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APPENDICES

86

SERVICE PROCEDURE

D24-IV

Main Burner & Pilot

Removal and Inspection

WARNING

Heater components may be HOT when performing the following steps in this procedure.

Take necessary precaution to prevent personal injury.

Main Burner Removal

Step 1.

Disconnect (un-plug) water heater from
electrical supply.

Step 2.

Turn “OFF” gas supply to water heater.

Step 3.

Rotate gas valve control knob to the “OFF” position
(see photo 17).

Step 4.

Disconnect Gas supply line from the gas valve
(see photo 17).

Step 5.

Disconnect wire leads from gas valve
(see photo 17).

Step 6.

Disconnect white flame sense wire & orange ignition
wire from Control Board (see photo 18).

Step 7.

Remove the two burner rack mounting screws (see photo 17).

Step 8.

Slide complete burner rack out from heater
(see photo 19).

Step 9.

To install burner, reverse above procedure.

Step 10.

Check for gas leaks and verify proper operation.

Gas Valve

Control Knob

Gas Supply

Line

Gas Valve

Wire Leads

Burner Rack

Mounting

Screw

Main Burner Inspection

Step 1.

Burner tubes should be free of any flue
scale or other debris. Clean
burner tubes using a stiff brush and/or
shop vac. Burner ports should have uniform
openings. Replacement is recommended for
burners where port area is deteriorated or
other unintended openings are present.

Step 2.

Insure pilot shield is in place (see photo 20).

Step 3.

Inspect pilot position to insure smooth burner
ignition from pilot flame. Pilot should be
mounted using the two mounting screws through
the burner support bracket resulting in a level
pilot position.

19

Pilot

Shield

17

20

Pilot spark wire

(Orange)

Pilot Flame Sense

Wire (White)

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Summary of Contents for 24/39

Page 1: ...e manual This manual must be kept with the appliance October 2013 Part No E132 Natural Gas HI FLO RANGE Models 32 143 65 173 81 264 62 341 54 418 54 440 Permanent Pilot Auto Ignition with Flue Damper E F Series G Series STANDARD RANGE Models 24 39 32 40 40 61 63 62 and 84 87 Permanent Pilot Auto Ignition ...

Page 2: ...e Health and Safety Regulations 1993 All installation and service on the Andrews Water Heater must be carried out by properly qualified personnel and therefore no liability can be accepted for any damage or malfunction caused as a result of intervention by unauthorised personnel The Andrews Water Heaters policy is one of continuous product improvement and therefore the information in this manual w...

Page 3: ...nted Systems Hi Flo Range 27 SECTION 4 COMMISSIONING Standard Range 30 Hi Flo Range 32 SECTION 5 OPERATION Standard Range 39 Hi Flo Range 39 SECTION 6 SERVICING Introduction 40 Burner Assembly Standard Range 40 Burner Assembly Hi Flo Range 40 Gas Control Valve Standard Range 41 Gas Control Valve Hi Flo Range 41 Flue Ways 41 Cleaning the Storage Vessel 42 Magnesium Anode s 42 Safety Valve 42 SECTIO...

Page 4: ...tic use within buildings and their curtilages This standard supersedes the following British Standards and Codes of Practice CP99 CP310 CP324 202 CP342 Part 2 Centralised Hot Water Supply BS 5440 Installation of flues and ventilation for gas appliances of rated output not exceeding 60kW Part 1 2000 Specification for installation of flues Part 2 2000 Specification for installation of ventilation fo...

Page 5: ...Engineers CIBSE TM13 All Codes of Practice draw attention to the design and operation of water systems with reference to avoidance of factors that favour colonisation by Legionellae bacteria These factors include stagnation lukewarm conditions 20ºC to 45ºC and the accumulation of debris scale and corrosion in the base of tanks and calorifiers Andrews Water Heaters has commissioned an independent e...

Page 6: ...r Orifice Diameter mm 2 95 3 05 3 86 3 86 4 22 in 0 116 0 120 0 152 0 152 0 166 Flue Size Secondary mm 100 100 100 125 125 in 4 4 4 5 5 Cold Water Feed Connection R in BSP Exl 1 1 1 1 11 4 Hot Water Flow Connection R in BSP Exl 1 1 1 1 11 4 Return Connection Rp in BSP Int 3 4 3 4 3 4 3 4 3 4 Drain Port Size R in BSP Ext 3 4 3 4 3 4 3 4 3 4 Max Working Pressure bar 10 3 10 3 10 3 10 3 10 3 lbf in2 ...

