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Installation and Operating Manual
RESIDENTIAL GAS WATER HEATERS
POWER DIRECT VENT GAS MODELS
WITH HOT SURFACE IGNITION
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
•
•
For Your Safety
AN ODO RANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE CONTACT THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
1410
328767-001
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Table of Contents
Related Manuals for American Water Heater Powerflex
Summary of Contents for American Water Heater Powerflex
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Page 1: For Your Safety
Installation and Operating Manual RESIDENTIAL GAS WATER HEATERS POWER DIRECT VENT GAS MODELS WITH HOT SURFACE IGNITION NOT FOR USE IN MANUFACTURED (MOBILE) HOMES • • For Your Safety AN ODO RANT IS ADDED TO THE GAS USED BY THIS WATER HEATER. ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. -
Page 2: Table Of Contents
TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE ... 3 Vent Pipe Preparation ..... . . 31 GENERAL SAFETY . -
Page 3: Safe Installation, Use And Service
SAFE INSTALLATION, USE AND SERVICE Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. -
Page 4: General Safety
GENERAL SAFETY www. americanwaterheater .com 328767-001... - Page 5 GENERAL SAFETY DANGER WARNING Breathing Hazard - Carbon Monoxide Gas • Install vent system in accordance with codes. • Do not operate water heater if flood damaged. • For operation above 10,100’, a high altitude orifice must be installed. • Do not operate if soot buildup is present. •...
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Page 6: Introduction
INTRODUCTION Thank You for purchasing this water heater. Properly operation of the water heater and your safety. Since installed and maintained, it should give you years of trouble we cannot put everything on the fi rst few pages, free service. READ ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER. -
Page 7: Installation Requirements For The Commonwealth Of Massachusetts
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS COMMONWEALTH OF MASSACHUSETTS For all side wall terminated, horizontally vented power vent, direct vent and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above fi... - Page 8 INSTALLATION GRAPHIC: GAS-FIRED POTABLE WATER HEATING/SPACE HEATING SYSTEM • If your water heater will be installed in the Commonwealth of Massachusetts, refer to the following graphic during installation and during modifications to the water supply system. TYPICAL MIXING VALVE INSTALLATION COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM EXPANSION TANK COLD WATER INLET...
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Page 9: Typical Installation
TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER - GAS MODELS (LIST REFERENCING FIGURES 1-5) 1 Termination Elbow with Rodent 18 Flexible Manifold Tube (see 37 Gas Orifi ce (see Figure 3 & Screen Figure 3 & Figure 4) Figure 4) 2 *Vent Pipe 19 ***Control Harness 38 Gas Manifold (see Figure 3 &... -
Page 10: Replacement Parts And Deliming Products
Natural gas and Propane main Vacuum relief valve burner with igniter assembly for install per local 40k and 45k Btu/hr models codes (not supplied with heater). Figure 6 Notes: Items not supplied with the water heater. ** The side recirculation loop connections may not be used as the primary water inlet and outlet connections. -
Page 11: Water Piping - Mixing Valve Usage
WATER PIPING - MIXING VALVE USAGE This appliance has been design certifi ed as complying with ANSI/CSA Standard for water heaters and is considered Mixing Valves suitable for combination Water (Potable) Heating and Water temperature over DANGER Space Heating but not space heating only applications. 125°F can cause severe burns instantly resulting in severe injury or death. -
Page 12: Water Heater Operation
Some people are more likely to be permanently injured WATER HEATER OPERATION by hot water than others. These include the elderly, Figure 9 shows the water heater’s sequence of operation children, the infi rm and the physically/mentally disabled. when a call for heat is initiated. The ignition control module Table 1 (published by U.S. -
Page 13: Electrical Requirements & Wiring Diagram
ELECTRICAL REQUIREMENTS & WIRING DIAGRAM CAUTION: LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN WARNING CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING. Electric Shock Hazard POWER VENT WIRING SCHEMATIC. Disconnect power before NOTE: REFER TO THE “INSTALLATION CHECKLIST” servicing. -
Page 14: Safety Lockouts
SAFETY LOCKOUTS This water heater has several lockout features designed to prevent the heater from operating in unsafe conditions. HIGH LIMIT CONTROLS (ENERGY CUT OFF) Thermostat/Water Temperature This feature is a part of the gas control valve/thermostat (see Figure 1, item 10) and limits the maximum water temperature. -
Page 15: Locating The New Water Heater
LOCATING THE NEW WATER HEATER • FACTS TO CONSIDER ABOUT THE LOCATION Sensors mounted in the metal drain pan that trigger an alarm or turn off the incoming water to the water heater Carefully choose an indoor location for the new water when leakage is detected. -
Page 16: Clearances To Combustibles
Clearances To Combustibles HIGH AMBIENT TEMPERATURE INSTALLATIONS Minimum clearances between water heater and As the room temperature rises, the water heater venting combustibles are 0” at the sides and rear, 5.5” from the is exposed to high temperatures from the inside and the front and 12”... -
