American Water Heater Power Flex 50-60K BTU, Power Flex 40-42K BTU User Manual
Flammable Vapor Ignition Resistant Compliant
Power Direct Vent
Gas Water Heater
Installation
Instructions and
Use & Care Guide
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch;
do not use any phone in your
building.
• Immediately call your gas supplier
from a neighbor’s phone. Follow
the gas supplier’s instructions.
• If you cannot reach your gas
supplier, call the fire department.
Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.
To obtain technical, warranty, or service assistance during or
after the installation of this water heater, visit our website at:
http://www.americanwaterheater.com
or 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
INSTALLER:
• AFFIX THESE INSTRUCTIONS TO OR ADJACENT
TO THE WATER HEATER.
OWNER:
• RETAIN THESE INSTRUCTIONS AND WARRANTY
FOR FUTURE REFERENCE. RETAIN THE
ORIGINAL RECEIPT AS PROOF OF PURCHASE.
6510418
September 2007
1
WATER HEATER SAFETY
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER indicates an imminently hazardous
DANGER
WARNING
CAUTION
CAUTION
• Do not use this appliance if any part has been under water. Immediately call a qualified service technician. Water
heaters subjected to flood conditions or any time the gas controls, main burner or pilot have been submerged in
water require replacement of the entire water heater.
• Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame. To
prevent the possibility of injury under these conditions, we recommend the hot water faucet be opened for several
minutes at the kitchen sink before using any electrical appliance which is connected to the hot water system. If
hydrogen is present, there will probably be an unusual sound such as air escaping through the faucet as water
begins to flow. Do not smoke or have any open flame near the faucet at the time it is open.
situation which, if not avoided, could result
in death or injury.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in death or injury.
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result
in minor or moderate injury.
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result
in property damage.
Important Instructions
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of
substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires
businesses to warn of potential exposure to such substances.
WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other
reproductive harm.
This appliance can cause low-level exposure to some of the substances included in the Act.
Table Of Contents
Water Heater Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installing Your Gas Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Unpacking the Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Location Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Vent Pipe System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Inlet/Outlet Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Water System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operating Your Water Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Lighting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operational Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance of Your Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . 18-20
Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-22
Repair Parts Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-24
PAGE
2
INSTALLING YOUR GAS WATER HEATER
Consumer Information
This water heater is design-certified by CSA International
as a Category I, direct vented water heater which takes
its combustion air from the outside of the structure and
exhausts all products of combustion to the outside of the
structure.
This 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)-current edition.
CSA America, Inc.
8501 Pleasant Valley Road
Cleveland, OH 44131
National Fire Protection Agency
1 Batterymarch Park
Quincy, MA 02169-7471
Check your phone listings for the local authorities
having jurisdiction over your installation.
Consumer Responsibilities
This manual has been prepared to acquaint you with the
installation, operation, and maintenance of your 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.
Do not discard this manual. You or future users of this
water heater will need it for future reference.
Service to the Power Direct Vent System should only be
performed by a qualified person.
If you lack the necessary skills required to properly install
this water heater, or you have difficulty following the
instructions, you should not proceed but have a qualified
person perform the installation of this water heater.
Massachusetts code requires this water heater to be
installed in accordance with Massachusetts Plumbing and
Fuel Gas Code 248 CMR Section 2.00 and 5.00.
A data plate identifying your water heater can be found
next to the gas control valve/thermostat. When referring to
your water heater, always have the information listed on
the data plate readily available.
Retain your original receipt as proof of purchase.
IMPORTANT: Do not remove any permanent instructions,
labels, or the data label from either the outside of the water
heater or on the inside of water heater panels.
Unpacking the Water Heater
WARNING
Excessive Weight Hazard
Use two or more people to move and install
water heater.
Failure to do can result in back or
other injury.
• 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/recycle all packaging
materials.
3
WARNING
FLAMMABLES
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
Storage of or use of gasoline or other
flammable vapors or liquids in the vicinity
of this or any other appliance can result in
serious injury or death.