Page 7: ...138 N A Gas Injector Orifice Diameter mm 2 40 2 58 3 25 3 18 N A 3 26 Auto Ignition in 0 094 0 101 0 127 0 125 N A 0 128 Flue Size Secondary mm 150 150 200 200 250 250 in 6 6 8 8 10 10 Cold Water Feed Connection R in BSP Exl 11 2 11 2 11 2 11 2 11 2 11 2 Hot Water Flow Connection R in BSP Exl 11 2 11 2 11 2 11 2 11 2 11 2 Return Connection Rp in BSP Int 3 4 3 4 3 4 3 4 3 4 3 4 Drain Port Size R in...

Page 8: ...the draught diverter to the top of the water heater using the location holes In some cases it may be necessary to drill the fixing holes in the top cover to fit the draught diverter to the water heater By using the draught diverter as a template position carefully over the flueway and mark the hole positions to be drilled 4mm Fit the adaptor socket 2 and caulk into the draught diverter as shown in...

Page 9: ...e heater is in an exposed position and out of use during a period of heavy frost it is recommended that the whole system is drained down to prevent damage due to the formation of ice inside the storage vessel THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL MUST ONLY BE USED WITH NATURAL GAS The installation of the gas supply must conform depending on it s size to the requirements of British Stand...

Page 10: ...a 220 240V 1Phase supply The fuse rating is 5 amps The method of connection to the mains electricity supply should facilitate complete electrical isolation of the appliance preferably by use of an unswitched shuttered socket outlet in conjunction with a fused three pin plug both complying with the requirements of BS 1363 Alternatively a fused double pole switch or fused spur box serving only the h...

Page 11: ...11 INSTALLATION SECTION 3 Standard Range Hi FloRange Fig3a Fig3b ...

Page 12: ...erials and fittings shall be asbestos free robust durable corrosion resistant and non combustible and shall comply with BS 5854 and BS 715 or BS 4076 as appropriate as well as being of a type accepted by the Local Gas Authority When passing up through or adjacent to combustible materials measures shall be taken to prevent the temperature of the combustible material from exceeding 60ºC 150ºF The fl...

Page 13: ...te evacuation of the flue products from the installation Where one flue is to be used more regularly or for longer periods than the others in the group it should be connected at the point nearest to the main flue See BS 6644 Clause 20 for further information and recommendations on this as well as general flue requirements Fit a flue clip or flange joint close to the diverter so that it is secure b...

Page 14: ...f 7kW net for installations up to 54kW net For installations exceeding 60kW the following permanent ventilation is required Low Level inlet 540cm2 plus 5cm2 per kilowatt in excess of 54kW total net input High Level outlet 270cm2 plus 2 5cm2 per kilowatt in excess of 54kW total net input Where the heater is to be installed in a compartment permanent air vents are required in the compartment at high...

Page 15: ...e heater s in the event of failure of either the inlet or extract fans The requirements for air supply by mechanical ventilation are given in BS 6644 Clause 19 3 and IGE UP 10 Pt 1 The permanent air vents shall be sited away from any extract fans Where an extract fan is fitted check for spillage at the draught diverter as detailed in BS 5440 Part 1 Appendix B It may be necessary to increase the ve...

Page 16: ...scale formation can occur in hot water systems and hot water heaters and the higher the temperature and volume of water used the more problematic the scale build up can be Water treatment is normally recommended when the hardness reaches 100 150ppm 7 10 degrees Clark and above This problem can be minimised by reducing the water temperature in the heater and by fitting suitable water pre treatment ...

Page 17: ...erformance System incorporated in the cold inlet dip tube The tube is designed to increase turbulence and reduce sediment build up reduce thermal stacking and increase delivery Mini Hydrojet Inlet Nipple Side Cold Inlet Connection All models now incorporate the new Mini Hydrojet system on cold inlet side connections This system ensures water is directed onto the tank base which minimises sediment ...

Page 18: ...ter feed and hot water outlet to these nipples with union adaptors for ease of servicing CAUTION DO NOT APPLY HEAT TO THESE NIPPLES IF MAKING CAPILLARY SOLDERED JOINTS AS THEY ARE FITTED WITH PLASTIC INSERTS MAKE THE CAPILLARY JOINTS TO THE PIPES BEFORE CONNECTING TO THE HEATER A DRAIN COCK IS SUPPLIED WITH THE HEATER AND THIS SHOULD BE FITTED TO THE APPROPRIATE BOSS AS SHOWN ON THE DRAWING After ...

Page 19: ...19 INSTALLATION SECTION 3 Fig 6A Fig 7 ...