Page 17: Important Notes And Warnings
• Important Notes and Warnings Do obtain new warning and instruction labels from the • This heater is certifi ed to be installed using Schedule manufacturer for placement on the blanket directly over 40 PVC or CPVC or polypropylene plastic vent material. the existing labels. -
Page 18: Installing The New Water Heater
INSTALLING THE NEW WATER HEATER WATER PIPING Consult a Qualifi ed Installer or Service Agency. Follow manufacturer’s instructions for installation of valves. Water temperature over DANGER Before changing the factory setting on thermostat, read 125°F can cause severe “Operating The Temperature Control System” section in burns instantly resulting in severe injury or death. -
Page 19: Combo Heating
COMBO HEATING 2. Install a drain valve at the lowest point of the heating loop so that water can be drained from the heating This section serves as a guide for the installation and use module without affecting the water heater. of “Combo”... -
Page 20: Closed Water Systems
CLOSED WATER SYSTEMS SHUT-OFF VALVE Water supply systems may, because of code requirements HOT-WATER COLD- OUTLET or such conditions as high line pressure, among others, WATER INLET have installed devices such as pressure-reducing valves, UNION UNION check valves, and back fl ow preventers. Devices such as these cause the water system to be a closed system. -
Page 21: Temperature-Pressure Relief Valve
TEMPERATURE-PRESSURE RELIEF VALVE No valve or other obstruction is to be placed between the T&P valve and the tank. Do not connect discharge piping directly to the drain unless a maximum of 6” air gap is WARNING provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge Explosion Hazard water in adequate quantities should circumstances... -
Page 22: Temperature-Pressure Relief Valve And
Note: The purpose of a temperature-pressure relief valve HIGH ALTITUDE INSTALLATION is to prevent excessive temperatures and pressures in the storage tank. The T&P valve is not intended for the WARNING constant relief of thermal expansion. A properly sized thermal expansion tank must be installed on all closed systems to control thermal expansion, see “Closed Water Breathing Hazard - Carbon Monoxide Gas Systems”... -
Page 23: Sediment Traps
model rating plate. The inlet gas pressure must not exceed piping system by closing its individual manual shut-off 14” w.c. for natural gas and propane gas. The minimum valve during any pressure testing of the gas supply piping inlet gas pressure shown on the rating plate is that which system at test pressures equal to or less than 1/2 psi. -
Page 24: Filling The Water Heater
must be readily accessible. Install in accordance with the FILLING THE WATER HEATER “Gas Piping” section. Refer to the current edition of the “National Fuel Gas Code”, ANSI Z223.1/NFPA 54. CAUTION Property Damage Hazard SHUT-OFF VALVE • Avoid water heater damage. HOT-WATER COLD- Fill tank with water before operating. -
Page 25: Venting
VENTING WARNING CAUTION Breathing Hazard - Carbon Monoxide Gas Improper Installation, use and service may result in property damage. • Install water heater in accordance with the instruction manual and NFPA 54. This unit includes an air intake terminal and an exhaust vent terminal. •... -
Page 26: Termination Clearances (Sidewall)
TERMINATION CLEARANCES (SIDEWALL) R N E E C O I N S I D D E T A Vent terminal Air supply inlet Area where is not permitted F I X E S E D C L O R A B O P E F I X E S E D... -
Page 27: Side Wall Vent Terminal Installation
Side Wall Vent Terminal Installation 5. The centerline of the air intake termination and the Important: When terminating the vent on a side wall, the centerline of the exhaust vent termination must not be following specifi cations pertaining to terminal location must closer than 8”... -
Page 28: Multiple Concentric Vent Installations
ORIENTATION OF EXHAUST PIPING AND COMBUSTION AIR PIPING RELATIVE PIPE NIPPLE (USE COMBUSTION TO EACH OTHER MAY BE VERTICAL (AS SHOWN) OR AT ANY OTHER ANGLE WITH ELBOW) TO SUIT THE INSTALLATION. 90° ELBOW STRAP (FIELD (SEE LOCAL SUPPLIED) CODES) EXHAUST SLOPE 1/4”... -
Page 29: Vent Pipe Termination
Vent Pipe Termination This water heater includes one (1) pair of more restrictive Vent Termination Screens and one (1) pair of less restrictive Vent Termination Screens. For safety and optimum effi ciency performance, ensure the correct Vent Termination Screen is installed for the vent length in your installation. -
Page 30: Venting Terminations And Sizing
Venting Terminations And Sizing Note: The same screens should be installed in the intake • Refer to Table 3 for vent pipe materials and sizing. If and the exhaust piping. These screens are supplied in the the installation requires a vent riser, suitable drainage vent kit. -
Page 31: Vent Pipe Material
• Vent Pipe Material Insertion Tool - Helpful for larger diameter pipe and This heater is certifi ed to be installed using Schedule fi ttings 6” and above. 40 PVC or CPVC or polypropylene or ABS plastic vent material for the exhaust. The combustion air intake material WARNING may be PVC, ABS, CPVC or polypropylene. - Page 32 Applicators: B. Deburring Select a suitable pure bristle type paint brush. Use Use a knife, plastic pipe deburring tool, or fi le to a proper width brush or roller to apply the primer remove burrs from the end of small diameter pipe. and cement (see chart below).
