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A.O. Smith PCG2J5040T3NOV 100 User's Manual

1. MANIFOLD TUBE GAS CONTROL VALVE THERMOSTAT REMOVAL REPLACEMENT Important Use only factory authorized replacement parts If you lack the necessary skills to properly perform the installation you should not proceed but get help from a qualified service technician Tools required 3 4 Open End Wrench or Crescent Wrench Phillips Head Screwdriver a short length of 1 2 threaded Pipe Removing the Gas Control Valve Thermostat 1 Set the gas control valve thermostat to its lowest setting by pressing the COOLER and HOTTER buttons together at the same time holding for 1 second Then press the COOLER button to the lowest setting Figure 112 2 Turn gas control switch to the OFF position located right side of the gas control valve thermostat and turn off the gas supply to the unit Figure 113 3 Disconnect the electric connection by unplugging the transformer from the wall outlet Figure 113 4 Release water pressure by opening a nearby hot water faucet let run until water is cool to touch Turn off water supply to the water heater 5 Remove the manifold cover outer door from the unit by depressing on the lower portion and pulling outward 6 Connect a drain hose to the drain valve and run it to an adequate drain or to the exterior of the building Open the water heater drain valve and allow the water to drain from the tank 7 Unplug all the e
2. Figure 62 CHAMBER GASKET 16 Reach inside the air intake chamber box and push on the center of the rubber wire protector pushing it and the wiring harness wires to the outside of Figure 62 the air intake chamber box Figure 62 17 Remove the wiring harness from the wire RUBBER WIRE channeling in the back center of the air intake PROTECTOR chamber box Figure 63 de o ELECTRICAL 18 The old wiring harness can now be discarded CONNECTION FER Installing the New Wiring Harness O CHAMBER SCREEN 19 Route the multi lead portion of the new wiring harness through the opening at the bottom of the Figure 63 RUBBER WIRE water heater s jacket Figure 64 PROTECTOR 20 Insert the fan wiring harness wire through the back and into the fan box compartment by threading the connector through the opening and insert in approximately 6 inches of wiring up to the rubber wire protector Figure 62 21 Push the rubber wire protector into place in the back of the air intake chamber box Note The rubber wire protector must be positioned properly and locked into place around both sides of the air intake chamber box Figure 63 REAR SIDE OF 22 Position the wiring harness wire in the wiring THE AIR INTAKE channeling molded down the back center of the air CHAMBER BOX intake chamber box Figure 63 Lo Y 23 Plug the electrical connections of the fan into the wiring
3. POWER ANODE CONTROL DISPLAY TERMINAL POWERED ANODE ROD REMOVAL REPLACEMENT Important Use only factory authorized replacement parts If you lack the necessary skills to properly perform the installation you should not proceed but get help from a qualified service technician Tools required Ratchet with 1 1 16 Socket Pliers and Teflon Tape or an approved pipe sealant Removing the Powered Anode Rod 1 Set the gas control valve thermostat to its lowest setting by pressing the COOLER and HOTTER buttons together at the same time holding for 1 second Then press the COOLER button to the lowest setting Figure 30 2 Turn gas control switch to the OFF position located right side of the gas control valve thermostat and turn off the gas supply to the unit Figure 31 3 Disconnect the electric connection by unplugging the transformer from the wall outlet Figure 31 4 Shut off the incoming water supply to the water heater and open a nearby hot water faucet to depressurize the water tank 5 Remove the manifold cover outer door and connect a hose to the drain valve and terminate it to adequate drain or to the exterior of the building Open the drain valve and allow at least 5 gallons of water from the tank to drain Close drain and remove hose 6 Unplug the electrical connection on top of the powered anode by pulling the wire connector up and off of the powered anode