Page 20: ...ve cold inlet hydrojet nipple and replace with 11 2 nipple supplied in fittings pack 3 Fit correx anodes into front hot and cold water connections using tees and bushes If top water connections of heater are to be used dependent on model type cap off front connections with blanking caps see Figs 1 and 2 on page 21 Note leave existing magnesium anodes in position 4 Fix potentiostat to heater casing...

Page 21: ...wered anodes E048 1 Potentiostat E010 2 11 2 BSP Sq tees C856 2 11 2 x 3 4 BSP Red Bushes C857 1 11 2 Nipple C534 1 Earth Strap E049 1 Envelope containing spade and ring terminals fixing clamps clips Earth return connection using earth strap Potentiostat 240V Permanent supply Output lead anode connections Remove hydrojet nipple and replace with 11 2 nipple supplied in fittings pack Fit correx anod...

Page 22: ...arked on the components are pointing in the direction of flow i e towards the water heater The cold water for services may be drawn from the 22mm compression port on item D1 a The water pressure at this point will be similar to that available at the hot water outlet of the water heater If port a is not used it should be sealed with the blanking plug supplied If higher flow rates are required for t...

Page 23: ...23 INSTALLATION SECTION 3 WATER CONNECTIONS Fig 9 Fig 10 ...

Page 24: ...hot location required i e top inlet outlet or front inlet outlet and using a suitable jointing compound blank off the two ports not required All Models Front inlet outlet water connections Models 32 143 Optional rear inlet outlet water connections Assemble onto the 3 4 BSP thread the 3 4 BSP coupler socket 1 and drain cock using a suitable jointing compound Select the Cold Hot location required an...

Page 25: ...izes are shown on page 5 Automatic Air Vent 32 143 62 341 54 418 54 440 Front Cold Inlet Hot Outlet All Models Drain Secondary Return Tapping Optional Rear Cold Inlet Hot Outlet Tappings 32 143 only T P Valve Tapping Optional Top Cold Inlet Hot Outlet on models 65 173 81 264 ...

Page 26: ...26 INSTALLATION SECTION 3 WATER CONNECTIONS Fig 13 Fig 14 ...

Page 27: ... can be used on unvented hot water storage systems with the addition of an Unvented Systems Kit part number B172 available from Andrews Water Heaters See Parts List Page 51 The Wall Mounting Assembly is available as an optional extra Item C4 must be fitted into the temperature relief port in the water heater tank When assembling items C1 and C2 ensure that the flow arrows marked on the components ...

Page 28: ...oved Document G3 All fittings and materials must be suitable for use with drinking water and listed in the current Water Research Centre Materials and Fittings Directory Installation of unvented hot storage water systems must comply with Part G of Schedule 1 of the Building Regulations 1991 Typical water service layout for Hi Flo Range single heater unvented system is shown in Fig 16 Typical water...

Page 29: ...29 INSTALLATION SECTION 3 WATER CONNECTIONS Fig 17 Fig 18 ...

Page 30: ...it for 3 minutes for any unburnt gas to vent 2 Turn the gas control knob to pilot 3 Fully depress the gas control knob and the piezo igniter With the pilot burner alight hold gas control knob in for 20 seconds When gas control knob is released the pilot should remain lit If not repeat this operation 4 Close and refit covers 5 Set temperature indication dial to required temperature as follows Setti...

Page 31: ... for 3 minutes before relighting Checking Main Burner Pressure 1 Turn burner OFF as above 2 Remove brass cap from pressure adjustment port 3 Release bleed screw A one turn and connect pressure gauge tube 4 Light burner according to the preceding instructions 5 Adjust burner pressure at screw B in accordance with data plate Turn screw clockwise to increase pressure and counterclockwise to decrease ...

Page 32: ...ot remains lit If not turn off then wait 3 minutes before repeating from step 2 Observe via the view port 5 Turn control knob to ON and turn control thermostat dial to required water temperature The burner will now light 6 Check pilot and gas connections for soundness with leak detection fluid whilst burner is alight Turn off seal any leakages then re test WARNING if pilot goes out do not attempt ...

Page 33: ...to OFF 2 Release bleed screw A and connect pressure gauge tube 3 Light burner as described above 4 Remove valve cap from port B and adjust pressure using exposed screw in accordance with data plate Turn screw clockwise to increase pressure and counterclockwise to decrease If possible check gas rate see Technical Data with meter and watch Refit valve cap to port B 5 Turn gas control to PILOT Remove...