- Page 33 E. Application of solvent cement G. Cleanup and joint movement • Apply solvent cement evenly and quickly around Remove all excess cement from around the pipe outside of pipe at a width a little greater than the and fi tting with a dry cotton rag. This must be done depth of the fi...
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Page 34: Vent Pipe Installation
Vent Pipe Installation Vent Pipe Runs The following guidelines should be followed when installing 1. The exhaust vent system must not, under any the air intake and exhaust vent system: circumstances, be run downhill then run uphill thus • Venting should be as direct as possible with a minimum forming a valley. -
Page 35: Blower Assembly Installation
BLOWER ASSEMBLY INSTALLATION Vent/Intake Pipe Connections To Blower/Air Duct 1. The plastic vent piping connects into the rubber 1. This power vented water heater comes with blower coupling located on the top of the blower assembly. assembly installed. This coupling includes gear clamps to connect the 2. -
Page 36: Coupling Installations According To Vent Sizes
Coupling Installations According To Vent Sizes 3” INLET PIPE 3” VENT 2” INLET PIPE 2” VENT PIPE PIPE 2”-3” 3” RUBBER ADAPTER COUPLING (SUPPLIED) (SUPPLIED) 2” RUBBER BLOWER COUPLING 3” PIPE (SUPPLIED) (SUPPLIED) AIR DUCT BLOWER ADAPTER AIR DUCT ADAPTER CONFIGURATION FOR HI-INPUT HEATERS CONNECTED TO 3”... -
Page 37: Sound Suppressor
SOUND SUPPRESSOR EXHAUST VENT INTAKE VENT TERMINAL Included with this water heater is a Tee fi tting confi gured TERMINAL as a sound suppressor. Depending on the confi guration SIDE WALL of the water heater this will be either a 2” or a 3” fi tting. The sound suppressor can be fi... -
Page 38: Installation Checklist
INSTALLATION CHECKLIST Note: Use and complete this checklist before lighting the heater. Correct any conditions that do not meet these instructions. Vent Termination Water Heater Location Horizontal Centrally located with the water piping system. 12” min. above grade/snow level. Located as close to gas piping and vent pipe system ... -
Page 39: Lighting Instructions
LIGHTING INSTRUCTIONS Read and understand these directions thoroughly before This heater is equipped with a Honeywell gas control/ attempting to operate the water heater. Make sure the thermostat and a hot-surface igniter. This control is a burner viewport is not missing or damaged. Make sure combination gas valve, thermostat and ignition controller the tank is completely fi... -
Page 40: Operating The Temperature Control System
OPERATING THE TEMPERATURE CONTROL SYSTEM It is recommended that lower water temperatures be used The water heater should be located in an area where to avoid the risk of scalding. It is further recommended, in the general public does not have access. If a suitable all cases, that the water temperature be set for the lowest area is not available, a cover should be installed over the temperature which satisfi... -
Page 41: Gas Control Valve/Thermostat
GAS CONTROL VALVE/THERMOSTAT 130°F 140°F 150°F 155°F 120°F 110°F 70°F ON/OFF TEMPERATURE SWITCH SETTING DIAL Figure 45 Approximate Time to induce a 2nd Temperature Temperature and 3rd Degree burn Dial Setting °F to adult skin VERY HOT Less than 1 second About 1.5 seconds Less than 5 seconds More than 30 seconds... -
Page 42: Start Up/Operational Conditions
FOR YOUR INFORMATION START UP CONDITIONS OPERATIONAL CONDITIONS Condensate Smelly Water Whenever the water heater is fi lled with cold water, some Each water heater contains at least one anode rod for condensate will form while the burner is ON. A water corrosion protection of the tank. -
Page 43: Periodic Maintenance
PERIODIC MAINTENANCE GENERAL UPKEEP Chemical vapo r corrosion of the fl ue and vent system may occur if air for combustion contains certain chemical Make it a habit to look around the heater, the vent piping, vapo rs. Spray can propellants, cleaning solvents, and the hot and cold water pipes. -
Page 44: Combustion Chamber And Burner Cleaning
