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American Water Heater Powerflex User Manual

American Water Heater Powerflex
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RESIDENTIAL GAS WATER HEATERS
Installation and Operating Manual
1410 328767-001
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
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.

Table of Contents

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American Water Heater Powerflex Specifications

General IconGeneral
CategoryWater Heater
BrandAmerican Water Heater
ModelPowerflex
TypeElectric
Capacity50 gallons
Voltage240V
Energy Factor0.95

Summary

Safe Installation, Use and Service

Important Definitions

Defines key roles like Qualified Installer, Service Agency, and Gas Supplier.

General Safety

Fire Hazard Precautions

Precautions against fire hazards, including installation on carpet and flood damage.

Hot Water Burn Hazard

Warning about severe burns from hot water, especially for vulnerable groups.

Explosion Hazard - Overheated Water

Risks of water tank explosion due to overheating and improper relief valve.

Flammable Vapors and Gas Safety

Hazards related to flammable liquids, ignition sources, and gas pressure.

General Safety Considerations

Property Damage Prevention

Hazards from improper installation, use, and service, including leaks.

Servicing Safety Precautions

Safety precautions before servicing, like disconnecting power and labeling wires.

Carbon Monoxide Gas Hazard

Risks of carbon monoxide gas from venting issues.

Flammable Vapors Explosion Risk

Danger of flammable vapors exploding and catching fire.

Introduction and Preparation

Qualified Installer Requirements

Defines the qualifications needed for installation and service personnel.

Pre-Installation Checklist

Key steps and considerations before beginning the installation process.

Massachusetts Installation Requirements

Carbon Monoxide Detector Installation

Mandates installation of CO detectors for side wall vented gas heaters.

Required Signage

Requirement for specific signage near the exhaust vent terminal.

Inspection and Manufacturer Venting Requirements

Role of inspector and manufacturer's venting system requirements.

Installation Graphics and Piping

Typical Mixing Valve Installation

Graphic and notes for typical mixing valve installation.

Typical Installation Overview

Component Identification

Identifies and lists various components of the water heater with figure references.

Combo Heating Connections

Water Piping and Mixing Valves

Mixing Valve Usage and Safety

Discusses safe use of mixing valves to prevent scalds.

Combination Heating Systems

Certification for combination water and space heating systems.

Water Heater Operation Sequence

Hot Water Burn Time Data

Shows time-to-burn relationship for different water temperatures.

Operational Sequence Diagram

Illustrates the water heater's sequence of operation upon a call for heat.

Electrical Requirements and Wiring

Electrical Safety Warnings

Critical electrical safety warnings before servicing.

Power Vent Wiring Schematic

Wiring diagram for power vent operation.

Safety Lockout Features

High Limit Controls

Explains the thermostat/water temperature high limit control.

Blower High Limit Switch Function

Describes the blower high limit switch and its function.

Blower Air Pressure Switches

Explains the function of the blower air pressure switches.

Water Heater Location Guidelines

Location Considerations

Key factors to consider when choosing a location for the water heater.

Leak Prevention and Drain Pans

Hazards related to water leaks and proper installation of drain pans.

Flammable Liquids and Gas Safety

Fire and explosion risks associated with flammable liquids and gas.

Installation Clearances

Clearances to Combustibles

Minimum required clearances from combustible materials.

Carpeted Floor Installation

Specific requirements for installing on carpeted floors.

Servicing Clearances

Importance of clearances for servicing the appliance.

High Ambient Temperature Installations

Considerations for installing in high ambient temperature environments.

Carbon Monoxide Gas Warning

Risks of CO gas if vent pipe is deformed or improperly connected.

Important Installation Notes

Vent Pipe Material and Joining

Details on approved vent pipe materials and joining procedures.

Insulation Blanket Usage

Information and warnings regarding the use of insulation blankets.

Air Intake Obstruction Warning

Warnings about obstructing air intake with insulating jackets.

Air Requirements for Operation

Importance of adequate air supply for safe operation.

Installing the Water Heater

Water Piping Installation

Instructions and warnings related to water piping installation.

Hot Water Scald Hazards

Hazards of hot water and precautions against scalding.

Combination Heating System Piping

Requirements for combination heating and potable water systems.

Combo Heating System Installation

System Requirements for Combo Heating

Lists essential requirements for installing combo heating systems.

