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GAS WATER HEATERS

1. Instructions GAS WATER HEATERS HEAT ENGINE REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater Remove panels to gain access 3 Remove the flexible elbow from the top of the heat engine Door opening 1 Unlock the door by rotating the lock counter clockwise Remove the right side panel with a wide slot screwdriver 1 Use a screwdriver to remove the screw from the bottom 2 Release the top and bottom door pins by prying the pins front of the right side panel out using a small screwdriver 2 Remove the three screws from the right side panel 3 Open the door the door remains fastened to the left towards the rear of the unit side panel 3 Remove the screw from the top of the unit 4 Push the panel back and lift out Remove the top casing front 1 Use a sc
2. BLOWER MOTOR REPLACEMENT GAS WATER HEATERS This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove 1 Disconnect the electrical power to the water heater Close the shutoff valve on the gas supply line to the water heater 3 Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver 4 Release the top and bottom door pins by prying the pins out using a small screwdriver 5 Open the door the door remains fastened to the left side panel 6 Remove the ten screws that secure the front cover of the heat engine Remove the front cover of the Heat Engine 7 Remove the two screws securing the circuit board and partially extract it 8 Carefully disconnect the Blower Motor wiring harness plug from the circuit board 9 Remove the three screw
3. Screw Ground Heat Engine Cabinet Electrode Spark Generator 319172 000 Rev 00 0610 Instructions HILIMIT TEMPERATURE SWITCH REPLACEMENT GAS WATER HEATERS This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove 1 Disconnect the electrical power to the water heater Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver 3 Release the top and bottom door pins by prying the pins out using a small screwdriver 4 Open the door the door remains fastened to the left side panel 5 Remove the ten screws that secure the front cover of the heat engine Remove the front cover of the Heat Engine 6 Remove the two screws securing the circuit board and partially extract it 7 Carefully disconnect the HiLimit
4. 35 50 2 509 2 gt gt EE 5 gt 5 w m nO NO R as U Retaining Clip G Screw 2 amp Flame Rod Retaining Clip 319172 000 Rev 00 62 0610 To 1 10 11 12 14 0610 nstall Re install the original HiLimit temperature switch Secure a new white gaskets in place on the Draft Hood and Combustion Chamber Reassemble the Draft Hood to the upper portion of heat engine Reassemble the Combustion chamber to the heat exchanger Reassemble the exhaust gasket and ring over the exhaust vent Re install the Heat exchanger assembly to the Heat Engine Cabinet Carefully reconnect the HiLimit temperature switch 2 thin red wires and the Blower motor wiring harness plug to the circuit board Carefully reconnect the black wire from the Spark generator to the electrode Slide the circuit board into its proper position and secure using the two screws Reassemble the orifice plate to the combustion chamber One of these screws also secures the Spark generator another one secures a ground lug Reassemble the top portion of the Gas valve to the burner chamber Re install the ECO switch Carefully reconnect the blue wire to the Flame sensor Reassemble the retaining clip that holds in the copper tube to the internal flow valve at the lower right hand side of the heat engine Reassemb
5. Instructions GAS WATER HEATERS HOSE HEAT ENGINE TO STORAGE TANK REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater Remove panels to gain access Remove Door To Remove 1 Close the shutoff valves on both the hot water and cold water lines 1 Disconnect the electrical power to the water heater 2 Drain the tank following the instructions in the Draining 2 Unlock the door by rotating the lock counter clockwise The Tank section in the Operating Manual with a wide slot screwdriver 3 Unscrew the fitting at both ends of the hose assembly s 3 Release the top and bottom door pins by prying the pins The upper hose is the hot water outlet from the heat out using a small screwdriver engine The lower hose is the cold water inlet to the 4 Open the door the
6. 2 Casing N WS 84 Casing Front 319172 000 Rev 00 Remove additional components Remove the casing bracket 1 Use Phillips screwdriver to remove the four screws holding the casing bracket to the tank Remove the flexible venting 1 Unwrap the insulation covering the venting 2 Loosen the gear clamps securing the venting 3 Remove the flexible venting Remove the Heat Engine 1 Close the shutoff valves on both the hot water and cold water lines 2 Close the shutoff valve on the gas supply line to the water heater 3 Drain the tank following the instructions in the Draining The Tank section in the Operating Manual 4 Disconnect the hoses from the heat engine top is water outlet and bottom is water inlet Disconnect the gas line from the heat engine Remove the 4 nuts holding the heat engine to the tank Requires 1 2 wrench socket or nut driver It may be necessary to remove part of the venting system to access some nuts 7 Remove the heat engine Remove the water lines Disconnect the hot water and the cold water lines from the tank Remove the condensation trap 1 Remove the venting to the unit 2 Use Phillips screwdriver to remove the two screws holding the condensation trap to the tank 3 Remove the condensation trap by pulling it straight out Remove the baffles 1 Remove the large baffle by pulling it straight up out of the
7. Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater Remove panels to gain access To Remove Door opening 1 Disconnect the electrical power to the water heater 1 Unlock the door by rotating the lock counter clockwise 2 Loosen the lower gear clamp that secures the venting with a wide slot screwdriver system to the exhaust elbow 2 Release the top and bottom door pins by prying the pins 3 Lift the venting system away from the exhaust elbow out using a small screwdriver 4 Remove the condensate tube from the condensate 3 Open the door the door remains fastened to the left trap side panel 5 Remove the two screws that secure the High temperature Switch Remove the top casing front 6 Remove the two screws that secure the Condensate 1 Use a screwdriver to remove the six screws securing Trap Assembly the top casing 7 Remove the Condensate Trap Assembly it could be a 2 Lift up and remove casing top front snug fit 8 Remove the exhaust elbow gasket Remove the right side panel