Page 34: ...st Shutting OFF burner To shut OFF the burner move switch to OFF then turn OFF the gas service cock The water heater should only be turned OFF for long periods eg holidays or in an emergency Otherwise the heater should be left to operate under normal thermostat control NB When using a time control ensure the heater is not turned OFF before the final water draw off occurs This will ensure the water...

Page 35: ...ect pressure gauge tube See Fig 24 3 Light burner as described previously 4 Remove cap from port B and adjust pressure using exposed screw in accordance with data plate See Fig 24 5 Shut OFF burner as described previously Remove pressure gauge tube and tighten bleed screw A 6 Re light burner as described previously B A ...

Page 36: ...ds only 7 days or more move electrical ON OFF switch to OFF then turn gas control knob to OFF Turn off gas service cock For shorter periods leave heater under thermostat control Checking Main Burner Pressure 1 Turn gas control knob to OFF 2 Release bleed screw A and connect pressure gauge tube 3 Light burner as described previously 4 Remove valve cap from port B and adjust pressure using exposed s...

Page 37: ...g and testing has been achieved hand this manual to the User or Purchaser and explain the method of economic and efficient operation Explain that 1 Other than for long shutdown periods the heater must be left operating normally 2 It is important that the control thermostat is set at the lowest temperature consistent with the user s needs Ensure that the user or purchaser is fully conversant with t...

Page 38: ...nguished Wait at least 5 minutes to allow for any unburnt gas to disperse Ventilate the area if possible FOR YOUR SAFETY IF YOU SMELL GAS 1 Turn off gas supply and open windows 2 Do not operate electrical switches 3 Extinguish any naked flames 4 Contact gas supplier if the smell of gas persists FOR YOUR SAFETY Do not store or use petrol aerosol or other flammable vapours or liquids in the vicinity...

Page 39: ...perating Sequence Hi Flo and Standard Range 1 When the control thermostat senses too cool water a signal is sent to the control sequence unit 2 The flue damper unit is de energised and thus allowed to open Hi Flo only 3 When the flue damper is fully open gas is allowed to pass to the pilot and simultaneous ignition begins Hi Flo only 4 When the pilot flame is established the main gas solenoid is a...

Page 40: ... main jet Remove main jet and clean with acetone Blow through main burner with compressed air CLEAN ORIFICES WITH WOOD SPLINTER DO NOT USE SHARP METALLIC OBJECTS 6 Re assemble in reverse order of steps 2 5 but note i Be sure to engage rear section of main burner supply pipe in it s location bracket on base pan of heater ii DO NOT OVERTIGHTEN THE THERMOCOUPLE CONNECTION SCREW IN FINGER TIGHT THEN T...

Page 41: ...Inspect and clean secondary flue installation as necessary 4 Lift out baffle from inside central flue way not Model 84 87 5 Clean flue way with a brush and remove deposits from underside of storage vessel and from flue baffle 6 Re assemble in reverse order Be sure to engage rear section of main burner supply pipe in it s location bracket on base pan of heater DO NOT OVERTIGHTEN THE THERMOCOUPLE CO...

Page 42: ...ain and flush out heater for 20 minutes minimum 9 Replace anode s 10 Restore gas supply and re light heater IMPORTANT Remove CorrexTM anode s if fitted and plug off the connections using 3 4 BSP plugs Hi Flo models only Re fit the CorrexTM anode s when the descaling operation is complete Magnesium sacrificial anode s is are fitted to the top of the storage vessel The anode s will prevent corrosion...

Page 43: ...s between the gas cock union and the control valve to burner manifold must be made using an approved jointing compound suitable for natural gas The gas valve must be fitted so that it is square relative to the centre line of the injectors 8 Re commission the heater as detailed in Section 4 Commissioning NOTE These instructions apply to all models but Model 32 143 is not fitted with a limit sensor ...

Page 44: ...nd seal any leakages DO NOT EXAMINE WITH A NAKED FLAME 10 Re light the heater and set thermostat to user s requirements NOTE Models 62 341 54 418 and 54 440 are fitted with an anchor bracket between the burner manifold and the heater body Remove two screws to release the anchor bracket 1 Turn off the gas control and the service cock Disconnect union joint on service cock 2 Disconnect thermostat co...

Page 45: ... thermopile and ECO connections Replace if necessary c Check if inlet gas pressure is too high or too low Pressure to multifunctional control should be 17 mbar 7in WG to 25 mbar 10in Wg d Pilot jet blocked Clean or replace pilot jet e Faulty magnet coil Replace multifunctional control f ECO safety thermostat operating at too low a temperature Replace faulty control BURNER WILL NOT a Thermostat set...

