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American Water Heater 40-42K, Installation Instructions Manual

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American Water Heater 40-42K Installation Instructions Manual Download Page 3

3

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.

• 

Remove exterior packaging and place installation com-
ponents 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.

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.

Summary of Contents for 40-42K

Page 1: ...e performed by a qualified installer service agency or the gas supplier WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death 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 fre...

Page 2: ...em 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 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 ...

Page 3: ...vice 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 Massachu...

Page 4: ...xplosion 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 vertica...

Page 5: ...stion 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 1 3 4 max At least 2 greater than the water heater and the inlet air pipe Pipe to an adequate drain NOTE Minimum clearances from combustible materials are stated on the data pla...

Page 6: ...rrect 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 tes...

Page 7: ...irement 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 ...

Page 8: ...d 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...

Page 9: ...rea where children or animals could block pipes 5 Do not locate the vent terminal too close to shrubs or bushes 6 Caulk all cracks seams and joints within 6 feet horizontally above and below the vent Figure 4 Minimum Termination Clearance for Outlet Vent A 12 in 30 cm min clearance above grade veranda porch deck balcony or maximum anticipated snow level B 12 in 30 cm min clearance on top or 4 ft c...

Page 10: ... customer service at 1 800 456 9805 for assistance To prevent potential condensate from collecting in the venting system slope the vent at a downward pitch of 1 8 per 5ft away from the water heater INLET OUTLET VENT TERMINATIONS Standard Horizontal Termination The standard horizontal air inlet termination is a 2 inch or 3 inch pipe which terminates at the exterior wall and utilizes a coupling to p...

Page 11: ...mmends installing a tempering valve or an anti scald device in the domestic hot water line as shown in Figure 9 These valves reduce the point of use temperature of the water by mixing cold and hot water and are readily available for use Point of use devices for reducing scald hazards that attach to faucets and shower heads are also available from plumbing supply houses Contact a licensed plumber o...

Page 12: ...re relief valve to discharge small quantities of hot water This is an unacceptable condition and must be corrected To prevent this it is recommended that a diaphragm type expansion tank suitable for potable water be installed on the cold water supply line The expansion tank must have a minimum capacity of 1 5 U S gallons for every 50 gallons of stored water Contact the local water supplier or plum...

Page 13: ...llow complete drainage of both the valve and discharge line IMPORTANT Do not use an extension cord to connect the water heater to an electrical outlet The water heater and the outlet are properly grounded Installed in accordance with prevailing provisions of local codes or in the absence of such National Electric Code ANSI NFPA 70 NOTE Always reference the wiring diagram for the correct electrical...

Page 14: ...sions of local codes or in the absence of such National Fuel Gas Code NFPA 54 ANSI Z223 1 Current Edition Slope 2 3 horizontal piping at a downward pitch of 1 8 per 5ft away from the water heater Not obstructed in any way Vent Termination Concentric 12 Min above grade snow level Slope exhaust outlet air inlet piping at a downward pitch of 1 8 per 5ft away from the water heater Horizontal Correct r...

Page 15: ...ADJUSTMENT is approximately 120 F CAUTION Hotter water increases the risk of scald injury Consult the instruction manual before changing the temperature 8 If the appliance will not operate follow the instructions TO TURN OFF GAS APPLIANCE and call a qualified person or gas supplier WARNING TURN OFF ALL ELECTRIC POWER BEFORE SERVICING 1 Set the thermostat to the lowest setting by first pressing the...

Page 16: ...ns such as a mixing valve should be used at the hot water taps used by these people or at the water heater Mixingvalvesareavailableatplumbingsupplyorhardwarestores seeFigure9 Followmanufacturer sinstructionsforinstallationof the valves Before changing the factory setting on the thermostat see Figure 13 and the table below Using the lowest hot water temperature that meets your needs will also provi...

Page 17: ...roduced 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 wate...

Page 18: ...rioration 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 and pilot burner Check for a soft blue flame Leaking or damaged water and gas piping Presence of flammable or corrosive materials in the installation area Presence of combustible materials near the water heater Verify proper operation after servici...

Page 19: ... on the manifold tube 6 Grasp the manifold tube and push down slightly to free the manifold from the gas control valve thermostat 7 Carefully remove the manifold assembly from the burner compartment Be sure not to damage internal parts 8 Check the burner to see if it is dirty or clogged The burner may be cleaned with soap and hot water Removing the Burner from the Manifold Assembly 1 Take off the ...

Page 20: ...t 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 thermostat Figure 16 NOTE L P gas systems use reverse left hand threads on the manifold tube 6 Refer to Gas Piping Figure 2 and disconnect the ground joi...

Page 21: ...k that all wiring is correct and secure 2 Replace hot surface igniter System in lockout 1 Gas supply is off or too low to operate 2 Hot surface igniter not positioned correctly 3 Low voltage to the water heater 4 Electric polarity to unit is incorrect test and cor rect Problem in the gas valve driver circuit 1 Turn power to the water heater off for 10 seconds and then back on 2 Replace gas control...

Page 22: ...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 CONDENSATION A 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 exhau...

Page 23: ...Natural Gas Burner 13 L P Gas Burner 14 Manifold Door Assembly Natural Gas 15 Manifold Door Assembly L P Gas 16 Two Piece Wire Connector w Retainer Clip 17 Manifold Door Gasket 18 Viewport Assembly 19 Outer Door 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 avail...

Page 24: ...hot surface igniter assembly Natural Gas Item 15 Manifold door assembly which contains the manifold tube gasket manifold door two piece wire connector with retainer clip and flame sense hot surface igniter assembly L P Gas Item 16 Contains two piece wire connector with retainer clip Item 17 Contains manifold door gasket Item 18 Contains viewport 2007 American Water Heater Company All Rights Reserv...

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