8. Lighting Instructions found in the Operating Manual 319172 000 Rev 00 Internal Flow Valve Heat Engine Cabinet 9 Screws Valve Mountin Copper Piping 22 G 319172 000 00 16 0610 Instructions GAS WATER HEATERS OUTLET THERMISTOR REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove Access To 1 Disconnect the electrical power to the water heater Door Pins Close the shutoff valve on the gas supply line to the water heater 3 Close the shutoff valves on both the hot water and cold water lines 4 Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver 5 Release the top and bottom door pins by prying the pins out using a small scre
9. 9 Remove the barbed fitting if installed 1 Use a screwdriver to remove the screw from the bottom front of the right side panel To Install 2 Remove the three screws from the right side panel towards the rear of the unit 1 Re install the barbed fitting if required 3 Remove the screw from the top of the unit 2 Ensure the gasket is placed correctly onto the exhaust 4 Push the panel back and lift out elbow prior to assembly 3 Install the new Condensate Trap Assembly 4 Secure the Condensate Trap Assembly with the two screws 5 Secure the High temperature Switch with the two screws 6 Connect the condensate tube to the condensate trap 7 Reposition the venting into the vent coupler 8 Tighten the lower gear clamp to secure the venting system to the exhaust elbow 9 Reassemble the right side panel 10 Reassemble the casing top front 11 Close and lock the door 12 Reconnect the electrical power to the water heater 13 Restart the water heater following the Lighting Instructions found in the Operating Manual 0610 47 319172 000 Rev 00 Casing Access NA Door Pins Door Lock I Screws N JA Venting System HA l Vi A Se L Coupling lt p x lt High temperature Switch 2 u Screw 2 Fitting Trap Exhaust Elbow Condensate T
10. Access To Door Pins D OB V Screws Casing Front 0610 41 319172 000 Rev 00 0610 42 VENTING EXHAUST ELBOW BARBED FITTING HIGH TEMPERATURE SWITCH DRAIN PAN ROUTE TO SUITABLE DRAIN A CONDENSATE TRAP CONDENSATE TUBE 319172 000 Rev 00 Instructions DRAIN VALVE REPLACEMENT GAS WATER HEATERS This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove 1 To ON 0610 Disconnect the electrical power to the water heater Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver Release the top and bottom door pins by prying the pins out using a small screwdriver Open the door the door remains fastened to the left side panel Close t
11. Reinstall the flexible venting in reverse order 14 Re fit the insulation around the exhaust elbows 15 Reinstall the casing bracket in reverse order 16 Reassemble the rear panel in reverse order 17 Reassemble the left side panel in reverse order 18 Reassemble the right side panel in reverse order 19 Reassemble the top casing front and back in reverse order 20 Close and lock the door 21 Open the shutoff valve on the gas supply line to the water heater 22 Reconnect the electrical power to the water heater 23 Restart the water heater following the Lighting Instructions found in the Operating Manual 319172 000 Rev 00 0610 60 319172 000 00 Instructions GAS WATER HEATERS HEAT EXCHANGER REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service
12. a qualified service technician to service this water heater Remove panels to gain access 2 Remove the three screws from the right side panel towards the rear of the unit Door opening 3 Remove the screw from the top of the unit 1 Unlock the door by rotating the lock counter clockwise 4 Push the panel back and lift out with a wide slot screwdriver 2 Release the top and bottom door pins by prying the pins To Remove out using a small screwdriver 3 Open the door the door remains fastened to the left 1 Disconnect the electrical power to the water heater side panel 2 Carefully disconnect the two wires from the High temperature Switch Remove the top casing front 3 Remove the two screws securing the High temperature 1 Use a screwdriver to remove the six screws securing Switch to the Condensate Trap the top casing 4 Remove the High temperature Switch 2 Lift up and remove casing top front To Install Remove the right side panel 1 Secure the new High temperature Switch with the two 1 Use a screwdriver to remove the screw from the bottom screws front of the right side panel 2 Carefully reconnect the two wires to the High temperature Switch Reassemble all the casing panels in the reverse order Close and lock the door Reconnect the electrical power to the water heater Restart the water heater following the Lighting Instructions found in the Operating Manual Top Casing Front Door Lock
13. baffle To Install 1 Install the new main baffle Reassemble the flexible venting to the heat engine and the storage tank Re fit the insulation around the exhaust elbows Reassemble the top casing Reconnect the electrical power to the water heater Restart the water heater following the Lighting Instructions found in the Operating Manual 0610 53 319172 000 00 Main Baffle Top Casing Flexible Venting 319172 000 Rev 00 0610 Instructions GAS WATER HEATERS CONDENSATION BAFFLE REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater Remove panels to gain access 2 Remove the three screws from the right side panel towards the rear of the unit Door opening 3 Remove the screw from the top of the unit 1 Unlock the
14. door remains fastened to the left heat engine side panel 4 Remove the hose assembly s 5 Carefully disconnect all the wiring harness plugs from the Display Panel 6 Carefully remove the door hinge pins from their retaining To Install fingers 1 Install the new hose assembly s Remove the top casing front 2 Tighten the fitting at both ends of the hose 1 Use a screwdriver to remove the six screws securing assembly s the top casing 3 Close the drain valve 2 Lift up and remove casing top front 4 Open the shutoff valves on both the hot water and cold water lines Remove the left side panel 5 Fill the tank following the instructions in the Filling The 1 Use a screwdriver to remove the screw from the bottom Water Heater section in the Operating Manual front of the left side panel 6 Check for leaks and repair as required 2 Remove the three screws from the left side panel towards 7 Reassemble the side panel the reverse order the rear of the unit 8 Reassemble the door in the reverse order 3 Remove the screw from the top of the unit 9 Carefully reconnect the wiring harness plugs to the 4 Push the panel back and lift out Display Panel 10 Reassemble the top casing in the reverse order 11 Reconnect the electrical power to the water heater 12 Restart the water heater following the Lighting Instructions found in the Operating Manual 0610 35 319172 000 Rev 00 lt AJ San
