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Service Handbook

1206

322153-000 Rev. 00

POWER VENTED GAS MODELS

WITH HOT SURFACE IGNITION

NOT FOR USE IN MANUFACTURED (MOBILE) HOMES

RESIDENTIAL GAS WATER HEATERS

TABLE OF CONTENTS

Note:

References to the Manual refer to the “Installation

and Operating Manual”.

GENERAL INFORMATION

CHECKING THE GAS SUPPLY PRESSURE

LEAKAGE CHECKPOINTS

TEMPERATURE ADJUSTMENT

ANODE ROD REMOVAL/REPLACEMENT

DIP TUBE REMOVAL/REPLACEMENT

DOOR-BURNER ASSEMBLY REMOVAL/
REPLACEMENT 8
FLAME SENSOR AND IGNITER REMOVAL/
REPLACEMENT 10
BURNER AND ORIFICE REMOVAL/
REPLACEMENT 12
DOOR GASKET REPLACEMENT

CONTROL MODULE REMOVAL/REPLACEMENT

VALVE MODULE REMOVAL/REPLACEMENT

TEMPERATURE SENSOR AND CABLE REMOVAL/
REPLACEMENT 21
GAS VALVE REMOVAL/REPLACEMENT

BLOWER REMOVAL/REPLACEMENT

ROTATING THE BLOWER

PRESSURE SWITCH REMOVAL/REPLACEMENT 26
FV SENSOR

CLEANING THE COMBUSTION CHAMBER

CLEANING THE BLOWER

TECHNICAL BULLETINS

TROUBLESHOTING CHART

Содержание GPVL-50

Страница 1: ...AL REPLACEMENT 6 DIP TUBE REMOVAL REPLACEMENT 7 DOOR BURNER ASSEMBLY REMOVAL REPLACEMENT 8 FLAME SENSOR AND IGNITER REMOVAL REPLACEMENT 10 BURNER AND ORIFICE REMOVAL REPLACEMENT 12 DOOR GASKET REPLACEMENT 16 CONTROL MODULE REMOVAL REPLACEMENT 18 VALVE MODULE REMOVAL REPLACEMENT 20 TEMPERATURE SENSOR AND CABLE REMOVAL REPLACEMENT 21 GAS VALVE REMOVAL REPLACEMENT 22 BLOWER REMOVAL REPLACEMENT 24 ROT...

Страница 2: ...raise 1 pound of water 1F 1 BTU 252 cal 0 252 kcal 1 cal 4 187 Joules BTU X 1 055 Kilo Joules BTU divided by 3 413 Kilowatts To convert from Fahrenheit to Centigrade F 32 times 5 9 or 556 equals degrees C One gallon of 120 F 49 C water weighs approximately 8 25 pounds Pounds X 45359 Kilogram Gallons X 3 7854 Liters of Hot Mixed Temp Cold divided by Hot Temp Cold Thermal Efficiency GPH X 8 25 X Tem...

Страница 3: ...e on main supply Technicians can not adjust main gas supply pressure Supply gas pressure is over desired pressure A d d g a s p r e s s u r e regulator Call the gas utility company to readjust gas pressure on main supply Technicians can not adjust main gas supply pressure Manifold gas pressure is more than 4 inch W C from values indicated on gas valve or rating plate Ensure there is adequate suppl...

Страница 4: ...ain water vapor which can condense on the cooler surfaces of the tank Droplets form and drip onto the burner This is common at the time of start up after installation and when incoming water is cold I Water in the water heater bottom or on the floor may be from condensation DO NOT replace the water heater until a full inspection of all possible water sources is made and necessary corrective steps ...

Страница 5: ... C 60 C is recommended by most dishwasher manufacturers Settings Temperature range on residential gas water heater is from 110 F 10 to 155 F 10 and a 70 F vacation setting The T P valve will open at 195 F 10 The water heater temperature adjusting dial see Figure 3 was factory set at the lowest temperature all the way counter clockwise to the mechanical stop unless specified differently by provinci...

