worn/damaged components that are not making good connection. 2 Replace the FV sensor. 15 Self diagnostic check has detected the presence of fl ammable vapors from the FV ( fl ammable vapor) sensor. 1 Do not touch any electrical switch, do not use any phone in your building, and do not try to light any appliance. 2 Smell around the water heater to ensure there are no gas leaks at the gas control valve/thermostat, in the supply gas line(s), or any other type of fl ammable vapor(s) in the area. 3 Carefully inspect the area surrounding the water heater for any substances such as gasoline, paint, paint thinners, varnish, or cleaners that could emit fl ammable vapors. Remove anything that can potentially emit fl ammable vapors from the area and store it properly in a different location. 4 Call the technical information support phone number shown on the water heater labeling for further assistance.
27 TROUBLESHOOTING cont. PROBLEMCAUSE SOLUTION NO HOT WATER Blower will not run. A) Blower unplugged. Plug blower back into 115 VAC. outlet. B) No power at outlet. Repair service to outlet. C) Thermostat defective. Replace thermostat. D) High limit control circuit open. Replace ECO. E) Blower motor defective. Replace Blower Assembly. F) Pressure switch defective. Replace Pressure Switch/Blower Assembly. NOT ENOUGH HOT WATER Thermostat problems. A) Thermostat set too low. Set temperature control higher. B) Thermostat or ECO defective. Replace thermostat or ECO as required. Others A) Heater undersized. Reduce hot water use. B) Low gas pressure. Contact dealer. C) Incoming water is unusually cold. Allow more time for heater to reheat. D) Leaking hot water pipes or fixtures. Have plumber check and repair leaks. VENT PIPE TOO HOT A) Defective air flow restrictor Take unit out of service immediately, call a qualified person to service the unit. B) Not enough dilution air to mix with flue gases in inlet elbow. Proper dilution air must be provided for combustion and dilution of flue temp. See “Combustion Air Supply/Vent Pipe System”, section. C) Dilution air too hot for mixing with flue gases. Supply air is too hot. Check for heat sources around intake terminal and blockage of dilution air leg. D) Wrong burner orifice. Install correct orifice. YELLOW FLAME A) Dirt in burner ports.Turn off heater and gas, clean burner head. B) Combustion air path restricted. Check intake venting arrangements for obstructions. C) Not enough dilution air for proper combustion. Check intake venting arrangements for obstructions. CONDENSATIONA) Water on the floor under heater. See “OPERATIONAL CONDITIONS”, section. B) Water dripping from blower assembly. Provide drip “TEE” to catch condensation from horizontal section of exhaust vent close to blower assembly. WATER LEAKS A) Improperly sealed, hot or cold supply connections, relief valve, drain valve or thermostat threads. Tighten threaded connections. B) Leakage from other appliances or water lines. Inspect other appliances near water heater. C) Condensation of flue products. See “OPERATIONAL CONDITIONS”, section. LEAKING T&P A) Thermal expansion in closed water system. Install thermal expansion tank (DO NOT plug T&P valve). B) Improperly seated valve. Check relief valve for proper operation (DO NOT plug T&P valve). HOT WATER ODORS (See ANODE ROD/WATER ODOR, Section)A) High sulfate or mineral content in water supply. Drain and flush heater thoroughly then refill. B) Bacteria in water supply. Chlorinate water supply. WATER TOO HOTA) Thermostat set too high. See “WATER TEMPERATURE REGULATION”, section. WATER HEATER SOUNDS SIZZLING-RUMBLINGA) Condensation dripping on burner. See “OPERATIONAL CONDITIONS”, section. B) Sediment at bottom of heater tank. See “MAINTENANCE OF YOUR WATER HEATER”, section. SOOTINGA) Improper combustion.See “Combustion Air Supply/Vent Pipe System”, section. HEATER LIGHTS BUT GOES OUT IN 4-5 SECONDSA) Outlet polarity is reversed. Test polarity and correct.
28 REPAIR PARTS ILLUSTRATION Item No. Parts Description 1 Blower 2 Pressure Switch (Not Pictured) 3 Flue Baffle 4 Heat Trap (Cold) 5 Heat Trap (Hot) 6 Cold Water Dip Tube 7 Anode Rod* 8 Temperature and Pressure Relief Valve 9 Drain Valve 10 Gas Control Valve/Thermostat 11 Flame Sensor/Hot Surface Igniter (HSI)** 12 FV Sensor** 13 FV Sensor Bracket** 14 Burner Door Assembly - Natural Gas / Ultra Low Nox** 15 Manifold Component Block w/Retainer Clip** 16 Viewport Assembly** 17 Burner Door Gasket** 18 Outer Door 19 Flexible Manifold Tube** 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 * Special anode rod available. See “Anode Rod/Water Odor” section. ** Pictured on next page. 1 3 4 5 6 7 8 9 13 18 10 14
29 Listed Parts Kits and Illustrations Item 11: Flame Sense/Hot Surface Igniter Assembly. Item 12: FV Sensor Item 13: FV Sensor Bracket Item 14: Burner door assembly (contains the manifold tube, gasket, manifold door\ , manifold component block with retainer clip, and flame sensor/hot surface igniter assembly). Natural\ Gas. Item 15: Manifold component block with retainer clip. Item 16: Viewport. Item 17: Burner door gasket. Item 19: Flexible manifold tube. ITEM 11 ITEM 14 ITEM 16 ITEM 17ITEM 15 ITEM 19 ITEM 12ITEM 13