operation, make sure that (1) no one is in front of or around the outlet of the T&P valve discharge line, and (2) that BLUE TIPS water discharge will not cause any property damage, as water may be extremely hot. Use care when operating LIGHT BLUE INNER INCORRECT CONES ARE... -
Page 45: Draining And Flushing
DRAINING AND FLUSHING To Flush The Water Heater Storage Tank: 1. Turn “OFF” the electrical supply to the water heater. Periodic draining and cleaning of sediment from the tank 2. Ensure the cold-water inlet valve is open. maybe necessary. It is recommended that the tank be 3. -
Page 46: Anode Rod Maintenance
ANODE ROD MAINTENANCE 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 EXPOSED SUPPORT is less than 3/8” . WIRE •... -
Page 47: Leakage Checkpoints
LEAKAGE CHECKPOINTS SERVICE Leakage from other appliances, water lines, or ground seepage should also be checked. If a condition persists or you are uncertain about the * To check where threaded portion enters tank, insert operation of the water heater contact a service agency. cotton swab between jacket opening and fi... -
Page 48: Reference Parts Listing
REFERENCE PARTS LISTING Replacement parts may be ordered 14 Outer Gas Door 39 Hot-Surface Igniter (see Figure 3 through your plumber or the local 15 Manifold Door Assembly (behind outer & Figure 4) (see also Figure 54 & distributor. When ordering replacement door) (see Figure 3 &... - Page 49 Natural gas and Propane Shown with (LP) main burner with Junction Box Cover igniter assembly for 40k removed for clarity. and 45k Btu/hr models † Flare †† Figure 56 Figure 54 Notes: Items not supplied with the water heater. Natural gas and Propane ** The side recirculation loop connections may not be (LP) main burner with used as the primary water inlet and outlet connections.
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Page 50: Troubleshooting Guidelines
TROUBLESHOOTING GUIDELINES These guidelines should be utilized by a qualifi ed service IGNITION STATE AND TIMING agent. IGNITION STATE TIMING 5 seconds (NG models) LOCKOUTS Pre-purge 15 seconds (LP models) Soft Lockout • Occurs when a system safety device trips to break the Hot Surface Igniter 10 seconds sequence of operation. -
Page 51: System Status And Error Codes
SYSTEM STATUS AND ERROR CODES READING THE LED FLASH SEQUENCE. The micro-controller inside the gas control monitors the The LED indicator light is active when the gas valve/ ignition sequence, temperature settings, and overall thermostat is in operation. The light will normally show a operation of the heater. -
Page 52: Corrective Actions
CORRECTIVE ACTIONS See the table below for corrective actions corresponding to the Corrective Action Number in the “System Status And Error Codes” section above. If following those corrective actions does not resolve the error, refer to “Other Symptoms“ table later in this manual. Corrective Action Corrective Action... - Page 53 Corrective Action Corrective Action Number 1. Gas supply is turned off or gas pressure is too low. Ensure supply pressure and manifold gas pressures are within requirements. Manifold pressure is nonadjustable, if gas supply pressure proves correct and manifold pressure is off by more than 0.3” WC replace the control. 2.
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Page 54: Other Symptoms
OTHER SYMPTOMS Problem Possible Cause(S) Corrective Action 1. Thermostat set too low 1. Turn temperature knob to higher setting 2. Leaking faucets/Wasted hot water 2. Repair faucets 3. Wrong piping connections 3. Correct piping: dip tube must be in cold inlet Insuffi... - Page 55 NOTES 328767-001 www. americanwaterheater .com...
- Page 56 500 Princeton Road, Johnson City, TN 37605 Phone: 800-999-9515 • Fax: 800-999-5210 www.americanwaterheater.com...
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Questions and answers
What is this on a gas hot water heater?
The PowerFlex part on an American Water Heater gas hot water heater refers to the blower assembly. It includes components such as the blower high limit switch, which ensures safe operation by shutting off the heater in case of overheating or unsafe conditions.
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