Страница 6: ...using a ratchet and a 1 1 16 socket turning counter clockwise see Figure 4 1 2 3 4 5 6 7 Installing Anode Rod Use Teflon tape or an approved pipe sealant on threads of the new anode rod Place the anode rod in the spud top of the tank and turn clockwise until the threads are hand tight Using a ratchet and 1 1 16 socket tighten down water tight Turn the main water supply back on Open a nearby hot wa...

Страница 7: ...e dip tube will come out with the piping in one piece Separate accordingly Installing Dip Tube Use Teflon tape or an approved pipe sealant on threads of the new dip tube Place the dip tube into the spud on top of the tank and turn clockwise until tight Using the pipe wrench continue to tighten until the joint is water tight Note Do not clamp the pipe wrench jaws on the threaded portion of the nipp...

Страница 8: ...he insulation in a safe place for reusing it later Use a 1 4 nutdriver or 1 4 socket ratchet to loosen the 2 hex head screws on the inner door so the inner door manifold burner assembly can be removed see Figure 7 Remove inner door manifold burner assembly by grasping the manifold and pull back slowly Rotating it to the left to clear the igniter and flame sensor Care should be taken when inner doo...

Страница 9: ...g the manifold tube should be started by hand turn clockwise for natural gas counter clockwise for L P Upon tightening with the fingers and confirming it has not been cross threaded tighten nut with a 3 4 open end wrench see Figure 7 Reinstall the insulation pad which was removed in step 7 above Reconnect all the electrical connections to the bottom of the gas control valve thermostat gently pushi...

Страница 10: ... 7 8 9 1 2 3 Remove and discard the old flame sensor and or hot surface igniter assembly Install the new Flame Sensor and or Hot Surface Igniter Route the new flame sensor and or hot surface igniter connector wire through manifold burner door opening Secure the assembly to the bracket using screw s removed in step 3 above Reconnect the wiring connection between the flame sensor igniter and the val...

Страница 11: ...ough viewport test the manifold tube connection at the gas control valve thermostat by brushing on an approved noncorrosive leak detection solution Important Do Not splash the solution onto any electrical connections If a leak is detected shut the water heater down by following the directions on the Lighting and Operating Instructions Repair the leak s and repeat step 6 above Upon verifying proper...

Страница 12: ...ew burner to the inner door manifold assembly rotate the assembly to visually check the top portion of the burner assembly and confirm the orientation of the condensation drain hole see Figure 19 and note Caution Must Be Taken Prior to installing the new inner door manifold burner assembly look inside the burner chamber to fully understand the correct positioning of the burner assembly and burner ...

Страница 13: ...onnections Upon verifying proper operation of the water heater replace the outer door ELECTRICAL CONNECTIONS MANIFOLD TUBE NUT HEX HEAD SCREWS NOTE OUTER DOOR AND INSULATION NOT SHOWN FOR CLARITY Figure 15 BURNER SUPPORT BRACKET LOCATED IN THE CENTRE OF THE CHAMBER STRIGHT SLOT FOR 40 50K BURNERS WITH STRAIGHT MANIFOLD TUBES CURVED SLOT FOR 60 75K BURNERS WITH OFFSET MANIFOLD TUBES Figure 16 4 5 6...

Страница 14: ...r orifices have different threads dependent upon the gas type right handed threads for natural gas turn clockwise to install and left handed threads for propane gas turn counter clockwise to install see Figures 18 19 Note Determine whether the orifice is tall or short and DO NOT replace them with each other Care MUST be taken to ensure the burner is installed correctly on the inner door manifold a...

Страница 15: ...o the bottom of the gas control valve thermostat gently pushing each connector up until it snaps into place see Figures 10 15 Reconnect the electrical power to the water heater in the wall outlet and turn the gas supply back ON to the gas control valve thermostat Restart the water heater by following the directions on the Lighting and Operating Instructions label located on the front of the water ...

Страница 16: ...y to free the manifold tube from the gas control valve thermostat see Figure 7 Remove the insulation pad on the inner door by cutting it if necessary Keep the insulation in a safe place for reusing it later Use a 1 4 nutdriver or 1 4 socket ratchet to loosen the 2 hex head screws on the inner door so the inner door manifold burner assembly can be removed see Figure 7 Remove inner door manifold bur...

