andrews 24/39 Installation And Service Manual Download Page 6

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Issue 2 14/07/16

General and Safety Information

1 General and safety information

1.1 General information

The Andrews Water Heater has been designed for use with

NATURAL GAS only and is manufactured to give an efficient,

reliable and long service life.

To ensure the continued, trouble-free operation of your heater at

maximum efficiency, it is essential that correct installation,

commissioning, operation and service procedures are carried

out strictly in accordance with the instructions given in this

manual. By law, installation and commissioning of the heater

must be carried out by properly qualified personnel.

The heater(s) must be installed in accordance with the following

requirements;

The current GAS SAFETY (INSTALLATION AND USE)

REGULATIONS

The current BUILDING REGULATIONS

The Water Supply (WATER FITTINGS) REGULATIONS 1999

Additionally, installation should be performed in accordance with

all relevant requirements of the Gas Supplier, Local Authority

and recommendations of the British Standards and Codes of

Practice detailed below.

1.2 British standards and codes of practice

1.2.1 Standard Range & Hiflo Range

BS 6700:

Specification for design, installation, testing

and maintenance of services supplying water

for domestic 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:

Specification for installation of flues.

Part 2:

Specification for installation of ventilation for

gas appliances.

BS 5546:

Installation of gas hot water supplies for

domestic purposes.

BS 6891

Installation of low pressure gas pipework of up

to 28mm in domestic premises.

BS 7206:

Specification for unvented hot water storage

units and packages.

Summary of Contents for 24/39

Page 1: ......

Page 2: ...lth and Safety Regulations 1993 All installation and service on Andrews Water Heaters 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 Andrews Water Heaters policy is one of continuous product improvement and therefore the information in this manual whilst comple...

Page 3: ...ex powered anodes 3 9 4 To install kit 3 9 5 Test the installation 3 9 6 Unvented systems standard range 3 9 7 Vented systems Hiflo range 3 9 8 Unvented systems Hiflo range 4 Commissioning 4 1 Standard range permanent pilot models 4 1 1 Lighting the burner 4 1 2 Shutting off the burner 4 1 3 Checking main burner pressure 4 2 Hiflo range permanent pilot models 4 2 1 Lighting the burner 4 2 2 Shutti...

Page 4: ...ls 8 3 Auto ignition units standard range 8 4 Auto ignition units Hiflo models 8 5 Checking correx anodes 8 6 LPG permanent pilot models LPG HIflo ranges 9 Parts list and illustrations 9 1 Standard Range models 24 29 32 40 40 61 63 62 Natural Gas 9 2 Standard Range models 84 87 Natural Gas 9 3 Standard Range models parts list Natural Gas 9 4 Standard Range LPG models L24 31 L32 35 L40 36 L63 71 9 ...

Page 5: ...ckout conditions 10 5 Service procedure D24 I 10 5 1 Thermostat circuit testing 10 5 2 Sensor resistance testing 10 5 3 Sensor resistance at various temperatures 10 6 Service procedure D24 II 10 6 1 Pilot operation testing 10 6 2 Pilot inspection 10 6 3 Pilot operation testing 10 7 Service procedure D24 III 10 7 1 Main burner operation testing 10 7 2 Checking manifold pressure 10 8 Service procedu...

Page 6: ...9 Additionally installation should be performed in accordance with all relevant requirements of the Gas Supplier Local Authority and recommendations of the British Standards and Codes of Practice detailed below 1 2 British standards and codes of practice 1 2 1 Standard Range Hiflo Range BS 6700 Specification for design installation testing and maintenance of services supplying water for domestic u...

Page 7: ...f rated inputs between 70kW and 1 8MW BS EN 12897 Water supply Specification for indirectly heated unvented closed storage water heaters IGE UP 1A 1B Strength tightness testing and direct purging IGE UP 2 Installation pipework IGE UP 10 1 Edition 4 Installation of gas appliances in industrial and commercial premises IGE UP 10 Pt 1 Edition 2 Installation of Gas Appliances in Industrial and Commerci...

Page 8: ... Health and Safety Executive HS G70 and the Chartered Institute of Building Services 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 Legionella bacteria These factors include stagnation lukewarm conditions 20 C to 45 C and the accumulation of debris scale and corrosion in the b...

Page 9: ...as Volume m3 h 17 18 26 31 37 Gas Injector Orifice Diameter mm 2 95 3 05 3 86 3 86 4 22 Flue Size Secondary mm 100 100 100 125 125 Cold Water Feed Connection R in BSP Exl 1 1 1 1 1 1 4 Hot Water Flow Connection R in BSP Exl 1 1 1 1 1 1 4 Return Connection Rp in BSP Exl 3 4 3 4 3 4 3 4 3 4 Drain Port Size R in BSP Exl 3 4 3 4 3 4 3 4 3 4 Max Working Water Pressure vented bar 10 3 10 3 10 3 10 3 10 ...