15. service technician to service this water heater To Remove 1 Disconnect the electrical power to the water heater Close the shutoff valves on both the hot water and cold water lines 3 Close the shutoff valve on the gas supply line to the water heater 4 Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver 5 Release the top and bottom door pins by prying the pins out using a small screwdriver 6 Open the door the door remains fastened to the left side panel 7 Remove the ten screws that secure the front cover of the heat engine Remove the front cover of the Heat Engine 8 Remove the two screws securing the circuit board and partially extract it 9 Carefully disconnect the Circulating Pump wiring harness plug from the circuit board 10 Drain the tank following the instructions in the Draining The Tank section in the Operating Manual 11 Disconnect the lower hose from the Water Inlet fitting on the left hand side of the Heat Engine Cabinet 12 Remove the two mounting screws for Water Inlet suction side of the pump 13 Remove the two screws on the discharge side copper piping of the pump 14 Remove the remaining four Circulating Pump mounting screws two located at the bottom of the Heat Engine Cabinet and two located at the Water Inlet 15 Remove the pump To Install 1 Assemble the new pump to the Heat Engine Cabinet using the four screws 2 Reassemble
16. the copper piping to the pump discharge side 3 Reassemble the Water Inlet fitting to the Heat Engine Cabinet 4 Reconnect the lower hose to the Water Inlet fitting 5 Open the shutoff valves on both the hot water and cold water lines 6 Fill the tank following the instructions in the Filling The Water Heater section in the Operating Manual 0610 10 Close and lock the door 12 13 Restart the water heater following the Lighting Secure the Ground Lug with the screw Carefully reconnect the wiring harness plug to the circuit board Slide the circuit board into its proper position and secure using the two screws Reassemble the front cover of the Heat Engine Open the shutoff valve on the gas supply line to the water heater Reconnect the electrical power to the water heater Instructions found in the Operating Manual Access To Door Pins 319172 000 Rev 00 Screw Ground Lug Circuit Board Circulation Pum Screws Pump Discharge S A gt T HEHE a 5 808 2 o gt 9 1 i a k ir 7 k A D VA Noe 2 5 2 lt 9 2 gt II F A iL 5 5 gt 3 i b o gt 25 5 0 319172 000 00 0610 Instructions
17. this water heater Remove panels to gain access Door opening 1 Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver 2 Release the top and bottom door pins by prying the pins out using a small screwdriver 3 Open the door the door remains fastened to the left side panel To Remove 1 Disconnect the electrical power to the water heater Close the shutoff valve on the gas supply line to the water heater 3 Close the shutoff valves on both the hot water and cold water lines 4 Drain the tank following the instructions the Draining The Tank section in the Operating Manual Top Casing Access To Front Door Pins Door Lock 0610 61 5 19 20 21 22 23 24 25 26 Remove the ten screws that secure the front cover of the heat engine Remove the front cover of the Heat Engine Remove the two screws securing the circuit board and partially extract it Carefully disconnect the HiLimit temperature switch 2 thin red wires and the Blower motor wiring harness plug from the circuit board Carefully disconnect the black wire from the Spark generator to the electrode Remove the two screws securing the retaining clip that holds in the copper tube to the fitting on the left side of the heat engine Remove the retaining clip Remove the two screws securing the retaining clip that holds in the copper tube to the internal flow valve
18. water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove 1 0610 Disconnect the electrical power to the water heater Close the shutoff valve on the gas supply line to the water heater Close the shutoff valves on both the hot water and cold water lines Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver Release the top and bottom door pins by prying the pins out using a small screwdriver Open the door the door remains fastened to the left side panel Remove the ten screws that secure the front cover of the heat engine Remove the front cover of the Heat Engine Carefully disconnect the three wire harness plugs leading to flow valve Two are for Flow Valve control one is for the Inlet Thermistor Access To Door Pins 9 Drain the tank following the instructions in the Draining The Tank section in the Oper
19. 9 Open the shutoff valves on both the hot water and cold water lines 10 Fill the tank with water 11 Reconnect the gas line 12 Reconnect the electrical power to the water heater 13 Open the shutoff valve on the gas supply line to the water heater 14 Use a approved water and soap solution to check the for gas leaks Repair as required 15 Reassemble the front cover of the Heat Engine 16 Close and lock the door 17 Restart the water heater following the Lighting Instructions found in the Operating Manual Heat Engine Cabinet Spark Generator Burner Orifice Plate Screw amp Washer 5 Gas Line Extension Gas lnlet Screw amp Fitting Washer 4 0610 20 319172 000 Rev 00 Instructions ECO SWITCH REPLACEMENT GAS WATER HEATERS This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist th
20. Casing Front 1 Use only Teflon tape or an approved pipe sealant on the threads Install the new Hot Water Outlet Nipple Anode Reconnect the hot water piping to the Hot Water Outlet Nipple Anode 4 Open the shutoff valve on the cold water line Fill the tank following the instructions in the Filling The Water Heater section in the Operating Manual Check for leaks and repair as required Reassemble the casing top front Close and lock the door Reconnect the electrical power to the water heater 0 Restart the water heater following the Lighting Instructions found in the Operating Manual sO ONO 0610 49 319172 000 Rev 00 Hot Water Outlet ipple Anode V 319172 000 Rev 00 0610 Instructions GAS WATER HEATERS DIP TUBE REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed E
21. N Upper Hose Assembly Hot A Heat Engine Outlet Fitting Heat Engine Inlet Fitting Lower Hose Assembly Cold Drain Valve 0610 37 319172 000 Rev 00 0610 38 319172 000 00 Instructions GAS WATER HEATERS TANK THERMISTOR REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove Access To 1 Disconnect the electrical power to the water heater Door Pins Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver 3 Release the top and bottom door pins by prying the pins out using a small screwdriver 4 Open the door the door remains fastened to the left side panel 5 Carefully disconnect the Tank Thermistor wiring harness plug from the Display Panel located on the door 6 Carefully