Read and follow water heater warnings and
instructions.
Flammable Vapors
Location Requirements
WARNING
Carbon Monoxide Poisoning Hazard
Do not install in a mobile home.
Doing so can result in death or
carbon monoxide poisoning.
Do not use or store flammable products such as gasoline,
solvents, or adhesives in the same room or area near the
water heater. If such flammables must be used, all gas
burning appliances in the vicinity must be shut off and their
pilot lights extinguished. Open the doors and windows for
ventilation while flammable substances are in use.
If flammable liquids or vapors have spilled or leaked in
the area of the water heater, leave the area immediately
and call the fire department from a neighbor’s home. Do
not attempt to clean the spill until all ignition sources have
been extinguished.
WARNING
Fire or Explosion Hazard
Read instruction manual before installing,
using or servicing water heater.
Improper use may result in fire or explosion.
Maintain required clearances to combustibles.
Keep combustibles such as boxes, magazines, clothes,
etc. away from the water heater area.
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.
• Consider the inlet and exhaust 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 the termination with a minimal length and number of elbows. The
venting system must comply with the requirements set
forth in the venting section of this manual.
• 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.
NOTE: This 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)-current edition.
4
CAUTION - PROPERTY DAMAGE HAZARD
The water heater should be located in an area where
leakage of the tank or connections will not result in
damage 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. Also any external plumbing
leak, including those from improper installation, may
cause early failure of the tank due to corrosion if not
repaired. If the owner/operator is uncomfortable with
making the repair a qualified person should be contacted.
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 condensate
formation or leaks in the piping connections or tank.
The pan must limit the water level to a maximum depth
of 1-3/4” and be two inches wider than the heater and
piped to an adequate drain. NOTE: The pan must not
restrict combustion air flow. 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” ID and pitched for
proper drainage.
Pipe to an
adequate drain
1-3/4”
max.
Clearances and Accessibility
FIGURE 1
Minimum Clearance
Locations
Back
Top View
Top to
ceiling
Sides
Sides
Front
24” min.
for service
Vent
NOTE: Minimum clearances from combustible materials
are stated on the data plate adjacent to the gas control
valve/thermostat of the water heater.
The water heater is certified for installation on a
combustible floor.
• IMPORTANT: If installing over carpeting, the carpeting
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 (76.2mm) in any direction or if in
a alcove or closet installation, the entire floor must be
covered by the panel.
WARNING
Fire Hazard
At least 2” greater
than the water heater and the
inlet air pipe.
• 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.
For continued protection
against the risk of fire:
Do not install water heater
on carpeted floor.
Do not operate water heater
if flood damaged.
• Figure 1 may be used as a reference guide to locate
the specific clearance locations. A minimum of 24
inches of front clearance and 4 inches on each side
should be provided for inspection and service.
State of California
NOTE: The water heater must be braced, anchored, or
strapped to avoid moving during an earthquake. Contact
local utilities for code requirements in your area or call
1-800-456-9805 and request instructions.
5
Gas Supply
WARNING
Explosion Hazard
Use a new CSA approved gas supply line.
Install a shut-off valve.
Figure 2
Gas Piping
Manual gas
shut-off valve
Install a readily accessible manual shut-off
valve in the gas supply
line as recommended
by the local utility.
Do not connect a natural gas water heater to
an L.P. gas supply.
Do not connect an 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
Read the data plate to be sure the water heater is made
for the type of gas you will be using in your home. This
information will be found on the data plate located near the
gas control valve/thermostat. If the information does not
agree with the type of gas available, do not install or light.
Call your dealer.
NOTE: An odorant is 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 the absence of local and state codes, the
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current
edition.
Tables 1 and 2 on the following page provide a sizing
reference for commonly used gas pipe materials. Consult
the “National Fuel Gas Code” for the recommended gas
pipe size of other materials.