Combo Heating Installation Options

Outlines installation options and requirements for heating modes.

Closed Water Systems and Thermal Expansion

Thermal Expansion Management

Explains thermal expansion and the need for expansion tanks.

Property Damage Prevention

Cautions regarding water heater damage and necessary precautions.

Temperature-Pressure Relief Valve (T&P Valve)

T&P Valve Explosion Hazard

Critical warnings regarding the T&P valve and discharge piping.

T&P Discharge Pipe Requirements

Caution about ensuring the T&P discharge pipe terminates at a drain.

T&P Valve Discharge Hazard

Hazards associated with hot water discharge from the T&P valve.

Relief Valve Insulation and High Altitude

High Altitude Installation Requirements

Requirements for operating the heater at high altitudes.

Gas Piping Safety and Installation

Safety warnings and requirements for gas piping installation.

Gas Piping and Sediment Traps

Gas Pipe Sizing and Codes

Guidelines for gas pipe sizing and compliance with codes.

Sediment Trap Installation

Importance and installation of sediment traps in gas piping.

Gas Piping Fire Hazard

Hazards related to gas piping installation and leak testing.

Filling the Water Heater

Water Heater Filling Procedure

Step-by-step instructions for filling the water heater tank.

Filling Safety Cautions

Cautions regarding filling the water heater and avoiding damage.

Venting System Installation

Venting Safety Precautions

Hazards from improper installation of the unit and vent system.

Carbon Monoxide Gas Warning

Risks of CO gas if vent pipe is not properly connected or obstructed.

Common Venting Prohibition

Prohibition against common venting with other appliances.

Sidewall Vent Termination Clearances

Figure 20: Vent Terminal Clearances

Diagram showing required clearances for vent terminals.

Vent Terminal Installation Details

Side Wall Vent Terminal Installation

Specifications for installing vent terminals on a sidewall.

Roof Vent Terminal Installation

Specifications for installing vent terminals through a roof.

Concentric Vent Termination Kit

Details on installing the concentric vent termination kit.

Concentric Vent Kits and Pipe Length

Multiple Concentric Vent Spacing

Spacing requirements for multiple concentric vent kits.

Vent Pipe Length Limitations

Information on maximum allowable vent pipe lengths.

Vent Pipe Termination and Sizing

Vent Termination Screens

Information on vent termination screens included with the heater.

Vent Pipe Length Table

Table detailing maximum vent pipe lengths and equivalent lengths.

Elbow Equivalent Lengths

Notes on equivalent lengths of elbows for vent pipe calculations.

Vent Screen Installation

Screen Selection by Vent Configuration

Guidance on selecting the correct vent screen based on configuration.

Figure 28 & 29: Vent Screen Usage

Illustrations showing vent screen usage for different models and lengths.

Vent Pipe Material and Preparation

Approved Vent Pipe Materials

Details on approved vent pipe materials and joining procedures.

Vent Pipe Preparation Steps

Steps for preparing vent pipe materials for joining.

Materials for PVC/CPVC Venting

Lists tools and materials for PVC/CPVC vent pipe installation.

Making the Vent Pipe Joint

Pipe Cutting and Deburring

Instructions for properly cutting, deburring, and chamfering vent pipes.

Dry Fitting Vent Pipe Joints

Importance of dry fitting pipe joints before cementing.

Solvent Cement Application and Joint Assembly

Applying Solvent Cement

Proper technique for applying solvent cement to pipe and fittings.

Joint Assembly and Curing

Step-by-step guide for assembling cemented pipe joints and curing.

Vent Pipe Installation Guidelines

Vent Pipe Runs and Supports

Guidelines for running vent pipes, including slope and support.

Vent Terminal Installation Requirements

Requirements for proper vent terminal installation and clearances.

Blower Assembly Installation

Connecting Vent Pipes to Blower

How to connect vent/intake pipes to the blower assembly.

Coupling Installations by Vent Size

Figure 36: Coupling Configurations

Diagrams for coupling installations based on vent sizes.

Sound Suppressor Installation

Side Wall Venting with Suppressor

Preferred locations for installing the sound suppressor on sidewall vents.

Vertical Venting with Suppressor

Using the sound suppressor in vertical vent installations.

Installation Checklist

Water Heater Location Checklist

Checklist items for water heater location verification.