4. Da ANIFOLD TUBE SCREW AT TRANSFORMER BOX 11 Ensuring that the gas supply line is turned off disconnect the gas piping at the ground joint union then remove the gas piping from the gas control valve thermostat Figure 116 Remove any other fittings that may be installed on the threaded pipe to the gas control valve thermostat Figure 116 After ensuring the water heater is completely drained thread a short length of 1 2 threaded pipe into the inlet connection of the gas control valve thermostat and use it to turn the gas control valve thermostat counterclockwise to remove Figure 117 12 13 Installing the Gas Control Valve Thermostat 14 Before installing apply Teflon tape or an approved pipe sealant on the threads of the new gas control valve thermostat only the threads that screw into tank 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 Min 35 foot pounds Figure 117 Remove the 1 2 threaded pipe from the gas control valve thermostat Reconnect the gas piping to the gas control valve thermostat use Teflon tape or an approved pipe sealant on threads of the piping Figure 116 Close the drain valve and turn on the cold water supply line filling t
5. SHORT LENGTH OF 1 2 TREADED PIPE Figure 118 PRESSURE SWITCH IMPORTANT WHEN BRUSHING ON AN d APPROVED NONCORROSIVE Te LEAK DETECTION SOLUTION DO NOT SPLASH SOLUTION ONTO ELECTRICAL CON NECTIONS j TRANSFORMER N CONNECTOR SENSE gt CONNECTOR MANIFOLD TUBE SCREW AT TRANSFORMER BOX GAS CONTROL VALVE THERMOSTAT i 1 ht E PRESSURE J N SWITCHIFAN FV SENSOR UN TY DISPLAY ANODE IF ROD CONNECTOR 23 24 25 26 27 Turn on the gas supply to the unit and test the gas supply line and union connections by brushing on an approved noncorrosive leak detection solution Figure 116 Turn on the electrical and the gas supplies to the water heater Plug in the electric connection from the transformer to the electric outlet Figure 113 Restart the water heater by following the directions on the Lighting and Operating Instructions label located on the front of the water heater As the burner is heating view flames through 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 any solution onto any electrical co
6. 30 000 Minimum Square Feet with 8 Ceiling Typical Room with 8 Ceiling 844 135 000 IMPORTANT e The area must be open and be able to provide the proper air requirements to the water heater Areas that are being used for storage or contain large objects may not be suitable for water heater installation e Water heaters installed in open spaces in buildings with unusually tight construction may still require outdoor air to function properly In this situation outside air openings should be sized the same as for a confined space e Modern home construction usually requires supplying outside air into the water heater area e Room exhaust fans may effect air requirements Confined Space For the correct and proper operation of this water heater ample air must be supplied for the combustion ventilation and dilu tion of flue gases Small enclosures and confined areas must have two permanent openings so that sufficient fresh air can be drawn from outside of the enclosure One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure The size of each o aning free area is deter mined by the total BTUH input of all gas utilization equipment i e water heaters furnaces clothes dryers etc and the method by which the air is provided The BTUH input can be found on the water heater rating plate Additional air can be provided by two methods 1 All air from in