Refer to Figure 2
NOTE: When installing gas piping, apply approved pipe
joint compound.
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 how to turn off the
gas to this unit.
2. Install a drip leg (if not already incorporated as part of
the water heater) as shown. The drip leg must be no
less than three inches long for the accumulation of dirt,
foreign material, and water droplets.
3. Install a ground joint union between the gas control
valve/thermostat and the manual shut-off valve. This is to
allow easy removal of the gas control valve/thermostat.
4. Turn the gas supply on and check for leaks. Test all
connections by brushing on an approved noncorrosive
leak-detection solution. Bubbles will show a leak. Correct
any leak found.
Gas Pressure
IMPORTANT: The gas supply pressure must not exceed
the maximum supply pressure as stated on the water
heater’s data plate. The minimum supply pressure is for
the purpose of input adjustment.
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 exceeding 14” W.C., 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 instructions 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 person after
installation of the gas piping system.
L.P. Gas Only
WARNING
Explosion Hazard
Have a qualified person make sure L.P. gas
pressure does not exceed 13” water column.
Examples of a qualified person include:
licensed plumbers, authorized gas company
personnel, and authorized service
personnel.
Failure to do so can result in death,
explosion, or fire.
6
VENT PIPE SYSTEM
WARNING
Carbon Monoxide Warning
Follow all the 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 to properly install
vent system.
Failure to do so can result in death,
explosion, or carbon monoxide poisoning.
Venting
This water heater has a direct vent system in which all air
for combustion is taken from the outside atmosphere and
all combustion products are discharged to the outdoors.
This water heater must be properly vented for removal
of exhaust gases to the outside atmosphere. Correct
installation of the vent pipe system is mandatory for the
safe and efficient operation of this water heater and is an
important factor in the life of the unit.
Vent pipe installation must be performed in accordance
with state and local codes, or in the absence of such, the
National Fuel Gas Code, NFPA 54, ANSI Z223.1-current
edition. IMPORTANT: Check to make sure the vent pipe is
not blocked in any way.
NOTE: Do not common vent this water heater with any
other appliance. Do not install in the same chase or
chimney with a metal or high-temperature plastic from
another gas or fuel burning appliance.
When assembling the air inlet and vent outlet pipe system,
BOTH pipe diameters MUST be the same size. For
example, if a 2 inch diameter pipe is used on the air inlet
pipe then a 2 inch diameter pipe MUST be used on the vent
outlet. This requirement also applies to 3 inch diameter
piping configurations.
Vent Pipe Material
The following plastic materials may be used for both the
combustion air inlet and exhaust outlet piping subject to
state and local codes:
• 2 or 3 inch Schedule 40 PVC or ABS
• 2 or 3 inch Schedule 40 or 80 CPVC
• DWV Pipe is acceptable
NOTE: Use only solid (not foam core) piping. Plastic pipe
and fittings are available through most plumbing suppliers.
Always check the marking on the pipe to make sure you
are using the correct material.
Vent Pipe Connection to Blower
A 3”x2” condensate drain coupler is supplied with every
40-42K BTU model to connect either 2” or 3” venting to the
blower. A 3” condensate drain coupler is supplied with every
50-60K BTU model to connect 3” venting to the blower.
IMPORTANT: These connections must be properly sealed
to prevent the leakage of the products of combustion into
the living area. If needed 3”x2” & 3” condensate drain
couplers are available through the Parts Department for new
installations or retrofits where condensate may run back to
the blower.
7
Vent Pipe Installation
The following guidelines should be followed when installing
the air inlet and exhaust outlet piping:
• Venting should be as direct as possible with a
minimum number of pipe fittings.
• Vent diameter must not be reduced unless
specifically noted in the installation instructions.
• Support all horizontal pipe runs every four feet
and all vertical pipe runs every six feet or
according to local codes.
• Vents run through unconditioned spaces where below
freezing temperatures are expected should be properly insulated to prevent freezing. For horizontal runs,
wrap the vent pipe with self-regulating 3 or 5 watt heat
tape. The heat tape must be U.L. listed and installed
per the manufacturer’s instructions.