22. This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove 1 Disconnect the electrical power to the water heater Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver 3 Release the top and bottom door pins by prying the pins out using a small screwdriver 4 Open the door the door remains fastened to the left side panel 5 Remove the ten screws that secure the front cover of the heat engine Remove the front cover of the Heat Engine 6 Carefully disconnect the wire leading to the Flame Rod 7 Remove the two screws securing the Flame Rod 8 Remove the Flame Rod and Gasket Ensure old gasket is completely removed and no material remains To Install 1 Secure the new Flame Rod and Gasket with the two screws 2 Carefully reconnect the wi
23. air to the top left side solenoid side panel 4 Install the Gas Valve Assembly into the heat engine 7 Remove the ten screws that secure the front cover of ensuring the Assembly is seated properly between the the heat engine Remove the front cover of the Heat Orifice Plate and the heat engine Engine 5 Secure the Orifice Plate with four screws Ensure the 8 Remove the two screws securing the circuit board and Spark Generator is properly secured partially extract it 6 Secure the Gas Inlet Fitting with two screws Ensure the 9 Carefully disconnect the Gas Valve wiring harness plug O ring is undamaged and properly positioned from the circuit board 10 Disconnect the gas line from the heat engine Access To 11 Remove the two screws that secure the Gas Inlet Door Pins Fitting 12 Remove the four screws that secure the Burner Orifice Plate One of these screws also secures the Spark Generator 13 Pull the Gas Valve Assembly away from the heat engine 14 Carefully disconnect the wire harness from the Gas Valve Assembly 15 Remove the five screws and washers securing the Burner Orifice Plate to the Gas Valve 16 Remove the four screws and washers that secure the Gas Line Extension to the Gas Valve 17 Remove the Gas Valve 0610 19 319172 000 Rev 00 7 Carefully reconnect the Gas Valve wiring harness plug to the circuit board 8 Slide the circuit board into its proper position and secure using the two screws
24. at the lower right side of the heat engine Remove the retaining clip Carefully disconnect the blue wire from the Flame sensor Remove the two screws securing the ECO switch Remove the ECO switch Remove the four screws around the outside of the orifice plate One of these screws also secures the Spark generator another one secures a ground lug Remove the five screws that secure the top portion of the Gas valve to the burner chamber Remove the four retaining screws that secure the heating core to the Heat Engine Cabinet There is one under the blower one under the combustion chamber and one on each side at the top Note When removing the upper two screws support the core so that it will not drop Remove the Heat exchanger assembly from the Heat engine Remove the exhaust gasket and ring Remove six screws securing the Combustion chamber to the lower portion of Heat exchanger Remove the Combustion chamber Remove the six screws securing the Draft hood to the upper portion of Heat exchanger Remove the Draft hood Carefully remove and retain but do NOT cut the HiLimit temperature switch from the heat exchanger Ensure old white gasket is completely removed and no material remains on the Draft Hood and Combustion chamber 319172 000 Rev 00 Spark Generator oe VEGF ISTY Q SNL Screw 2 Circuit Board Heat Engine ECO Switch gt gt 9 5 g
25. ating Manual 10 Remove the two screws that fasten the copper piping to the Circulation Pump discharge side 11 Remove the two screws from the flange on the outlet side of the flow valve and remove the clamp 12 Remove the two screws fastening the flow valve mounting bracket to the Heat Engine Cabinet 13 Remove the two screws fastening the copper piping to the flow valve mounting bracket 14 Remove the two screws fastening the flow valve to the mounting bracket 15 Remove the Internal Flow Valve To Install 1 Secure the new Internal Flow Valve to the mounting bracket with the two flow valve mounting screws 2 Secure the copper piping to the flow valve mounting bracket using the two copper piping mounting screws 3 Secure the mounting bracket with two screws 4 Secure the piping for the outlet side of the flow valve with the clamp and two screws 5 Secure the copper piping to the Circulation Pump discharge side with two screws 6 Carefully reconnect the three wire harness plugs 7 Open the shutoff valves on both the hot water and cold water lines 8 Fill the tank following the instructions in the Filling The Water Heater section in the Operating Manual 9 Reassemble the front cover of the Heat Engine 10 Close and lock the door 11 Open the shutoff valve on the gas supply line to the water heater 12 Reconnect the electrical power to the water heater 13 Restart the water heater following the
26. ating the lock counter clockwise with a wide slot screwdriver Release the top and bottom door pins by prying the pins out using a small screwdriver Open the door the door remains fastened to the left side panel Carefully disconnect all the wiring harness plugs from the Display Panel Carefully remove the door hinge pins from their retaining fingers Remove the top casing front 1 Use a screwdriver to remove the six screws securing the top casing 2 Lift up and remove casing top front Top Casing Access To Front Door Pins Door Lock Screws 0610 57 Remove the top casing 1 2 Use screwdriver to remove the two screws securing the top casing Lift up and remove casing top rear Remove the right side panel 1 2 3 4 Use a screwdriver to remove the screw from the bottom front of the right side panel Remove the three screws from the right side panel towards the rear of the unit Remove the screw from the top of the unit Push the panel back and lift out Remove the left side panel 1 2 3 4 Use a screwdriver to remove the screw from the bottom front of the left side panel Remove the three screws from the left side panel towards the rear of the unit Remove the screw from the top of the unit Push the panel back and lift out Remove the rear panel Use a screwdriver to remove the four screws on the back side Lift off the panel 1