Page 10: ... Volume m3 h 16 16 23 28 34 Gas Injector Orifice Diameter mm 1 5 1 6 1 6 2 25 2 25 Flue Size Secondary mm 100 100 100 125 125 Cold Water Feed Connection R in BSP Exl 1 1 1 1 1 1 4 Hot Water Flow Connection R in BSP Exl 1 1 1 1 1 1 4 Return Connection Rp in BSP Exl 3 4 3 4 3 4 3 4 3 4 Drain Port Size R in BSP Exl 3 4 3 4 3 4 3 4 3 4 Max Working Water Pressure vented bar 10 3 10 3 10 3 10 3 10 3 Max...

Page 11: ...r Orifice Diameter mm 2 40 2 58 3 25 3 18 N A 3 26 Permanent Pilot Flue Size Secondary mm 150 150 200 200 250 250 Cold Water Feed Connection R in BSP Exl 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 Hot Water Flow Connection R in BSP Exl 1 1 2 1 1 2 1 1 2 11 2 1 1 2 1 1 2 Return Connection Rp in BSP Exl 3 4 3 4 3 4 3 4 3 4 3 4 Drain Port Size R in BSP Exl 3 4 3 4 3 4 3 4 3 4 3 4 Max WorkingWaterPressure ve...

Page 12: ...1 85 1 78 1 78 Flue Size Secondary mm 150 150 200 200 250 Cold Water Feed Connection R in BSP Exl 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 Hot Water Flow Connection R in BSP Exl 1 1 2 1 1 2 1 1 2 11 2 1 1 2 Return Connection Rp in BSP Exl 3 4 3 4 3 4 3 4 3 4 Drain Port Size R in BSP Exl 3 4 3 4 3 4 3 4 3 4 Max WorkingWaterPressure vented bar 10 3 10 3 10 3 10 3 10 3 Max WorkingWaterPressure unvented bar 5 5 ...

Page 13: ...les for which the water heater is suitable to use and the corresponding water heating energy efficiency and annual electricity consumption 3 Thermostat temperature setting C 65 60 65 60 Sound power level LWA indoors dB 47 49 47 49 Ability to off peak hours functioning 3 Enables smart control settings 4 1 Electricity 2 Fuel 3 If applicable 4 If smart control settings value is 1 the water heating en...

Page 14: ... with smart controls Qfuel week smart kWh Weekly electricity consumption with smart controls Qelec week smart kWh Weekly fuel consumption without smart controls Qfuel week kWh Weekly electricity consumption without smart controls Qelec week kWh Storage volume V I 114 151 189 284 379 Mixed water at 40 C V40 I 155 271 333 420 916 Harmonised standards applied EN 13203 2 Specific precautions that shal...

Page 15: ...o only 2 11 2in x 3in Nipples 32 143 Model only 3 2 Assembling the draught diverter The draught diverter must be assembled with the legs provided Attach the legs to the draught diverter with the nuts and bolts provided Fit the draught diverter 1 as shown in Fig 1 to the water heater using the screws provided For Standard Range fit the draught diverter to the top of the water heater using the locat...

Page 16: ...for Hiflo and 300mm for Standard Range should be left at the front of the heater for removal of the burner Clearances at the sides and rear of the heater should be at least 305mm Above service clearances for removal of the anodes and flue baffles should be provided as detailed below Standard Range Models 24 39 32 40 40 61 762mm Model 63 62 1143mm Model 84 87 1270mm Hiflo Range Model 32 143 597mm M...

Page 17: ...and Use Regulations 1998 The valve must be easily identified and readily accessible After installation the system should be pressure tested for soundness and purged in accordance with BS 6891 or IM 2 and IM 5 as appropriate 3 4 1 Installation of the LPG supply Fig 3 When using propane or butane cylinders connect a minimum number of cylinders as listed below together with a manifold before connecti...

Page 18: ...lug both complying with the requirements of BS 1363 Alternatively a fused double pole switch or fused spur box serving only the heater may be used The point of connection to the mains electricity supply should be readily accessible and adjacent to the appliance Fig 3a and 3b Connect the electrical supply to the main control panel terminal block via the cable glands in the base of the control panel...

Page 19: ... Main Printed Circuit Board Timer Link Flue Damper Link OFF OFF 0 Gv2 Yellow wires Black Purple Orange Red Green Yellow White H T Flame Detect Earth Return Main Earth Stud Pilot Assembly White Black Yellow Flue Damper 24Vac ECO ECO 1 ECO 2 FD 24V FD 0V FD 2 FD 1 Stat Stat Orange Yellow Yellow 1 2 3 4 Pink 24Vac 24Vac 24 Vac ON OFF Switch Gv1 ON ON LIVE FAN L NEUTRAL FAN N MFF2 MFF1 CH2 CH1 Timer 1...

Page 20: ...bustible materials measures shall be taken to prevent the temperature of the combustible material from exceeding 60 C The flue shall not be closer than 50mm to any combustible material except when passing through when it must be enclosed by a non combustible sleeve and separated from the sleeve by not less than 25mm air space Flues shall be of a size not less than specified in Section 2 Technical ...

Page 21: ...tch exceeding 45 At or above ridge level 1m above roof intersection 1m above roof intersection The base of the terminal should be 600mm above the level of the adjacent roof edge The base of the terminal should be 600mm above the level of the adjacent roof edge 600mm above roof intersection 600mm above roof intersection 250mm above roof intersection Not applicable Pitch not exceeding 45 With parape...