Страница 17: ...er heater to perform properly DO NOT OPERATE THE WATER HEATER IF THE DOOR GASKET DOES NOT CREATE A SEAL BETWEEN MANIFOLD DOOR AND COMBUSTION CHAMBER Reconnect the manifold tube to the gas control valve thermostat Note Do Not apply any thread sealant at this connection To prevent any cross threading the manifold tube should be started by hand turn clockwise for natural gas counter clockwise for L P...

Страница 18: ...o the water heater from the wall outlet 4 Remove the front Torx screw at the bottom of the gas control valve thermostat as illustrated in Figure 21 5 Use a flat blade screwdriver to release the two tabs at the top of the gas control valve thermostat and lift the electronic control straight up see Figures 22 23 6 Disconnect the temperature sensor cable Note When removing the control module from the...

Страница 19: ...19 TABS DISCONNECT TEMPERATURE SENSOR CABLE HERE ELECTRONIC CONTROL MODULE THREADED CONTROL FITTING DO NOT REMOVE FROM WATER HEATER Figure 23 ...

Страница 20: ...ectronic Control Module as outlined in Removing Electronic Control Module above Note When removing the control module from the gas control assembly disengage the pins on the valve module without causing damage 5 Remove the screw and the ground tab with a Torx screwdriver see Figure 24 6 Insert a flat blade screwdriver between the casting and the locking tabs at the bottom of the valve 7 Carefully ...

Страница 21: ...tronic Control Module as outlined in Removing Electronic Control Module section above Note When removing the control module from the gas control assembly disengage the pins on the valve module without causing damage 5 Remove the Valve Module as outlined in Removing Valve Module section above 6 Use a screwdriver to pry under the sensor retainer finger to remove the temperature sensor and cable see ...

Страница 22: ...eads have a pre applied white sealing material Thread a short length of 1 2 threaded pipe into the inlet connection of the new gas control valve thermostat and use it to turn the gas control valve thermostat clockwise to tighten into place Note Do Not over tighten or damage may result but it needs to be water tight see Figure 27 Remove the 1 2 threaded pipe from the gas control valve thermostat Re...

Страница 23: ...23 ELECTRICAL CONNECTIONS MANIFOLD TUBE NUT HEX HEAD SCREWS NOTE OUTER DOOR AND INSULATION NOT SHOWN FOR CLARITY Figure 26 THREADED PIPE HANDLE Figure 27 ...

Страница 24: ... power and ground connectors through the junction box opening and place the blower on top of the water heater Reconnect the power connector and the ground connector Reinstall the junction box cover and screw removed in step 5 above Tighten with 1 4 nutdriver or 1 4 socket ratchet Align the screw holes on the blower assembly with those on the top of the heater Using the six screws removed in step 6...

Страница 25: ...the water heater To rotate the blower outlet remove the four nuts with 11 32 nut driver see Figure 29 securing the flue collector to the blower housing Pull the blower assembly forward to free it from the mounting studs Rotate the blower housing clockwise or counter clockwise and align the four holes and screws together Reattach the blower housing to the flue collector 11 32 nut Figure 29 This pow...

Страница 26: ...sing a hex head screwdriver remove and retain the 2 screws securing the pressure switch to the bracket see Figure 30 1 2 3 4 5 6 7 8 Installing Pressure Switch Using a hex head screwdriver secure the new pressure switch to the bracket with the screws removed in step 8 above Care should be taken to ensure the proper orientation of the bracket and pressure switch see Figure 30 Using a hex head hex s...

Страница 27: ...Gas Control Led Status Codes section for an explanation of the codes applicable to the control installed on your water heater If an FVS lockout occurs check around the water heater for sources of chemical contamination such as flammable vapors including gas vapors solvents paint and thinners as well as sources of water and detergents Note Resetting the heater will reset the FVIR circuit if all sou...