Page 46: ...nlet to heater c Thermostat faulty Check and replace if necessary NOT ENOUGH a Check gas pressures at burner and at gas inlet to heater HOT WATER b Check amount of water being used against recovery rate given on data plate If usage too high more heating capacity needed WATER DRIPPING a Check if this stops when water in heater is hot If yes then FROM BASE OF condensation is the problem caused by in...

Page 47: ...ock is open IGNITION NO b Check gas control knob is ON PILOT FLAME c Check ECO for failure PILOT LIGHTS BUT a Main gas valve not energised opal light is on Check for MAIN BURNER loose contacts DOES NOT b Check for 24V AC at intermittent pilot ignition control terminal No 3 Replace control if faulty c Check for 24V AC at main gas valve terminals Replace valve if faulty FLUE DAMPER a Faulty damper u...

Page 48: ...STANDARD Model 84 87 A12 A4 C1 A13 A14 C5 C4 A8 A9 B11 B2 B3 B5 B7 B12 B1 C3 B13 B6 B8 B9 A10 A2 A12 A3 A1 B10 B4 B6 A15 A7 C2 A6 C3 A16 A16 63 62 only 63 62 only A1 A3 A5 A2 A1 A12 A4 C1 A2 A11 A13 A14 A15 C3 A9 A8 C8 A6 A7 A9 A8 A10 B1 B7 B13 B12 B11 B5 B2 B3 B9 B6 B8 B4 B6 B10 A16 ...

Page 49: ...A C301 C301 Cleanout Pad Cover 1 A16 C247 C247 C247 C247 Nipple 3 4 NPT x 3 4 BSP 1 A16 C247 Nipple 3 4 NPT x 3 4 BSP 2 B1 E145 E146 E147 E148 E003 Burner Assy comprising 1 items B2 B3 B5 B7 B12 B2 C405 C406 C406 C407 C407 Pilot Supply Pipe 1 B3 C993 C994 C994 C996 C997 Burner Supply Pipe 1 B4 C965 C965 C965 C966 C974 Multifunctional Control 1 B5 C684 C684 C684 C684 C684 Thermocouple 1 B6 C136 C13...

Page 50: ...46 Hi Flo Model 32 143 Hi Flo Models 65 173 and 81 264 50 PARTS LIST AND ILLUSTRATIONS SECTION 9 ...

Page 51: ...34 Nipple 1 1 2 BSP 4 A20 E050 E050 E050 Hydrojet Cold Inlet Connection 1 side 1 1 2 BSP B1 E031 C537 C541 Burner Assy comprising items 1 B2 B6 and B8 B9 B2 C503 C503 C503 Burner Bar 5 B3 C505 C505 C505 Burner Manifold 1 B4 E017 E552 Injector 2 69mm P P 2 40mm A I 5 B4 C538 E551 Injector 2 87mm P P 2 58mm A I 5 B4 C542 E553 Injector 3 66mm P P 3 25mm A I 5 B5 C507 C507 C507 Pilot Assy c w injector...

Page 52: ...52 PARTS LIST AND ILLUSTRATIONS SECTION 9 Hi Flo Models 62 341 and 54 418 440 ...

Page 53: ... 2 BSP 4 A20 E050 E050 Hydrojet Cold Inlet Connection 1 side 1 1 2 BSP B1 C544 C549 Burner Assy comprising items 1 B2 B6 and B8 B9 B2 C503 C503 Burner Bar 7 9 B3 C545 C550 Burner Manifold 1 B4 C546 E550 Injector 3 45mm P P 3 18mm A I 7 C551 Injector 3 60mm P P 9 E549 Injector 3 26mm A I 9 B5 C507 C507 Pilot Assy c w injector and electrode 1 B6 C547 C547 Pilot Supply Pipe 1 B7 C252 C252 Pilot Injec...

Page 54: ...54 PARTS LIST AND ILLUSTRATIONS SECTION 9 Unvented Systems Kit Hi Flo Range Unvented Systems Kit Standard Range ...

Page 55: ...alve 1 D5 C783 Tundish 1 D6 C772 Adaptor 1 B173 Wall Mounting Kit for Expansion Vessel D7 Hose Assembly 1 D8 Wall Bracket Assembly 1 Unvented Systems Kit Hi Flo Range Ref Part No Description Qty B172 Unvented Systems Kit Complete 1 C1 C784 Pressure Reducing Valve Strainer 1 C2 C785 Check Valve 1 C3 C782 Expansion Vessel 1 C4 C380 Temperature Pressure Relief Valve 1 C5 C384 Tundish 1 C6 C786 Expans...