Page 22: ... should be so designed that high velocity air streams do not occur within the space housing the heater s The grilles should have a total minimum free area for the water heater s in addition to any other requirements as follows Where the heater is to be installed in a room the following permanent ventilation is required 5cm2 per kW in excess of 7kW net for installations up to 54kW net For installat...

Page 23: ... 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 ventilation area to compensate for the extract fan 4 The vapours emitted by halogen based compoun...

Page 24: ...CorrexTM anode features an indicator light which shows green to indicate correct function and red to indicate malfunction An additional CorrexTM BEMS version is available which provides a remote warning signal These anodes are available as an optional extra on all Andrews heaters In hard water areas scale formation can occur in hot water systems and hot water heaters and the higher the temperature...

Page 25: ...0 Fax 01376 340004 SENTINEL PERFORMANCE SOLUTIONS LTD 7650 Daresbury Park Daresbury Warrington Cheshire WA4 4BS Tel 01928 704330 Fax 01928 562070 www sentinelproducts com HYDROTEC UK LTD Hydrotec House 5 Manor Courtyard Hughenden Avenue High Wycombe Bucks HP13 5RE Tel 44 0 1494 796040 Fax 44 0 1494 796049 www hydrotec co uk ...

Page 26: ... and increase delivery Fig 6a The upper jet ports direct the flow outward to being the dynamic mixing action Hydrojet System Fig 6b Tank Heater Casing 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 build up from day one of installation Mini Hydrojet Inlet Nipple Side Cold Inlet...

Page 27: ...lve flush the system and fill the heater Open the hot taps to allow air to escape from the system When the water is free of air close the taps and check for leaks at the gas control thermostat drain cock and the pipe connections at the top of the heater All water connections for Standard Range are shown in Fig 7 Typical water service layout for Standard Range single heater vented system is shown i...

Page 28: ...y 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 requirements of BS1363 A Alternatively a fused double pole switch or fused spur box serving only the heater may be used The point of connection to the mains should be readily accessible and adjacent to th...

Page 29: ...sting the system it is recommended that a maximum test pressure of 8bar is employed Fig 10 The heater can be used on unvented hot water storage systems with the addition of an Unvented Systems Kit part number B171 available from Andrews Water Heaters Item D4 must be fitted into the temperature relief port in the water heater tank D6 Adaptor For use with D4 on heater models 40 61 63 62 84 87 When a...

Page 30: ...ations Typical water service layout for Standard Range single heater unvented system is shown in Fig 11 Typical water service layout for Standard Range multiple heater unvented system is shown in Fig 12 30 Issue 2 14 07 16 3 Installation Fig 11 Fig 12 Terminal Terminal See table page 9 Roof Roof Split flue clamp Split flue clamp Split flue clamp To drain To drain To drain Cold water take off Cold ...

Page 31: ...be observed when installing the system Water draw off dead legs should comply with CP 342 Part 2 Table 1 and BS 6700 Fig 13 Models 65 173 81 264 Optional top inlet outlet water connections Select the cold 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...

Page 32: ...ystems are shown in Figs 15 and 16 Fig 13 Fig 14 All connection sizes are shown on page 5 Optional top cold inlet hot outlet on models 65 173 81 264 T P valve tapping Optional rear cold inlet hot outlet tappings 32 143 only Drain secondary return tapping Front cold inlet hot outlet all models 1 0m Roof Cold water feed Cold water inlet Hot water service Hot water service Safety valve see note Front...

Page 33: ... feed Cold water feed Cold water inlet Cold water inlet Hot water service pipe Hot water service pipe Drain secondary return tapping Drain secondary return tapping Common return Drain secondary return tapping Drain secondary return tapping Common return Open vent Overflow Overflow ...

Page 34: ...itted to the pipework upstream of item C1 The pipework fitted to the tundish outlet should be at least 28mm diameter and should be terminated at a suitable drain 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 Schedul...

Page 35: ... 35 Installation 3 Fig 19 Fig 20 1 0m Roof To drain Common return Cold water inlet Cold water take off Hot water service pipe 1 0m Roof To drain Common return Cold water inlet Cold water take off Hot water service pipe ...

Page 36: ...ould remain lit If not repeat this operation 4 Close and refit covers 5 Set temperature indication dial to required temperature as follows 6 Turn the gas control knob to ON and the burner should light If not wait for at least 3 minutes and repeat from step 1 4 1 2 Shutting Off The Burner For long periods only 7 days or more turn gas control knob to PILOT depress slightly and turn clockwise to OFF ...

Page 37: ...ntrol knob to PILOT position 3 Depress knob and activate piezo igniter 4 Keep knob pressed in for a further 40 seconds after pilot lights then release knob and check that pilot 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 Che...

Page 38: ...flame No adjustment is provided for the pilot The restrictor C on the gas control see Fig 24 should be turned fully counterclockwise to the fully open position When viewed from the front of the heater the pilot flame should appear as shown in Fig 25 4 2 5 Checking for Spillage at the draught diverter If an extract fan is fitted carry out a spillage check as set out in BS 5440 Part 1 Appendix B If ...

Page 39: ...F 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 in the tank is left in a hot condition 4 3 3 Checking main burner pressure 1 Turn gas supply OFF 2 Release bleed screw A and connect pressur...