Страница 28: ...nner Door Manifold Burner Assembly Use a vacuum cleaner shop vac to remove all loose debris in the combustion chamber Reassemble following the procedure under Installing Inner Door Manifold Burner Assembly 1 2 3 CLEANING THE COMBUSTION CHAMBER ...

Страница 29: ...ush to brush off the outer edge of the blower wheel to dislodge the dirt stuck on the blades and the inside of the housing Rotate the wheel until all blades are clear Note The wheel is a balanced component Do not bend dent or distort the blades as this can upset the wheel balance and affect the blower operation Vacuum out the loosened dirt Accessing the inside of the blower wheel through the rear ...

Страница 30: ... thinning of the flue tube walls has occurred due to contamination of the combustion air or because of excessive condensation Inverted or Deformed Tank Heads Often this accompanies collapsed flues but one or both heads can be deformed THE FIX The only effective means of control is to install water hammer arrestors These devices have diaphragms which separate an air chamber from the water in the pi...

Страница 31: ...he water heater Leaking heaters cannot be repaired DISCOLORED WATER SYMPTOMS Rusty brown black or yellow water appearing in the hot water CAUSES Complaints of discolored water are commonly blamed on water heaters and storage tanks but in fact it is a rare occurrence for today s high quality glass lined tanks to have a lining failure significant enough to allow water to contact enough bare metal to...

Страница 32: ...nd manganese in the water Water with little or no dissolved oxygen Temperatures below 138 F Items that can increase the potential for this bacteria are Water softeners Well water Long periods of no water movement Other factors that may contribute to smelly water Chlorides of Magnesium and Calcium leave a bitter taste Chloride of Sodium produces a salty taste Sulfates 50 ppm gives a medicinal taste...

Страница 33: ... hot water lines must receive treatment STEP 9 Leave the chlorine solution undisturbed for one hour or more STEP 10 After the contact time has elapsed drain the tank according to steps 2 3 4 STEP 11 Close the drain valve and refill the tank Allow the tank to sit for 15 minutes Repeat steps 2 3 and 4 Continue to flush the tank if the water is discolored or contains a chlorine odor STEP 12 Close the...

Страница 34: ...turn the pointer so it lines up with the pressure indicating needle Turn the gas control switch ON so the heater cycles on Watch the pressure gauge If the system is closed the pressure will start to climb steadily and rapidly A small amount of thermal expansion control may be built into the system because of trapped air pockets or a water hammer arrestor In that case the pressure will increase sli...

Страница 35: ...e replaced Leakage at the threaded relief valve connection Remove relief valve and reseal connection Large volume of hot water sporadically discharged from the relief valve The relief valve relieves water quickly when actuating on temperature The only cause of this problem is a malfunctioning thermostat INSULATION BLANKETS GENERAL The purpose of an insulation blanket is to reduce the standby heat ...

Страница 36: ...water heater Check flue way flue baffle and burner Check with gas utility company Replace with correct orifice Turn temperature knob to higher setting Install adequate heater Correct piping dip tube must be in cold inlet Advise customer Clean flue locate source and correct 1 2 3 4 5 6 7 8 DRIP FROM RELIEF VALVE Pressure build up Heater stacking Closed water system Improperly seated valve 1 2 3 4 U...

Страница 37: ...wire Control locked out 1 2 3 4 5 6 Plug in power cord check fuses and or supply voltage Turn temperature knob to higher setting Replace air pressure switch Replace blower Repair and reconnect wires Reset determine cause of lockout 1 2 3 4 5 6 BLOWER RUNS CONTINUOUSLY Air pressure switch not closing duetoinsufficientdraft checkfor a Vent piping blocked b Piping length too long c Clogged dirty blow...

Страница 38: ...n Flash three second pause Flammable Vapor Sensor Lockout Eight One Flash three second pause FVS Fault Detected Eight Two Flash three second pause Temperature Sensor Fault Detected Eight Three Flash three second pause Electronics Fault Detected Eight Four Flash three second pause Valve Fault Detected IGNITION STATE AND TIMING IGNITION STATE TIMING Pre purge 5 seconds NG models 15 seconds LP models...

Страница 39: ...39 This page intentionally left blank May be used for notes or to record other installation information ...

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