Page 56: ...56 PARTS LIST AND ILLUSTRATIONS SECTION 9 24 Volt Auto System Kit B258 24 Volt Auto System Kit B217 ...

Page 57: ...lt Gas Valve 1 E126 24 volt Solenoid Coil 2 E127 Pilot Assembly nat gas 1 E128 Ignition Flame Probe 1 E135 HT Lead 24 1 24 Volt Auto System Kit Standard Range Part No Description Qty 1 t i K m e t s y S o t u A t l o V 40 2 8 5 2 B E839 Pilot assembly 1 C521 On Off Switch 1 C531 Label Andrews 1 C644 Label Warning 1 C989 Label On Off 1 Label Wiring 1 Z090 Gas Control Valve 1 1 d r a o b t i u c r i...

Page 58: ...control board with plug in wiring controls temperature ignition and flue damper operation Reduced number of parts for servicing and wiring Plug in wiring reduces chance of miswiring Water heater display will show diagnostic codes in the event the water heater needs servicing Aids in diagnosing and servicing the water heater Water heater display can show up to 10 previous error codes in the service...

Page 59: ...5 ohms resistance at 70 deg F Sensor inside well for lower sensor Some models use an additional upper sensor w o well with same resistance values Control Board Honeywell Integrated Control Board for Temperature Control Flue Damper and Ignition Control Functions Operates on 24 volts AC current from transformer Some models use single sensor boards others use two sensors Control Display Honeywell LCD...

Page 60: ...ilot flame The control board constantly monitors pilot flame through the flame sensor rod If pilot flame is lost pilot and main burners are shut down After a 65 second inter purge period the control will attempt to re light the pilot beginning at sequence 3 above 7 Main burner fires until the thermostat is satisfied The control board interrupts 24 volts through the damper and the gas valve circuit...

Page 61: ...mper begin to open Increase thermostat setting if tank is warm and make sure the control display status reads Heating Check wire connections of board to display See illustration With the control cover tilted down measure the voltage between red and black wire pin connections to display Voltage should be 24 volts AC measured at the back of the Control Display If no voltage at Display check wire har...

Page 62: ...ode and displaying temperature sensors Error code 63 on display See Main Burner Short Cycles Does the flue damper rotate to the fully closed position Error code 56 on display Check for debris limiting damper rotation If no debris replace damper System okay Damper vane show in open position If damper is closed disconnect from harness and REMOVE damper from water heater Harness shown disconnected fr...

Page 63: ... 3 seconds until Max Setpoint is shown in the display Step 2 Pressing Select button will change display to next mode SELECT SET Status F idle Operational Water Temp The following is the sequence of modes available in Service Mode by pressing the Select button Error Code Number Display Reset This is only shown if there is an operating error in the User Mode Max Setpoint SELECT SET Statu s idle Oper...

Page 64: ...le Water Temp Operational 2b Water Temperature Upper Sensor Displays if there is an upper sensor some models SELECT SET Status F idle Operational Upper Sensor 2c Water Temperature Lower Sensor Displays if there are two sensors SELECT SET Status F idle Operational Lower Sensor SELECT SET Status F idle Operational Max Setpoint value in Water Heater Display Max Setpoint Page 10 Troubleshooting ...

Page 65: ...Operational Flame Current ȝA 4 Setpoint Display Change SELECT SET Status F idle setpoint Operational 5 F C Display Change SELECT SET Status F C idle Operational F setpoint 6 Differential Display only shows the differential of the thermostat SELECT SET Status F idle Differential Operational Page 11 Troubleshooting ...

Page 66: ... setpoint Step 1 In service mode press the Select button until Max Setpoint is displayed SELECT SET Status F idle Max Operational Setpoint Page 12 Troubleshooting WARNING Setting the water temperature to the maximum set point can result in scalding hot water delivered to the taps It is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the ...

Page 67: ...imum setpoint value This will limit the maximum setpoint the user can select Note The maximum setpoint is approximately 180 F Step 4 Press Set button to confirm new Max Setpoint value and stop setting mode Page 13 Max Setpoint stops flashing SELECT SET Status F idle Operational Max Setpoint SELECT SET Status F idle Operational Max Setpoint Max Setpoint continues to flash while making adjustments T...

Page 68: ... 1 In Service Mode Press the Select button until Water Temp is displayed in the upper right section of the water heater display For water heaters using two temperature sensors in the tank this will be the average reading between the two sensors For water heaters using a single sensor this is the reading for the sensor Step 2 For water heaters using two temperature sensors pressing the Select butto...