Page 40: ... to OFF then turn gas control knob to OFF Turn off gas service cock For shorter periods leave heater under thermostat control 4 4 3 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 screw in accordance with data plate 5 Turn scre...

Page 41: ...at any air vents must be kept clear and items must not be placed or stored in the vicinity of the heater Advise of precautions necessary to prevent damage to the heater and systems in the event of the system remaining inoperative during frost conditions Advise the user or purchaser that for continued efficient and safe operation of the heater it is important that magnesium anodes are inspected ann...

Page 42: ...inutes to allow for any unburnt gas to disperse Ventilate the area if possible Warning Hotter water increases the risk of scalding Before changing the temperature refer to instruction manual or data label Hot water can produce third degree burns in 6 seconds at 60 C 30 seconds at 54 C Danger FOR YOUR SAFETY IF YOU SMELL GAS 1 Turn off gas supply and open windows 2 Do not operate electrical switche...

Page 43: ...e ECO This means that once the water has cooled sufficiently the ECO circuit will close and allow the heater to be relit A replacement gas control valve must be an identical model with the same code number 5 2 HIflo Range 5 2 1 Permanent pilot models operating sequence 1 With the pilot lit the solenoid coil holds the inlet gas port on the gas valve open 2 The knob on the gas valve is set to the ON...

Page 44: ...ut and is associated with high water temperature the ECO is probably operational and the cause of overheating should be investigated 5 3 3 Temperature stratification stacking When small amounts of hot water are drawn repeatedly the thermostat responds to each feed of cold water and activates the main burners Each time this occurs more heat may be put back in the tank than was drawn off As this con...

Page 45: ... the gas service cock 2 Turn off the cold water supply to the heater 3 Turn on the hot water draw off taps served by the water heater or for multiple installations turn off the hot water outlet connection valve and secondary return valve 4 Drain down using the drain valve on the heater 6 3 Burner assembly standard range 6 3 1 The burner assembly should be checked and cleaned annually 1 Depress gas...

Page 46: ... Fig 19 Slide inner door to left on Models 63 62 and 84 87 lower the inspection port and turn gas control knob to ON The main burner will light 9 Check main burner connection tube at control valve with leak detection fluid and seal if necessary Replace outer cover 6 4 Burner assembly HIflo Range 6 4 1 The burner assembly should be checked and cleaned annually 1 Turn gas control valve knob to OFF a...

Page 47: ...uirements 6 5 Gas control valve Standard Range The gas control valve should be checked and serviced by a qualified person fully conversant with this item To remove gas control first drain appliance disconnect gas pipe union and turn control anti clockwise taking care not to damage threads knobs or the valve itself 6 6 Gas control valve HIflo Range The gas control valve should be cleaned and checke...

Page 48: ...ed in Section 4 Note The flue ways should be checked and cleaned annually 6 8 Fuel ways HIflo range 1 Remove burner as described in Burner Assembly HIflo Range 2 Remove the split clamp and raise the flue system to clear the draught diverter socket 3 Remove securing screws and remove top cover complete with draught diverter and adaptor ring 4 Remove top insulation and keep safe 5 Remove flue collec...

Page 49: ...ydrochloric acid based descale fluid The requirement is normally 5 litres for Standard Models and 10 litres for HIflo Models or more dependant on amount of limescale present 5 After a minimum of one hour restore gas supply and turn on main gas burner for 2 minutes maximum 6 Isolate gas supply and drain descale fluid through drain port 7 Open cold water feed valve and fill heater tank 8 Drain and f...

Page 50: ...ed with limescale it should be either wire brushed to reveal bright metal or replaced 6 11 Safety valve HIflo models Check the condition and operation of the safety valve as described below During Servicing Examine the safety valve for deposits or let by Clean or replace as necessary When Re Commissioning Operate the safety valve ensuring no let by when the valve is reset and reseated 6 12 Restart...

Page 51: ...injectors 8 Re commission the heater as detailed in Section 4 Commissioning Note Models 62 341 L62 309 54 418 54 440 and L54 399 are fitted with an anchor bracket between the burner manifold and the heater body Remove two screws to release the anchor bracket 7 2 User adjustable control thermostat with limit sensor phial and overheat ECO 1 Turn off the gas control and the service cock 2 Drain the h...

Page 52: ...r and allowing it to fall out 6 Re assemble pilot assembly and connect pilot pipe only to gas control valve with the pilot assembly outside the heater Turn on gas service cock Turn gas control to PILOT and press knob whilst testing pilot connection at gland nut for soundness with leak detection fluid Seal any leakages and re test Turn gas control valve and service cock to OFF 7 Re assembly is reve...

Page 53: ...ifold and draught shields 6 Remove two screws and remove burner fixing bracket 7 Draw burner forwards to clear it s rear location slot Replace with new burner 8 Re assembly is the reverse of steps 2 to 5 9 Light the heater in accordance with the lighting instructions All gas joints must be checked for soundness using leak detection fluid Turn off and seal any leakages DO NOT EXAMINE WITH A NAKED F...

Page 54: ...ilable STAY ON b Check 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 to 25 mbar 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 400mV from thermopile ind...