7. Minimum Metal Drain Pan piped to an adequate drain NOTE Drain pan diameter must be at least 2 inches wider than the diameter of the water heater The water heater must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition FV Sensor Bracket NOTE If on a well system the expansion tank should be set to the maximum pressure of the pump tank White Rodgers gas control valve thermostat shown in this figure Figure 1 COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS Combustion Air Requirements AWARNING Carbon Monoxide Warning Water heater must be vented to outdoors Vent must be installed by a qualified technician using the local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition and or the installation instructions Examples of a qualified technican include gas technicians authorized gas company personel and authorized service persons Failure to so do can result in death or carbon monoxide poisoning IMPORTANT Air for combustion and ventilation must not come from a flammable or corrosive at mosphere Any failure due to flammable or corro sive elements in the atmosphere is excluded from warranty coverage The following types of installation not limited to the following will require outdoor air for combus tion d
8. eee eene eee erence ee eee e neers eee ea deere eeeaaaeeeeeeeaeeeeseeaaeeeseniaeeeeeneaas Gas Water Heater Sizing Guide and Leakage Checkoonts General THOME HOT tee tien ee haat ee ee Aas EE E BASIC INSTALLATION amp OPERATION INSTALLATION OF RESIDENTIAL GAS WATER HEATER Water See Labels and Water ge Cold E Exhaust Vent to Shut Off Installation Instructions Ouside of Building Valve and Use amp Care Guide for clearances Massachusett Install a vacuum relief in cold water line per section 19 MGL 142 Use Draft Hood supplied with unit Union Expansion Tank Pressurize to Equal Supply Water Pressure Relieve water pressure on the expansion tank before adjusting air pressure To Fixtures Hot Tempered Water Untempered _To Fixtures Temperature Pressure Relief Valve Hot Water Cold with discharge piped to an Water H d Control adequate drain Do not cap or plug Display a Manual Gas Shut off Valve 5 Air Intake Chamber 8 Air is drawn in for combustion Keep area clean and free from flammables and flammable vapors ge Gas Control Valve Thermostat Ge H Recommended setting of 120 F Follow the Mixing Valve C 4 Do not cap or plug Manufacturer s Instructions Ar p 6 Maximum Air Gap NOTE Local codes may vary Drain Electrical Plug Union Sediment Trap Drip Leg 3
9. i Lighting Instructions aaa a Eel ee ecg ADJUSTING TEMPERATURE CONTROL Adjusting the Temperature on the Electronic Control Display Using the Electronic Control Display Electronic Control Display Troubleshooting COMPONENTS REMOVAL REPLACING External Inspection and Cleaning eee eeeeeae i a iaeiiai iek i aee iee eia Electronic Control Display Removal Replacement Powered Anode Removal Replacement tnr nn annete EEEEEEEEAESEE ESENE E EEEE EEE En nnne neen Pressure Switch Removal Replacement Transformer Removal Replacement i Air Intake Chamber Box Removal Replacement nnn nnne eneen Wiring Harnesss Removal Replacement eee enne eee eeeecneee eee eneeeeeesaeeeeeeseeeeeeetieeeeessneeeeene Air Intake Chamber Fan Removal Replacement Ennn nennen Pressure Tubing Removal Replacement sssesssseeessrressrrirrnserrnnasnninansittnnaasntdnnaneannaadaaannndtnnaaaaadanenannaaaa Inner Door Manifold Burner Assembly Removal Replacement i Flame Sense Hot Surface Igniter Removal Replacement i Burner Removal Replacement i Burner Orifice Removal Replacement i Gas Control Valve Thermostat Removal Renlacement neeese tertttnrrnnstnestettrnr rennen nnee ne CHECKPOINTS GENERAL INFORMATION Checking the Gas Supply Pressure
10. 6 Disconnect the electrical flag terminals and air pressure tubing to the pressure switch Figure 96 7 Using a 3 4 open end wrench or a crescent wrench remove the manifold tube from the gas control valve thermostat turning counterclockwise natural gas Grasp the manifold tube and push down slightly to free the manifold tube from the Figure 95 gas control valve thermostat Figure 95 IMPORTANT nu gt 8 Use a 1 4 nut driver or 1 4 socket amp ratchet to LEAK DETECTION SOLUTION SSE VALVENMERMOSTAT loosen the 2 hex head screws on the inner door DO NOT SPLASH SOLUTION Se H ONTO ELECTRICAL CON so the inner door manifold burner assembly can NECTIONS nh be removed Figure 97 E TI I SWITCHIFAN 9 Remove inner door manifold burner assembly by MANIFOLD TUBE E fll A FV SENSOR grasping the manifold and pulling straight back POWER SUPPLY if IGNITERI wo ee are should be taken when inner door and burner TRANSFORMER h COME j i Y assembly passes rough jacket opening that it D CONNEGTOR Li IL ROR CONNECTOR does not damage any of the electrical wiring or the air pressure hose Figure 98 10 Go to step 11 Figure 96 PRESSURE SWITCH MANIFOLD TUBE Removing Old Burner 11 After noting the position of the condensation drain hole on the top of the burner Turn the inner door manifold burner a