27. ctions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove 1 0610 Disconnect the electrical power to the water heater Close the shutoff valves on both the hot water and cold water lines Drain the tank following the instructions in the Draining The Tank section in the Operating Manual Disconnect the discharge piping from the Temperature amp Pressure Relief Valve Remove the Temperature amp Pressure Relief Valve 45 To Install 1 Use only Teflon tape or approved pipe sealant on the threads Install the new Temperature amp Pressure Relief Valve Open the shutoff valves on both the hot water and cold water lines Fill the tank following the instructions in the Filling The Water Heater section in the Operating Manual Check for leaks and repair as required Close and lock the door Reconnect the electrical power to the water heater Restart the water heater following the Lighting Instructions found in the Operating Manual 319172 000 Rev 00 Temperature amp Pressure Relief Valve Discharge Piping 0610 46 319172 000 Rev 00 Service Instructions GAS WATER HEATERS CONDENSATE TRAP REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained
28. disconnect the Tank Thermistor wiring harness plug from the Heat Engine Cabinet 7 Loosen the screw on the Tank Thermistor bracket and remove the bracket 8 Remove the Tank Thermistor To Install 1 Install the new Tank Thermistor Reinstall the Tank Thermistor bracket around the thermistor and tighten the screw 3 Carefully reconnect the Tank Thermistor wiring harness plug to the Heat Engine Cabinet 4 Carefully reconnect the Tank Thermistor wiring harness plug to the Display Panel Close and lock the door Reconnect the electrical power to the water heater Restart the water heater following the Lighting Instructions found in the Operating Manual NO U 0610 39 319172 000 Rev 00 Instructions GAS WATER HEATERS EXHAUST VENT HIGH TEMPERATURE SWITCH REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of
29. door by rotating the lock counter clockwise 4 Push the panel back and lift out with a wide slot screwdriver 2 Release the top and bottom door pins by prying the pins To Remove out using a small screwdriver 3 Open the door the door remains fastened to the left 1 Disconnect the electrical power to the water heater side panel 2 Loosen the upper gear clamp that secures the venting system to the vent coupler Remove the top casing front 3 Lift the venting system out of the vent coupler 1 Use a screwdriver to remove the six screws securing 4 Remove the drain tubing from the condensate trap the top casing 5 Carefully disconnect the two wires from the High 2 Lift up and remove casing top front temperature Switch 6 Remove the two screws that secure the exhaust elbow Remove the right side panel 7 Remove the exhaust elbow it could be a snug fit 1 Use a screwdriver to remove the screw from the bottom 8 Remove the exhaust elbow gasket front of the right side panel 9 Remove the Condensation Baffle no nn To To Install oor Pins Door Lock 1 Install the new Condensation Baffle 2 Ensure the gasket is placed correctly onto the exhaust elbow prior to assembly Screws Casing Front 0610 55 319172 000 Rev 00 Secure the exhaust elbow with the two screws 00000000 12 Restart the water heater following the Lighting Instructions found in the Operating Manual 4 Carefully r
30. e four screws 2 Carefully reconnect the wiring harness plugs to the Display Panel 3 Close and lock the door 4 Open the shutoff valve on the gas supply line to the water heater 5 Reconnect the electrical power to the water heater 6 Restart the water heater following the Lighting Instructions found in the Operating Manual 0610 Access To Door Pins 319172 000 Rev 00 Instructions GAS WATER HEATERS INLET THERMISTOR REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove Access To 1 Disconnect the electrical power to the water heater Door Pins Close the shutoff valve on the gas supply line to the water heater 3 Close the shutoff valves on both the hot water and cold water lines 4 Unlock the door by rotating the l
31. e help of a qualified service technician to service this water heater To Remove 1 Disconnect the electrical power to the water heater Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver 3 Release the top and bottom door pins by prying the pins out using a small screwdriver 4 Open the door the door remains fastened to the left side panel 5 Remove the ten screws that secure the front cover of the heat engine Remove the front cover of the Heat Engine 6 Carefully disconnect the two wire leads to the ECO switch 7 Remove the two screws securing the ECO switch 8 Remove the ECO switch To Install 1 Secure the new ECO switch using the two screws Carefully reconnect the two wire leads to the ECO switch 3 Reassemble the front cover of the Heat Engine 4 Close and lock the door 5 Reconnect the electrical power to the water heater 6 Restart the water heater following the Lighting Instructions found in the Operating Manual 0610 21 Access To Door Pins 319172 000 Rev 00 ATE Lem Al TI al ort 4 Instructions POWER CORD GAS WATER HEATERS This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure
32. econnect the two wires to the High temperature Switch 5 Connect the drain tubing to the condensate trap 6 Reposition the venting into the vent coupler 7 Tighten the upper gear clamp to secure the venting system to the vent coupler 8 Reassemble the right side panel 9 Reassemble the casing top front 10 Close and lock the door 11 Reconnect the electrical power to the water heater Venting System CT a Vent Coupling Gear Clamp e Exhaust Elbow Screw Condensate Trap Condensate Tube 0610 56 319172 000 Rev 00 Instructions GAS WATER HEATERS TANK REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater Remove panels to gain access Remove Door 1 2 3 Disconnect the electrical power to the water heater Unlock the door by rot
33. erly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove To Install 1 Disconnect the electrical power to the water heater 1 Fasten the Gas Line Extension to the new Gas Valve Close the shutoff valve on the gas supply line to the with the four screws and washers Ensure the O ring is water heater undamaged and properly positioned 3 Close the shutoff valves on both the hot water and cold 2 Secure the Burner Orifice Plate to the Gas Valve with water lines five screws and washers 4 Unlock the door by rotating the lock counter clockwise 3 Carefully reconnect the wire harness to the Gas Valve with a wide slot screwdriver Assembly green wire pair to the lower right solenoid 5 Release the top and bottom door pins by prying the pins yellow amp black pair wire to the lower left solenoid black out using a small screwdriver amp white pair to the top right side solenoid and black amp 6 Open the door the door remains fastened to the left brown p