Page 55: ...eeded WATER DRIPPING a Check if this stops when water in heater is hot If yes then condensation is the problem caused FROM BASE OF by incorrectly designed flue or by tank cooling excessively i e more hot water being used than HEATER recovery rate of heater If so more heating capacity needed b If water continues to drip when heater is hot problem is leaking joint or storage vessel RUMBLING NOISE a ...

Page 56: ... d Flue damper not open faulty unit replace 8 5 Checking correx anodes 1 If red light is flashing on power pack immerse wires in water including the earth anode wires white wires HIflo x 2 OR Standard Range x 1 and black earth wire power pack earth low voltage side 2 If light stays red replace power pack E010 2 x Anode on HIflo C995 single Anode on Standard Range heaters 3 If light goes green inve...

Page 57: ...ner primary air shutter settings are correct to dimensions given below If not reset to dimensions given below If the whistling persists continue to reduce the settings until the whistling stops Heater Model Air shutter dimension A in mm L32 143 8 L65 169 5 L81 251 10 L62 309 8 L54 399 8 Locking Pin A Air Shutter Burner Injector ...

Page 58: ...58 Issue 2 14 07 16 9 Parts List and Illustrations 9 Parts list and illustrations 9 1 Standard Range models 24 29 32 40 40 61 63 62 Natural Gas 9 2 Standard Range model 84 87 Natural Gas Fig 30 Fig 31 ...

Page 59: ...0 Cleanout Pad 1 A15 N A N A N 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 Items B2 B3 B5 B7 B12 1 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 ...

Page 60: ...60 Issue 2 14 07 16 9 Parts List and Illustrations 9 4 Standard Range LPG models L24 31 L32 35 L40 36 L63 71 Fig 31 9 5 Standard Range LPG model L84 74 Fig 31 ...

Page 61: ...ata Badge 1 A10 C736 Data Badge 1 A10 C737 Data Badge 1 A10 C738 Data Badge 1 A10 C739 Data Badge 1 A11 C671 Flue Baffle 1 A11 C672 Flue Baffle 1 A11 C673 Flue Baffle 1 A12 C333 Service Anode 1 A12 C333 Service Anode 2 A13 C694 Clean out Pad Seal 1 A14 C300 Clean out Pad 1 A15 C301 Clean out Pad Cover 1 A16 C247 Nipple 3 4 NPT X 3 4 BSP 1 A16 C247 Nipple 3 4 NPT X 3 4 BSP 2 B1 C815 Burner Assy Com...

Page 62: ...op Cover Outer Jacket 1 C1 C465 Top Cover Outer Jacket 1 C1 C466 Top Cover Outer Jacket 1 C1 C670 Top Cover Outer Jacket 1 C2 C416 Base Assy c w Rad Pan 1 C2 C417 Base Assy c w Rad Pan 1 C2 C668 Base Assy c w Rad Pan 1 C2 B669 Base Assy c w Rad Pan 1 C3 C689 Special Screws 10 C4 C661 Combustion Chamber 1 C4 C662 Combustion Chamber 1 C4 C663 Combustion Chamber 1 C4 C664 Combustion Chamber 1 C5 C698...

Page 63: ...Issue 2 14 07 16 63 Parts List and Illustrations 9 9 7 HIflo model 32 143 Natural Gas 9 8 HIflo models 65 173 and 81 264 Natural Gas Fig 32 Fig 33 ...

Page 64: ...0 E050 Hydrojet Cold Inlet Connection side 1 1 2 BSP 1 B1 E031 C537 C541 Burner Assy Comprising Items B2 B6 B8 B9 1 B2 C503 C503 C503 Burner Bar 5 B3 C505 C505 C505 Burner Manifold 1 B4 E017 Injector 2 69mm P P 5 B4 E552 Injector 2 40mm Auto 5 B4 C538 Injector 2 87mm P P 5 B4 E551 Injector 2 58mm Auto 5 B4 C542 Injector 3 66mm P P 5 B4 E553 Injector 3 25mm Auto 5 B5 C507 C507 C507 Pilot Assy c w I...

Page 65: ...Issue 2 14 07 16 65 Parts List and Illustrations 9 9 10 HIflo models 62 341 and 54 418 440 Natural Gas Fig 34 ...

Page 66: ...Nipple 1 1 2 BSP 4 A20 E050 E050 Hydrojet Cold Inlet Connection side 1 1 2 BSP 1 B1 C544 C549 Burner Assy Comprising Items B2 B6 B8 B9 1 B2 C503 C503 Burner Bar 7 9 B3 C545 C550 Burner Manifold 1 B4 C546 Injector 3 45mm P P 7 B4 E550 Injector 3 18mm Auto 7 B4 C551 Injector 3 60mm P P 9 B4 E549 Injector 3 26mm Auto 9 B5 C507 C507 Pilot Assy c w Injector and Electrode 1 B6 C547 C547 Pilot Supply Pip...

Page 67: ...Issue 2 14 07 16 67 Parts List and Illustrations 9 9 12 HIflo LPG model L32 143 Fig 31 9 13 HIflo LPG models L65 169 L81 251 Fig 31 ...