Page 69: ...le only when the burners are in operation Step 1 Make sure the status displays Heating or draw enough hot water to start the burners Step 2 Enter the Service Mode described previously Step 3 Press the Select button until a number value is displayed with Flame Current to the right of the number The value displayed is in microamps ȝA SELECT SET Status Operational Flame Current Heating ȝA To Display ...

Page 70: ...nt Operational Setpoint Flashes Troubleshooting WARNING Setting the water temperature to the maximum set point can result in scalding hot water delivered to the taps It is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the installation Make sure the water heater control display is not in a public area that can result in the temperature ...

Page 71: ... Display and Change Temperature Format F C To Change Temperature Format in Display from F to C or C to F Step 1 While in Service Mode press Select button until F C is shown in the upper right portion of the water heater display SELECT SET Status idle Operational F F C Step 2 Press Set button to change temperature format F C symbol will flash in the water heater display SELECT SET Status idle Opera...

Page 72: ...ECT SET Status idle Operational C F C Step 3b Press Temperature Down button to change temperature format to F SELECT SET Status idle Operational F F C Step 4 Press Set button to confirm F or C format F C will stop flashing SELECT SET Status F idle Operational F F C Page 18 Troubleshooting ...

Page 73: ...this Service Manual explains the error codes with corrective actions to repair the water heater Example of Error Code in the Display Error Code History In Service Mode pressing the Select button after the Software Version item 8 in the previously described sequence of service modes will show an error code history if there have been any previous operating problems with the water heater If the displ...

Page 74: ...ect the error code index starting with the most recent error code 10 SELECT SET Status idle Operational Step 3 Press the Select button to view the error code for code 10 If there is a number displayed note what the number is The label next to the water heater display will identify the code number If no number is displayed with only a in the water heater display then there has not been an error cod...

Page 75: ...ew the error code number if any for that index number Continue on to index 1 the oldest error code index The water heater display will store up to 10 error codes with the oldest code starting in code index 1 with the most recent code in code index 10 Step 7 10 seconds after the last button press the Water Heater Display will revert back to the current error code display To exit Service Mode either...

Page 76: ... the water heater display with Service Needed shown below the error code number Note the error code and the definition in the chart below This label appears on the control box under the water heater display The following sections will provide instructions for servicing each error code Page 22 Troubleshooting ...

Page 77: ... control will also go through 3 attempts to relight the burners every hour in the soft lockout condition All other error codes will put the water heater into a Hard Lockout condition in which the water heater will not operate and cannot be reset in the User Mode To reset a hard lockout first enter the Service Mode described earlier by pressing both the Temperature Up and Select Buttons at the same...

Page 78: ...sing your hands or tools Turn power OFF Draw water to cool tank below 120 deg F Check lower sensor Is the sensor fully inserted into the well Sensor is held in place with a clip fastened to the well see photo 9 Check lower sensor wire making sure it is not damaged or has breaks in the wire insulation Check upper harness wires to upper sensor if used some models If sensor clip is damaged replace cl...

Page 79: ...en corrected Once cause of overheating condition has been diagnosed and corrected the control may be reset Reconnect and switch on power to the water heater Enter service mode on the water heater display see illustration Press button under Lockout Reset and hold for 3 seconds Set thermostat to the desired setting Water heater should start Monitor temperatures for one complete heating cycle making ...

Page 80: ...ermostat Circuit Testing Upper thermister location applicable models Lower thermister access located inside control box Sensor Resistance Testing Upper Sensor 1 Determine resistance value of upper sensor Test across grey wires 2 Draw quart of water off T P valve Using a thermometer determine water temperature 3 Use table below to verify correct resistance per water temperature measured Lower Senso...

Page 81: ... during this test Tighten pilot tube connection at the gas valve Check incoming gas pressure to water heater if okay replace gas valve Check for clogged or kinked pilot tube clogged pilot orifice Clean or replace as needed see Pilot Burner Inspection Is there 22 27 volts AC input across wire leads MV PV PV yellow red wires at Gas Valve see photo 12 Check wire harness for damage or loose connection...

Page 82: ...to see if pilot shield is touching pilot flame sensor or flame sensor touching pilot hood Bend shield to prevent interference or replace pilot shield Check pilot flame sense wire for broken insulation Replace pilot if defective Reinstall pilot and burner assembly Reconnect gas line union turn on gas Make sure pilot shield clears flame sense rod Check for Gas Leaks Page 28 Reconnect power and verif...