34. he door by rotating the lock counter clockwise with a wide slot screwdriver 3 Release the top and bottom door pins by prying the pins out using a small screwdriver 4 Open the door the door remains fastened to the left side panel 5 Remove the ten screws that secure the front cover of the heat engine Remove the front cover of the Heat Engine 6 Remove the two screws securing the circuit board and partially extract it 7 Carefully disconnect the Transformer wiring harness plugs from the circuit board 8 Remove the four screws securing the Transformer to the Heat Engine Cabinet 9 Remove the Transformer To Install 1 Secure the new Transformer to the Heat Engine Cabinet with the four screws 2 Carefully reconnect the Transformer wiring harness plugs to the circuit board 3 Slide the circuit board into its proper position and secure using the two screws 4 Reassemble the front cover of the Heat Engine 5 Close and lock the door 6 Reconnect the electrical power to the water heater 7 Restart the water heater following the Lighting Instructions found in the Operating Manual 8 0610 25 Access To Door Pins 319172 000 Rev 00 Heat Cabinet pa Ne s A N 319172 000 00 26 0610 Instructions GAS WATER HEATERS FLAME ROD REPLACEMENT
35. he gas supply line Fill the tank following the instructions in the Filling The Water Heater section in the Operating Manual Carefully reconnect the wire harnesses Reassemble the side panel in the reverse order Sa WU 00000000 00202000 0610 B we 9 10 11 HH lt Reassemble the flexible venting in the reverse order Re fit the insulation around the exhaust elbows Reassemble the top casing in the reverse order Reconnect the electrical power to the water heater 13 Restart the water heater following the Lighting Instructions found in the Operating Manual Nut 319172 000 Rev 00 0610 4 319172 000 00 Instructions GAS WATER HEATERS CULATION PUMP REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified
36. he shutoff valves on both the hot water and cold water lines Drain the tank following the instructions in the Draining The Tank section in the Operating Manual Remove the Drain Valve nstall Use only Teflon tape or an approved pipe sealant on the threads Install the new Drain Valve Open the shutoff valves on both the hot water and cold water lines Fill the tank following the instructions in the Filling The Water Heater section in the Operating Manual Check for leaks and repair as required Close and lock the door Reconnect the electrical power to the water heater Restart the water heater following the Lighting Instructions found in the Operating Manual 43 Access To Door Pins 319172 000 Rev 00 Instructions GAS WATER HEATERS TEMPERATURE amp PRESSURE RELIEF VALVE REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instru
37. is heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove 1 Disconnect the electrical power to the water heater Close the shutoff valves on both the hot water and cold water lines 3 Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver 4 Release the top and bottom door pins by prying the pins out using a small screwdriver 5 Open the door the door remains fastened to the left side panel 6 Drain the tank following the instructions in the Draining The Tank section in the Operating Manual 7 Unscrew the Water Inlet Filter To Install 1 Install the new Water Inlet Filter 2 Close the drain valve 3 Open the shutoff valves on both the hot water and cold water lines 4 Fill the tank following the instructions in the Filling The Water Heater section in the Operating Manual 5 Close and lock the door 6 Reconnect the electrical power to the water heater 7 Restart the water heater following the Lighting Instructions found in the Operating Manual 0610 33 Access To Door Pins 319172 000 Rev 00 Heat Cabinet Water Inlet Filter Water Inlet Fitting 0610 34 319172 000 Rev 00
38. le the retaining clip that holds in the copper tube to the fitting on the left hand side of the heat engine Open the shutoff valves on both the hot water and cold water lines Fill the tank following the instructions in the Filling The Water Heater section in the Operating Manual Check for leaks and repair as required Reassemble the front cover of the Heat Engine Close and lock the door Open the shutoff valve on the gas supply line to the water heater Reconnect the electrical power to the water heater Restart the water heater following the Lighting Instructions found in the Operating Manual 63 Screw 6 SS Draft Hood er C gt Gasket Draft Exhaust Hood Ring Heat Exchanger RE Gasket Draft Hood Gasket Combustion i gt Chamber II E ss Combustion Chamber Las P IS gt HiLimit DO 17 Temperature Switch Screw 6 Combustion Chamber 319172 000 Rev 00
39. ng Screw 2 0610 10 319172 000 Rev 00 Instructions DIS PLAY PANEL REPLACEMENT GAS WATER HEATERS This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove 1 Disconnect the electrical power to the water heater Close the shutoff valve on the gas supply line to the water heater 3 Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver 4 Release the top and bottom door pins by prying the pins out using a small screwdriver 5 Open the door the door remains fastened to the left side panel 6 Carefully disconnect all the wiring harness plugs from the Display Panel 7 Remove the four screws securing the Display Panel 8 Remove the Display Panel To Install 1 Assemble the new Display Panel to the door using th
40. nlist the help of a qualified service technician to service this water heater Remove panels to gain access Remove the top casing front 1 Use a screwdriver to remove the six screws securing the top casing Screws 2 Lift up and remove casing top front Screws To Remove 1 Disconnect the electrical power to the water heater Close the shutoff valve on the cold water line 3 Follow the instructions in the Draining The Tank section in the Operating Manual to drain approximately 5 gallons 20 litres of water from the tank Close the drain valve 5 Disconnect the cold water piping from the Cold Water Inlet Nipple Dip Tube 6 Remove the Cold Water Inlet Nipple Dip Tube gt Install Casing Front 1 Use only Teflon tape an approved pipe sealant the threads Install the new Cold Water Inlet Nipple Dip Tube Reconnect the cold water piping to the Cold Water Inlet Nipple Dip Tube 4 Open the shutoff valve on the cold water line Fill the tank following the instructions in the Filling The Water Heater section in the Operating Manual Check for leaks and repair as required Reassemble the casing top front Close and lock the door Reconnect the electrical power to the water heater 0 Restart the water heater following the Lighting Instructions found in the Operating Manual sO ONO 0610 51 319172 000 Rev 00 Cold Water Inlet Nipple Dip T