Page 68: ...13 C489 Flue Box Top Cover 1 A14 C299 Cleanout Pad Seal 1 A15 C300 Cleanout Pad 1 A16 C301 Cleanout Pad Cover 1 A17 C247 Drain Tapping Connector 3 4 BSP 1 A19 C534 Nipple 1 1 2 BSP 4 A20 E050 Hydroject Cold Inlet Connection 1 B1 E032 Burner Assy 1 B1 C565 Burner Assy 1 B1 C566 Burner Assy 1 B2 C503 Burner Bar 5 B3 C505 Burner Manifold 1 B4 E018 Injector 1 6mm 5 B4 C570 Injector 1 7mm 5 B4 C571 Inj...

Page 69: ...Issue 2 14 07 16 69 Parts List and Illustrations 9 9 15 HIflo LPG models L62 309 L54 399 Fig 31 ...

Page 70: ...14 C299 Cleanout Pad Seal 1 A15 C300 Cleanout Pad 1 A16 C301 Cleanout Pad Cover 1 A17 C247 Drain Tapping Connector 3 4 BSP 1 A19 C534 Nipple 1 1 2 BSP 4 A20 E050 Hydroject Cold Inlet Connection 1 B1 C567 Burner Assy 1 B1 C568 Burner Assy 1 B2 C503 Burner Bar 7 B2 C503 Burner Bar 9 B3 C545 Burner Manifold 1 B3 C550 Burner Manifold 1 B4 C572 Injector 1 78mm 7 B4 C572 Injector 1 78mm 9 B5 C576 Pilot ...

Page 71: ...Issue 2 14 07 16 71 Parts List and Illustrations 9 9 17 Unvented systems kit Standard Range 9 18 Unvented systems kit HIflo range Fig 35 Fig 36 D3 D6 D5 C3 C4 C2 C5 C6 C1 C7 D2 D1 D7 D4 ...

Page 72: ... D3 C782 Expansion Vessel 1 D4 E462 Temperature Pressure Relief Valve 1 D5 C783 Tundish 1 D6 C772 Adaptor 1 D7 C788 Hose Assembly 1 9 20 Unvented systems kit HIflo range parts list Ref Part No Description Qty B290 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 ...

Page 73: ...Issue 2 14 07 16 73 Parts List and Illustrations 9 9 21 24 Volt auto system kit B217 9 22 24 Volt auto system kit B258 Fig 37 Fig 38 ...

Page 74: ... Thermostat Knob 1 G059 230 Volt Gas Valve 1 E126 24 Volt Solenoid Coils 2 Z092 Gas Valve Automatic Ignition Complete with 240 Volt Solenoid Coils 1 Z093 240 Volt Solenoid Coil s 1 E127 Pilot Assembly nat gas 1 E128 Ignition Flame Probe 1 E135 HT Lead 24 1 9 24 24 Volt auto system kit HIflo range parts list Part No Description Qty B258 240 Volt Auto System Kit 1 E839 Pilot Assembly 1 C521 On Off S...

Page 75: ...onnection 25mm NPT connection to gas valve for 370 000 Btu hr and over for natural gas 19mm NPT for rest Schedule 40 black iron pipe recommended Approved Gas Type Natural or Propane Gas supply must match the gas type listed on the water heater rating label Minimum Clearance for Servicing 610mm Front Clearance 508mm Top 152mm Sides Maximum Water Supply Pressure 150 PSI Thermostat Sensor s Redundant...

Page 76: ... if the pilot cannot be lit after 3 ignition trials The water heater display indicates a lockout condition by showing an error code number 62 or 63 with Service Needed in the display window Refer to error codes in the diagnostic section of this Service Manual In a Soft Lockout condition the control will wait for 60 minutes and then make 3 more attempts to light the pilot and establish the main bur...

Page 77: ... Does water heater display operate Does damper begin to open Increase thermostat setting if tank is warm and make sure the control display status reads Heating 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 Replace display if voltage is present at display pin term...

Page 78: ...ill Not Light Error code 55 on display Remove damper from heater and jump black yellow wires of heater harness Error code 62 on display See Pilot Lights No Flame Signal Error code 63 on display See Main Burner Short Cycles Error code 56 on display Check for debris limiting damper rotation If no debris replace damper Does the flue damper rotate to the fully closed position No No No No No Yes Yes Ye...

Page 79: ... and accessing information in aiding servicing of the water heater This procedure is for service and installation personnel only To enter the Service Mode follow the steps illustrated below Step 1 Press Select and Temperature Up buttons together and hold for 3 seconds until Max Setpoint is shown in the display Step 2 Pressing Select button will change display to next mode Fig 41 Fig 42 Max setpoin...

Page 80: ... if there is an operating error in the User Mode 1 Max Setpoint Display Change 2a Water Temperature Average Displays average if there are two sensors sensor temperature displayed if single sensor is used 2b Water Temperature Upper Sensor Displays if there is an upper sensor some models Fig 43 Fig 44 Fig 45 Fig 46 Error code shown in water heater display Max setpoint value in water heater display ...

Page 81: ...endix 10 2c Water Temperature Lower Sensor Displays if there are two sensors 3 Flame Current of Pilot Flame Sensor Displays only in the Heating Cycle 4 Setpoint Display Change 5 F C Display Change Fig 47 Fig 48 Fig 49 Fig 50 ...