Page 83: ...ity of wires with ohmeter Are ground wires okay Check for loose or damaged flame sense lead from pilot to Control Board see illustration to the right Is flame sense lead okay Repair wire lead or replace pilot Repair ground wire s or replace as needed NOTE Check continuity of sense lead to flame rod If no continuity clean pilot flame rod or replace pilot Check pilot flame appearance if weak check f...

Page 84: ... brown wire lead from MV terminal of gas valve Is there 22 27 volts AC across brown wire lead ground see photo 15 Replace control board Be sure control display is showing Heating pilot is lit and control is not sparking Recheck voltage across control board pin terminals 5 8 MV MV PV Is voltage present Check wire harness for damage or loose connections Repair or replace as needed Check incoming gas...

Page 85: ...tion Instructions N Check burner tubes for scale or debris build up Clean burner as necessary see Main Burner and Pilot Removal and Inspection Check tank flues for blockage or debris build up causing restriction see Flue Baffle Removal Inspection Check for unstable pilot flame or oxidation of the flame rod on pilot causing weak pilot signal Make sure pilot shield is in place and does not touch pil...

Page 86: ... Step 8 Slide complete burner rack out from heater see photo 19 Step 9 To install burner reverse above procedure Step 10 Check for gas leaks and verify proper operation Gas Valve Control Knob Gas Supply Line Gas Valve Wire Leads Burner Rack Mounting Screw Main Burner Inspection Step 1 Burner tubes should be free of any flue scale or other debris Clean burner tubes using a stiff brush and or shop v...

Page 87: ...ng Screws Ground Wire Location Pilot Burner Inspection Step 1 Inspect pilot for the following a Broken or cracked ceramic insulators If found pilot must be replaced b Damaged electrode or flame sense wire If found pilot must be replaced c Oxidation build up on flame rod Clean flame rod or replace pilot as necessary Step 2 Inspect pilot orifice a Remove 7 16 ferrule nut from bottom of pilot b Remov...

Page 88: ...p 2 Unplug wire connections from board Pull out sensor Remove clip Wire connections DANGER 120 volt exposure To avoid personal injury unplug while performing this procedure Page 34 23 25 24 26 Step 3 To remove board tilt control panel to the right and slide control hook tabs from slots in control panel IMPORTANT When replacing lower sensor make sure sensor is fully inserted into the well and secur...

Page 89: ...Step 8 Remove collector cover from water heater by using pipe wrench as illustrated in photo 30 Step 9 Remove flue baffles from water heater Note it may be necessary to use pliers to loosen and remove baffles from flue tubes see photo 31 Step 10 Visually inspect flue baffles Flue baffles may show signs of oxidation this is normal If the oxidation has deteriorated any portion of the flue baffle rep...

Page 90: ...node locations Step 10 Remove screws from side or top of collector cover Note it may be necessary to chisel away some foam to access screws see photo 34 Step 11 Locate and remove anode rods from top of water heater 1 1 16 hex socket Note anodes located outside of the collector see photo 35 may require foam to be chiseled away to access anode rods see next page for approx anode locations Step 12 Vi...

Page 91: ...ES 20A 14A 15A 5A 13A 16A 4A 3A 6A 11A 12A 9A 10A 8A 7A 2A 1A 19A 18A 17A 2 3 5 4 30 6 28 29 27 19 23 26 25 22 21 20 15 15A 16 16A 17 17A 18 14 13 12 10 11 1 9 24 8 7 See description and part number table overleaf ...

Page 92: ...oard S9360B1010C 3b Z138 3b X Control Board T Stat Board S9360B1015C 3b Z139 3b X X X X Control Display 1B Z140 1b X X X X X Transformer 230V 24V 13c Z141 13c X X X X X Sensor Well 23 Z142 23 X X X X X Main Power On Off Switch 7b Z143 7b X X X X X Damper 6 Effikal PCF Series 5 Z144 5 X X X Damper 8 Effikal PFC Series 5 Z145 5 X Damper 10 Effikal PCF Series 5 Z146 5 X Gas Valve VR8601CB1012 4a Z090...

Page 93: ...93 Notes ...

Page 94: ...94 Notes ...

Page 95: ...95 Notes ...

Page 96: ...i Commercial Wood Lane Erdington Birmingham B24 9QP Email andrews baxicommercialdivision com www andrewswaterheaters co uk ublication Date OCT2013 Sales 0845 070 1056 Technical 0845 070 1057 0087 RS 33961 ...

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