41. ock counter clockwise with a wide slot screwdriver 5 Release the top and bottom door pins by prying the pins out using a small screwdriver 6 Open the door the door remains fastened to the left side panel 7 Remove the ten screws that secure the front cover of the heat engine Remove the front cover of the Heat Engine 8 Carefully disconnect the wire harness plug leading to thermistor 9 Drain the tank following the instructions in the Draining The Tank section in the Operating Manual 10 Remove the retaining screw for the inlet thermistor using an offset right angle Phillips screwdriver 11 Remove the thermistor To Install 1 Secure the new thermistor in place with the retaining screw 2 Open the shutoff valves on both the hot water and cold water lines 3 Fill the tank with water Check for leaks and repair as required 4 Carefully reconnect the wiring harness plug to the thermistor 5 Reassemble the front cover of the Heat Engine 6 Close and lock the door 7 Open the shutoff valve on the gas supply line to the water heater 8 Reconnect the electrical power to the water heater 9 Restart the water heater following the Lighting Instructions found in the Operating Manual 0610 13 319172 000 Rev 00 Instructions GAS WATER HEATERS INTERNAL FLOW VALVE REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired
42. re leading to the Flame Rod 3 Reassemble the front cover of the Heat Engine 4 Close and lock the door 5 Reconnect the electrical power to the water heater 6 Restart the water heater following the Lighting Instructions found in the Operating Manual 0610 27 Access To Door Pins 319172 000 Rev 00 Heat Cabinet 0610 28 319172 000 Rev 00 Instructions GAS WATER HEATERS SPARK GENERATOR REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove Access To 1 Disconnect the electrical power to the water heater Door Pins Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver 3 Release the top and bottom door pins by prying the pins out using a small screwdriver 4 Open
43. rewdriver to remove the six screws securing To Remove the top casing 2 Lift up and remove casing top front 1 Disconnect the electrical power to the water heater Close the shutoff valve on the gas supply line to the Remove the flexible venting water heater 1 Unwrap the insulation covering to expose the front elbow 3 Close the shutoff valves on both the hot water and cold of the venting water lines 2 Loosen the gear clamps securing the venting 4 Drain the tank following the instructions in the Draining The Tank section in the Operating Manual no Access To 5 Disconnect the hoses from the heat engine top is water Door Pins outlet and bottom is water inlet Door 6 Disconnect the gas line from the heat engine Lock 7 Carefully disconnect the wire harnesses from the heat engine Screws Screws Top Casing Front 0610 1 319172 000 Rev 00 ST pi p N SI TN CD MS b 9 Remove the 4 nuts holding the heat engine to the tank Requires 1 2 wrench socket or nut driver It may be necessary to remove part of the venting system to access some nuts Remove the heat engine To Install N Assemble the new heat engine to the tank Reconnect the hoses to the heat engine Reconnect the gas line Open the shutoff valves on both the hot water and cold water lines Open the shutoff valve on t
44. s securing the Blower Motor 10 Remove the Blower Motor To Install 1 Assemble the new Blower Motor using the three screws 2 Carefully reconnect the wiring harness plug to the circuit board 3 Slide the circuit board into its proper position and secure using the two screws 4 Reassemble the front cover of the Heat Engine 5 Close and lock the door 6 Open the shutoff valve on the gas supply line to the water heater 7 Reconnect the electrical power to the water heater 8 Restart the water heater following the Lighting Instructions found in the Operating Manual 0610 Access To Door Pins 319172 000 Rev 00 Heat Circuit S IK JA p Blower Motor Mounting Screw 3 FIM A m 319172 000 00 0610 Instructions GAS WATER HEATERS CIRCUIT BOARD REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If yo
45. the circuit board 4 Slide the circuit board into its proper position and secure using the two screws 5 Reassemble the front cover of the Heat Engine 6 Close and lock the door 7 Reconnect the electrical power to the water heater 8 Restart the water heater following the Lighting Instructions found in the Operating Manual 9 0610 23 Access To Door Pins 319172 000 Rev 00 Screw Ground Lug 2 Heat Engine Cabinet N Screw 2 855 0610 24 319172 000 00 Instructions TRANSFORMER GAS WATER HEATERS This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove 1 Disconnect the electrical power to the water heater Unlock t
46. the door the door remains fastened to the left side panel 5 Remove the ten screws that secure the front cover of the heat engine Remove the front cover of the Heat Engine 6 Remove the two screws securing the circuit board and partially extract it 7 Carefully disconnect the Spark Generator wiring harness plug from the circuit board 8 Remove the screw securing the Ground Lugs Remove the screw securing the Spark Generator 10 Remove the two screws securing the Electrode assembly It may be necessary to remove the Power Cord to gain access to the two screws 11 Carefully disconnect the wire harness from the Spark Generator 12 Remove the Spark Generator Electrode assembly and Gasket Ensure old gasket is completely removed and no material remains To Install 1 Carefully reconnect the wire harness to the new Spark Generator 2 Secure the Electrode assembly and Gasket with the two screws Secure the Spark Generator with the screw Secure the Ground Lugs with the screw 5 Carefully reconnect the Spark Generator wiring harness plug to the circuit board Slide the circuit board into its proper position and secure using the two screws Reassemble the front cover of the Heat Engine Close and lock the door Reconnect the electrical power to the water heater 0 Restart the water heater following the Lighting Instructions found in the Operating Manual D sO ON 0610 29 319172 000 Rev 00
47. to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove 1 Disconnect the electrical power to the water heater Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver 3 Release the top and bottom door pins by prying the pins out using a small screwdriver 4 Open the door the door remains fastened to the left side panel 5 Remove the ten screws that secure the front cover of the heat engine Remove the front cover of the Heat Engine 6 Remove the two screws securing the circuit board and partially extract it 7 Carefully disconnect the Power Cord wiring harness plug from the circuit board 8 Remove the two screws securing the Ground Lugs 9 Remove the two screws securing the Power Cord to the Heat Engine Cabinet 10 Remove the Power Cord To Install 1 Secure the new Power Cord to the Heat Engine Cabinet with the two screws 2 Secure the Ground Lugs with the two screws 3 Carefully reconnect the Power Cord wiring harness plug to