11. IMPORTANT WHEN BRUSHING ON AN APPROVED NONCORROSIVE LEAK DETECTION SOLUTION DO NOT SPLASH SOLUTION ONTO ELECTRICAL CON NECTIONS MANIFOLD TUBE 1 I IGNITERI 1 POWER SUPPLY g FLAME TRANSFORMER CONNECTOR Figure 88 PRESSURE SWITCH B Si Il SENSE 2 CONNECTOR BURNER S TIP END TAB GAS CONTROL VALVE THERMOSTAT 4 U id i mi PRESSURE A SWITCHIFAN d d FV SENSOR CONNECTOR dp IT DISPLAY ANODE IH ROD CONNECTOR MANIFOLD TUBE FLAME SENSE HOT SURFACE IGNITER REMOVAL REPLACEMENT Important Use only factory authorized replacement parts If you lack the necessary skills to properly Figure ee perform the installation you should not proceed but get help from a qualified service technician RE Tools required 3 4 Open End Wrench or Crescent D y Wrench Phillips Head Screwdriver Ratchet with 1 4 riser Eo oen mm socket or 1 4 Nut Driver OO Replacing the Flame Sense Hot Surface Igniter HOTTER Ve pi COOLER Assembly Electronic Control Display 1 Set the gas control valve thermostat to its lowest setting by pressing the COOLER and HOTTER buttons together at the same time holding for 1 second Then press the COOLER button to the lowest setting Figure 89 2 Turn gas control switch to the OFF po
12. pressure Use only gas shown on rating plate e Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use H Do not operate if soot buildup Do not obstruct water heater air intake with insulating jacket Do not place chemical vapor emitting products near water heater Gas and carbon monoxide detectors Read instruction manual before are available installing using or servicing water heater Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual CAUTION Improper installation and use may result in property damage e Do not operate water heater if flood damaged e Install in location with drainage e Fill tank with water before operation e Be alert for thermal expansion Refer to instruction manual for installation and service TABLE OF CONTENTS INTRODUCTION Senvice Handbook Introduction 2 2 deg See EAR EE lge Eiere Table Of Contents ilari ih een i hotel iodato INSTALLATION OPERATION Basic Installation amp Operation Combustion Air and Vent System Requirements nnt KNOW YOUR WATER HEATER Know the Water Heaters Component Parts ssssesssseestnrrtnrstrssettttttrtntttnstatst ttt tt Enn EnEn annat EErEE EEE En nnne mEnE Water Heater Operation e een r a dati eat DEA aaaea a a a a eaoaai a aA Filling and Draining the Water Heater
13. 90 gal 97 gal 104 gal A thermostatic mixing valve set for a maximum temperature of 120 F is recommended to be installed to prevent a scalding hazard Based on tub water temperature of 105 Note Because the desired fill time is normally 10 minutes recovery capacity is not used for this calculation All water used is supplied by storage NOTE The draw efficiency of a gas or electric water heater storage tank is considered to be 70 LEAKAGE CHECKPOINTS A Water at the draft hood is water vapor which has To check where threaded portion enters tank condensed out of the combustion products This is insert cotton swab between jacket opening and caused by a problem in the vent fitting If cotton is wet follow draining instructions B Condensation may be seen on pipes in humid in the Draining the Water Heater section and then weather or pipe connections may be leaking remove fitting Put pipe dope or Teflon tape on the The powered anode rod fitting may be leaking threads and replace When you are finished follow DO Small amounts of water from temperature pressure the steps in Filling the Water Heater section relief valve may be due to thermal expansion or high water pressure in your area E The temperature pressure relief valve may be leaking at the tank fitting F Water from a drain valve may be due to the valve being slightly opened G The drain valve may be leaking at the tank fitting H