Page 82: ...y will show a if there are no error codes Fig 51 Fig 52 Fig 53 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 t...

Page 83: ...e Max Setpoint will flash to indicate setting mode Step 3 Press the UP or DOWN buttons to change the maximum 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 Fig 54 Fig 55 Fig 56 Fig 57 Max setpoint flashes Max setpoint continues to flash while mak...

Page 84: ...he 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 button again displays the Upper Sensor temperature reading Upper Sensor will be displayed in the lower right ...

Page 85: ...ater heater display Step 3 To raise the temperature setpoint press the Temperature Up button until the desired temperature is shown on the water heater display Fig 62 Fig 63 Fig 64 Fig 65 Note The maximum temperature that can be set in the Water Heater Display is limited to the Max Setpoint described previously To change the Max Setpoint refer to the procedure To Change the Maximum Setpoint Limit ...

Page 86: ...ew setpoint Setpoint stops flashing in the water heater display 10 4 7 To 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 Step 2 Press Set button to change temperature format F C symbol will flash in the water heater disp...

Page 87: ...utton to change temperature format to F Step 4 Press Set button to confirm F or C format F C will stop flashing Step 5 Pressing Select button will return display to setpoint in format selected F or C immediately Fig 70 Changes to C Fig 71 Fig 72 Fig 73 F C flashes Changes to F F C flashes F C symbol stops flashing Setpoint shown in F ...

Page 88: ...ay shows there is not a current error code The Water Heater Display will provide up to 10 previous error codes The oldest error code will be stored in code index 1 and the most recent in code index 10 10 4 10 To view previous error codes Step 1 In Service Mode press the Select button until the next display after the Software Version If there are no current error codes the display will show Step 2 ...

Page 89: ... 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 wait ...

Page 90: ...tch failed to close stuck open 56 Damper end switch failed to open stuck closed 6 Flame sensed out of normal sequence before opening gas valve or after closing gas valve 23 Flame detected before ignition 24 Flame detected after a heating cycle completes 31 Upper sensor readings faulty 32 Lower sensor readings faulty 57 Flame rod shorted to ground 58 AC line frequency error signal too noisy or freq...

Page 91: ...ll 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 time for 3 seconds Then press the lower right button under Lockout Reset in the water heater display and ...

Page 92: ...ose to 0 ohms Replace wire harness if high resistance is measured over 0 5 ohms Check wires for intermittent connections shorts frayed insulation Replace if necessary If wire harness checks out O K check resistance of sensor Refer to section on Sensor Resistance Testing If sensor resistance is not near the values shown in the table then replace upper or lower sensor as indicated by error code numb...

Page 93: ...n 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 sure the maximum tank temperature remains well below 93 C This water heater is equipped with a manual reset type gas shutoff device designed to shut off the gas to the burners if excessive water temperature occurs To reset the contr...

Page 94: ... 24045 23399 22771 22163 21573 21000 20445 10 19906 19383 18876 18383 17905 17440 16990 16553 16128 15715 15 5 15314 14925 14548 14180 13823 13477 13140 12812 12494 12185 21 1 11884 11592 11308 11032 10763 10502 10248 1000 9760 9526 26 7 9299 9078 8862 8653 8449 8250 8057 7869 7685 7507 32 7333 7165 7000 6839 6683 6531 6383 6238 6098 5961 37 5827 5697 5570 5446 5326 5208 5094 4982 4873 4767 44 466...

Page 95: ...arefully insert meter probe in wire plug to check pin terminals Make sure control is in the trial for ignition sequence see Sequence of Operation Check wire harness for damage or loose connections Repair or replace as needed Turn on power to the water heater and verify proper operation Is there spark at the pilot Replace control board Replace control board Check for Loose or damaged ignition wire ...

Page 96: ...s 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 Check for Gas Leaks Reconnect power and verify proper ignitions 10 6 2 Pilot inspection Make sure pilot shield clears flame...

Page 97: ...must be in the heating mode with the pilot lit to display a reading See section on accessing service mode on the water heater display Yes Correct improper venting condition Refer to Installation Instructions No Make sure pilot shield is in place and not bent or damaged refer to section on main burner and pilot assembly Determine cause for condensing and correct Possible under sized water heater or...

Page 98: ...n terminals 5 8 Refer to wiring diagram Disconnect brown wire lead from MV terminal of gas valve Is there 22 27 volts AC across brown wire lead ground 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 Is pilot lit See pilot will not light Check incoming gas pressure to gas valve and...

Page 99: ...ast 1 w c above the manifold pressure Replace regulator screw and pressure tap cap when finished Is manifold pressure O K Determine cause of incorrect gas pressure and correct Contact your gas supplier Check venting conditions clogged vent down drafts or negative building pressure Is vent system okay Replace gas valve No No Correct improper venting condition Refer to Installation Instructions No Y...

Page 100: ... ignition wire from Control Board Step 7 Remove the two burner rack mounting screws Step 8 Slide complete burner rack out from heater Step 9 To install burner reverse above procedure Step 10 Check for gas leaks and verify proper operation 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 s...