Gas Supply and Piping Checklist

Checklist items for gas supply and piping verification.

Vent Pipe System Checklist

Checklist items for the vent pipe system verification.

Vent Termination Checklist

Checklist items for vent terminal locations.

Water System Piping Checklist

Checklist items for water system piping verification.

Electrical Connections Checklist

Checklist items for electrical connections verification.

Lighting Instructions

Safety Before Lighting

Crucial safety warnings before attempting to light the heater.

Operating Instructions Sequence

Step-by-step instructions for operating the water heater.

Operating the Temperature Control System

Water Temperature and Scald Prevention

Discusses recommended water temperatures and precautions against scalding.

Gas Control Valve and Thermostat

Thermostat Setting Dial

Illustration of the gas control valve and thermostat settings.

Temperature Dial Setting Chart

Table showing temperature settings and burn times.

Information for Your Information

Start-Up Conditions and Sounds

Conditions and noises that may occur during start-up.

Condensate Formation and Leaks

Explains condensate formation and potential confusion with leaks.

Smoke, Odor, and Strange Sounds

Common initial smoke, odor, and sounds during start-up.

Smelly Water and Anode Rods

Causes and solutions for smelly hot water from the anode rod.

Hydrogen Gas Hazard

Warning about potential hydrogen gas production in unused systems.

Periodic Maintenance Schedule

General Upkeep and Cleaning

Routine checks and cleaning for the heater and surrounding area.

Venting System Inspection

How to inspect the vent system for obstructions or damage.

Burner Operation and Inspection

Visual inspection of the burner and igniter for proper operation.

Burner Cleaning and Housekeeping

Combustion Chamber Cleaning

Procedure for cleaning the burner and air openings.

Housekeeping Safety

Maintaining a clean and safe area around the water heater.

Temperature-Pressure Relief Valve Test

Procedure for testing the temperature-pressure relief valve.

Draining and Flushing the Tank

Procedure to Drain Water Heater Tank

Step-by-step instructions for draining the water heater tank.

Procedure to Flush Water Heater Tank

Step-by-step instructions for flushing the water heater tank.

Anode Rod Maintenance

Anode Rod Inspection and Signs of Depletion

Importance of anode rod inspection and signs of depletion.

Anode Rod Replacement Procedure

Procedure for replacing the anode rod.

Leakage Checkpoints and Service

Troubleshooting Water Leaks

Guide to help identify sources of suspected water leaks.

Leak Source Identification Diagram

Diagram illustrating potential leak points on the water heater.

Reference Parts Listing

Front View Component Identification

Front view illustration with numbered parts for reference.

Rear View Component Identification

Rear view illustration with numbered parts for reference.

Burner and Blower Assembly Diagrams

Figure 54: Burner Assembly

Illustration of the natural gas/propane burner assembly.

Figure 55: Burner Assembly

Another view of the burner assembly with parts.

Figure 56: Blower Assembly Components

Illustration of the blower assembly components.

Troubleshooting Guidelines

Lockout Conditions

Explains soft and hard lockouts and their causes.

Heater Control Reset Procedure

Procedure for resetting the heater control after a lockout.

Ignition State and Timing Parameters

Table detailing ignition states and their timing parameters.

System Status and Error Codes

Reading LED Flash Sequences

How to interpret LED flash sequences for error codes.

LED Flash Sequence Error Table

Table listing LED flash sequences and their meanings.

Corrective Actions for Errors

Corrective Actions 1-7

Specific corrective actions for various error codes.

ECO Reset Procedure

Procedure for manually resetting the ECO.

Corrective Actions Continued

Corrective Actions 8-17

Specific corrective actions for various error codes.

Other Symptoms and Solutions

Insufficient Hot Water Troubleshooting

Possible causes and corrective actions for insufficient hot water.

Water Too Hot Troubleshooting

Possible causes and corrective actions for water being too hot.

Slow Hot Water Recovery Troubleshooting

Possible causes and corrective actions for slow hot water recovery.

Relief Valve Drip Troubleshooting

Possible causes and corrective actions for relief valve drips.

Smelly Water Troubleshooting

Possible causes and corrective actions for smelly hot water.

Condensation and Water Leakage

Explains condensation and troubleshooting water leakage.

Exhaust Pipe Overheating

Possible causes and corrective actions for overheating exhaust pipes.

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