48. top of the flue tube 2 Remove the small baffle by pulling it straight out of the side of the flue tube Remove the tank temperature sensor 1 Remove the clip and slide the sensor out Remove the earthquake straps 1 Remove the bolts at the clamp that hold the two halves of the earthquake strap To Remove 1 Lift tank out of position Hint Screw a short length of 3 4 NPT pipe into the sides of the water heater to use as handles to move the water heater 0610 To Install 1 Fit the new tank in position Hint Screw a short length of 3 4 NPT pipe into the sides of the water heater to use as handles to move the water heater To Reassemble Reinstall the earthquake straps in the reverse order 2 Reinstall the tank temperature sensor and clip in reverse order 3 Install the large baffle 4 Install the small baffle into the condensation trap by fitting the tabs into the slots inside the condensation trap and then install condensation trap and small baffle into tank in reverse order 5 Reinstall the venting 6 Connect the hot water and cold water lines to the tank 7 Assemble heat engine to the tank 8 Reconnect the gas line 9 Reconnect the hoses to the tank 10 Open the shutoff valves on both the hot water and the cold water lines 11 Fill the tank following the instructions in the Filling The Water Heater section of the Operating Manual 12 Carefully reconnect the wire harnesses 13
49. u lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater To Remove Access To 1 Disconnect the electrical power to the water heater Door Pins Close the shutoff valve on the gas supply line to the water heater 3 Unlock the door by rotating the lock counter clockwise with a wide slot screwdriver 4 Release the top and bottom door pins by prying the pins out using a small screwdriver 5 Open the door the door remains fastened to the left side panel 6 Remove the ten screws that secure the front cover of the heat engine Remove the front cover of the Heat Engine Remove the two screws securing the circuit board 8 Carefully disconnect all the wiring harness plugs from the circuit board 9 Remove the circuit board To Install 1 Carefully reconnect the wiring harness plugs to the circuit board 2 Assemble the new circuit board to the Heat Engine Cabinet and secure using the two screws Reassemble the front cover of the Heat Engine Close and lock the door 5 Open the shutoff valve on the gas supply line to the water heater Reconnect the electrical power to the water heater 7 Restart the water heater following the Lighting Instructions found in the Operating Manual D 0610 9 319172 000 Rev 00 Heat Cabinet 5 2 Circuit Board Mounti
50. ube 319172 000 Rev 00 0610 Instructions GAS WATER HEATERS MAIN BAFFLE REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater Remove panels to gain access Top Casing Rear Remove the top casing front 1 Use a screwdriver to remove the six screws securing the top casing Screws 2 Lift up and remove casing top front Screws Remove the top casing rear 1 Use a screwdriver to remove the two screws securing the top casing 2 Lift up and remove casing top rear Remove the flexible venting 1 Unwrap the insulation covering the venting 2 Loosen the gear clamps securing the venting 3 Remove the flexible venting To Remove Top 1 Disconnect the electrical power to the water heater Casing Front 2 Remove the main
51. ube 0610 319172 000 Rev 00 Instructions GAS WATER HEATERS ANODE REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service this heater Maintenance and service requires trade knowledge in the areas of plumbing electricity and gas If you lack these skills or have difficulty understanding these instructions you should not proceed Enlist the help of a qualified service technician to service this water heater Remove panels to gain access Remove the top casing front 1 Use a screwdriver to remove the six screws securing the top casing Screws 2 Lift up and remove casing top front Screws To Remove 1 Disconnect the electrical power to the water heater Close the shutoff valve on the cold water line 3 Follow the instructions in the Draining The Tank section in the Operating Manual to drain approximately 5 gallons 20 litres of water from the tank Close the drain valve 5 Disconnect the hot water piping from the Hot Water Outlet Nipple Anode 6 Remove the Hot Water Outlet Nipple Anode gt Install
52. wdriver 6 Open the door the door remains fastened to the left side panel 7 Remove the ten screws that secure the front cover of the heat engine Remove the front cover of the Heat Engine 8 Carefully disconnect the wire harness plug leading to thermistor 9 Drain the tank following the instructions in the Draining The Tank section in the Operating Manual 10 Remove the two screws from the flange on the return fitting and remove the clamp 11 Remove the thermistor To Install 1 Secure the new thermistor in place with the clamp and two screws 2 Open the shutoff valves on both the hot water and cold water lines 3 Fill the tank with water Check for leaks and repair as required 4 Carefully reconnect the wiring harness plug to the thermistor 5 Reassemble the front cover of the Heat Engine 6 Close and lock the door 7 Open the shutoff valve on the gas supply line to the water heater 8 Reconnect the electrical power to the water heater 9 Restart the water heater following the Lighting Instructions found in the Operating Manual 0610 17 319172 000 Rev 00 Heat Cabinet ss gt 200 5 O Instructions GAS WATER HEATERS GAS VALVE REPLACEMENT This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is prop
53. wiring harness plug from the circuit board 8 Cut the plug off 9 Remove the HiLimit Temperature Switch To Install 1 Extract one pin from the new plug feed the new HiLimit Temperature Switch around the heat exchanger and re insert the pin into the plug 2 Carefully reconnect the HiLimit wiring harness plug to the circuit board 3 Slide the circuit board into its proper position and secure using the two screws 4 Reassemble the front cover of the Heat Engine 5 Close and lock the door 6 Reconnect the electrical power to the water heater 7 Restart the water heater following the Lighting Instructions found in the Operating Manual 0610 31 Access To Door Pins 319172 000 Rev 00 HiLimit Temperature Heat Exchanger x Heat Engine Cabinet MA WA 7 e lt ks 319172 000 Rev 00 32 0610 Instructions INLET WATER FILTER REPLACEMENT GAS WATER HEATERS This instruction has been prepared to acquaint you with the service of your gas fired water heater It is your responsibility to ensure that your water heater is properly installed and maintained Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and or property damage Thoroughly read and understand all instructions before you attempt to install operate or service th

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