• Do not connect this venting system with an existing
vent or chimney.
• Do not common vent with the vent pipe of any other
water heater or appliance.
The combustion air inlet and exhaust outlet piping and
termination may be installed in one of the following type
terminations:
1. Standard Horizontal (2 Pipe)
2. Vertical (2 Pipe)
3. Concentric Vent - Through the Wall
All pipe, fittings, pipe cement, primers and procedures
must conform to American National Standard Institute and
American Society for Testing and Materials (ANSI/ASTM)
standards in the United States. This water heater has been
design certified by CSA International for use with the listed
plastic vent pipe material.
IMPORTANT: Do not use vent elbows in this vent pipe
installation (see figure 3 below).
Figure 3
Correct and Incorrect
Pipe Fittings
Mesh Metal
Rodent Screen
CORRECT FITTINGS
90° Medium
Sweep Elbow
45° Sweep
Elbow
INCORRECT FITTINGS
90° Long
Sweep Elbow
Note: It is important to select the proper pipe cement
for the type plastic pipe being used.
3. Assemble the parts quickly while the cement is still
wet. Twist the pipe 1/4 turn during insertion and hold
for 30 seconds.
Vent Pipe Length
Size the exhaust outlet and combustion air inlet pipes as
specified in Table 3 below. This table lists the maximum
allowable length in feet of the exhaust outlet and combustion air inlet pipes as related to the number of required
elbows and the termination. The specified maximum
lengths are for the separate inlet and exhaust pipe systems
and not the combined length of both systems. Minimum
pipe length is 3 feet with one elbow per side.
1. Determine termination type and pipe size.
2. Determine number of elbows in exhaust pipe (Do not
include elbows in the termination.) Corresponding
number indicates the maximum length of exhaust pipe.
3. Determine number of elbows in inlet pipe. (Do not
include elbows in the termination.) The corresponding
number indicates the maximum length of inlet pipe.
Table 3 - Maximum Allowable Length in Feet of Exhaust and
Pipe
Size
(in)
2 40 35 30 25 20 15 10 Std. Horizontal
2 40 35 30 25 20 15 10 Vertical
3 120 115 110 105 100 95 90 Std. Horizontal
3 115 110 105 100 95 90 85 Vertical
Table 4 - Maximum Allowable Length in Feet of Exhaust and
Pipe
Size
(in)
2 N/A Std. Horizontal
2 N/A Vertical
3 45 40 35 30 25 20 15 Std. Horizontal
3 55 50 45 40 35 30 25 Vertical
NOTE:s:
1. N/A - Not Applicable
2. The above maximum lengths are for outlet pipe systems.
3. Maximum of 6 elbows may be used. Use only medium or long
sweep elbows. See figure 8 for details.
4. Two 45° elbows are considered equivalent to one 90° elbow.
5. Minimum length is 3 foot with 1 elbow.
6. Use schedule 40 or 80 CPVC, 40 ABS, or 40 PVC pipe and fittings.
Inlet Air Pipe - (42K BTU/Hr models only)
Number of 90° Elbows (medium or long sweep only)
0123456
Inlet Air Pipe - (50K/60K BTU/Hr models only)
Number of 90° Elbows (medium or long sweep only)
0123456
Termination
Options
Termination
Options
Tee Connector
45° Vent
Elbow
90° Vent
Elbow
All joints in the inlet and outlet piping must be properly
cemented. Size and cut all piping before cementing.
1. Cut the pipe end square and remove all ragged edges
and burrs. Make sure the inside of the pipe is clean
and free of cuttings and loose dirt. Chamfer the end
and apply primer to the fitting and pipe.
2. Using a suitable grade of pipe cement, apply a moderate, even coat inside the fitting. Apply a liberal amount
of cement to the outside of the pipe to socket depth.
8
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