Page 101: ...ation build up on flame rod Clean flame rod or replace pilot as necessary Step 2 Inspect pilot orifice a Remove 11mm ferrule nut from bottom of pilot b Remove pilot tube and orifice from pilot c Inspect pilot tube for blockage Clean or replace as necessary d Inspect pilot orifice for blockage Clean or replace as necessary 10 8 2 Control board replacement Step 1 Disconnect Power Step 2 Unplug wire ...

Page 102: ...ion from top of water heater to expose collector cover Step 7 Remove screws from side or top of collector cover Note it may be necessary to chisel away some foam to access screws Step 8 Remove collector cover from water heater by using pipe wrench Step 9 Remove flue baffles from water heater Note it may be necessary to use pliers to loosen and remove baffles from flue tubes Step 10 Visually inspec...

Page 103: ...er Step 7 If required turn off water supply and disconnect top plumbing connection from top of water heater Step 8 Remove screws holding jacket head to top of water heater and remove jacket head from top of water heater Note it may be necessary to use a screw driver to pry underneath jacket head Step 9 Remove insulation from top of water heater to expose collector cover remove if necessary see nex...

Page 104: ...ater Step 14 Check for leaks Step 15 Reinstall collector cover insulation over collector cover Step 16 Reinstall jacket head flue damper and draft diverter Reconnect venting Step 17 Reconnect plumbing connection to top of water heater if required Step 18 Restore water supply and power to water heater Step 19 Verify proper operation ...

Page 105: ...eral assembly Parts table page 98 1 2 2 23 22 23 22 5 6 7 3 21 4 22 23 10B 9 11 8 22 23 24 10A 12 13 14 15 20 19 18 17 16 Fig 89 Powered anodes are located in front for models 65 173 auto GB and 81 264 auto GB All other models use rear location ...

Page 106: ...106 Issue 2 14 07 16 10 Appendix 10 12 Burner assembly Parts table page 99 22 40 23 24 25 27 28 26 41 43 42 29 30 31 33 34 37 32 38 36 35 15 39 Fig 90 ...

Page 107: ...Issue 2 14 07 16 107 Appendix 10 10 13 Control box assembly Parts table page 100 63 64 65 59 58 57 66 55 56 68 62 61 60 54 51 52 53 50 48 46 44 45 67 69 47 49 12 Fig 91 ...

Page 108: ...Cover 1 10A Z137 Thermstate Lower 1 10A Z130 Thermstate Lower 1 10B Z136 Thermstate Upper 1 11 Z175 Nipple 1 12 Z129 Control Box Assy Single Sensor 1 12 Z176 Control Box Assy Single Sensor 1 12 Z135 Control Box Assy Dual Sensor 1 12 Z177 Control Box Assy Dual Sensor 1 12 Z131 Control Box Assy Dual Sensor 1 12 Z132 Control Box Assy Dual Sensor 1 13 Z178 Mini Diptube 1 14 Z179 Nipple 1 15 Z180 Burne...

Page 109: ...Z216 Gas Valve Nat 1 26 Z218 Burner Manifold 1 26 Z219 Burner Manifold 1 26 Z220 Burner Manifold 1 27 Z222 External 10 Washer 4 28 Z223 10 Machine Screw 4 29 Z224 Wing Nut 2 30 Z225 Tooth Washer 2 31 Z226 Z Shield c w Welded Stud 2 32 Z227 Wind Angle Shield 2 33 Z228 Pilot Mounting Screw 2 34 Z229 Burner Support 1 34 Z230 Burner Support 1 34 Z231 Burner Support 1 35 Z233 Pilot Shield 1 36 Z234 Pil...

Page 110: ... Display Control Harness 1 51 Z256 Water Tight Bushing 1 52 Z143 On off Switch 1 53 Z257 Snap Bush Top 1 54 Z258 Control Panel 1 55 Z259 Terminal Block 1 56 Z260 Terminal Strip 1 57 Z261 Terminal 1 58 Z141 Transformer 1 59 Z138 Control Board 1 59 Z139 Control Board 1 60 Z262 Bottom Plug 1 61 Z263 Snap Bush Bottom 1 62 Z264 Strain Relief Bushing 1 63 Z265 Control Box Cover 1 64 Z140 Display Control...

Page 111: ... please ensure you safely remove the power supply and isolated the appliance from the water and gas connections Dispose of the appliance correctly according to the laws and regulations in force The appliance and accessories cannot be discarded along with normal household waste and should be recycled where appropriate More than 90 of the materials that make up the appliance are recyclable ...

Page 112: ...112 Issue 2 14 07 16 ...

Page 113: ...Issue 2 14 07 16 113 ...

Page 114: ...114 Issue 2 14 07 16 ...

Page 115: ...chnological information contained in these technical instructions as well as any drawings and technical descriptions supplied remain our property and shall not be multiplied without our prior consent in writing Subject to alterations ...

Page 116: ...hase for y Please make sure w to activate o Register n ve the right to make changes and impr r we rese lus ll l descriptions and i il l ll descriptions and i A Conditions of Sale which are available on request our warranty to be monitored y ou attach proof of purchase for andrewswaterheaters co uk registe w ww our warranty y vements in our products which may a o make changes and impr ro vided in t...

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