14. Combustion products contain water vapor which can condense on the cooler surfaces of the tank Droplets form and drip onto the burner or run on the floor 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 loose connections or the relief valve DO NOT replace the water heater until a full inspection of all possible water sources is made and necessary corrective steps taken SS MAKMUM AIR GAP i Leakage from other appliances water lines or ground seepage should also be checked Figure 122 53 GENERAL INFORMATION Draw efficiency is the quantity of hot water available to the consumer before the outlet water temperature decreases 25 degrees F A 40 gallon water heater will typically provide 70 28 gallons of this usable hot water 60 is the minimum The burner or elements are allowed to operate during this test Incoming cold water mixes the remaining stored water below this 25 degree limitation Energy Factor is an indicator of the combined thermal efficiency and standby efficiency of a water heater The higher the energy factor the more efficient the water heater will be Minerals and gases will separate from water as temperature increases R Value is a measure of the resistance of a substance to heat flow Recovery rate is the amount of water that is hea
15. Drawing Direct to outdoors 1 sq in per 4000 BTUH Horizontal Ducts 1 sq in per 2000 BTUH Single Opening 1 sq in per 3000 BTUH Example A water heater with an input rating of 50 000 BTUH using horizontal ducts would require each opening to have a minimum free area of 25 square inches Minimum free area 50 000 BTUH x 1 sq in 2000 BTUH 25 sq IN These openings connect directly with the outdoors through a ventilated attic a ventilated crawl space or through an outside wall Consult the local codes of your area for specific ventilation and combustion air requirements Vertical Ducts 1 sq in per 4000 BTUH ABLE VENT TO OUTDOORS INSTALL ABOVE ee INSULATION 1 ss Zei CONFINED OUTLET SPACE AIR TO ATTIC 1 SQ INCH PER 4000 BTUH INLET AIR FROM Ke CRAWL SPACE ALTERNATE AIR INLET 1 SQ INCH PER a 4000 BTUH 100 SQ INCH MINIMUM EACH OPEN n FOUNDATION VENT ALL AIR FROM OUTDOORS INLET AIR FROM VENTILATED CRAWL SPACE OUTLET AIR TO VENTILATED ATTIC Figure 4 GABLE VENT e TO OUTDOORS INSTALL ABOVE a INSULATION OUTLET AIR TO ATTIC 1 SQ INCH PER 4000 BTUH 100 SQ INCH MIN EACH INLET AIR DUCT 1 SQ INCH PER 4000 BTUH 100 SQ INCH MIN 12 MAXIMUM ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC Figure 5 COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS 1 SQ INCH PER 2000 BTUH 100 SQ INCH MINIMUM
16. Open the water heater drain valve and allow all the water to drain from the tank Flush the tank with water as needed to remove sediment 6 Close the drain valve refill the tank and restart the heater as directed in the lighting instructions on the front of the heater IMPORTANT Condensation may occur when refilling the tank and should not be confused with a tank leak NOTE If the water heater is going to be shut down for an extended period the drain valve should be left open Figure 19 A Outer Door E Adequate Drain J 15 LIGHTING INSTRUCTIONS Read and understand these directions thoroughly before attempting to operate the water heater Make sure the view port is not missing or damaged Make sure the tank is completely filled with water before operating the water heater The gas control valve thermostat has an On Off Switch and needs to be turned on before the water heater is operational Check the label on the front of the water heater near the gas control valve thermostat for the correct gas Do not start this water heater with any gas other than the one listed on the label If you have any questions or doubts consult the gas supplier or gas utility company The following Lighting Instruction label appears on the front of the water heater FOR YOUR SA
17. buttons together at the same time holding for 1 second Then press the COOLER button to the lowest setting Figure 68 2 Turn gas control switch to the OFF position located right side of the gas control valve thermostat and turn off the gas supply to the unit Figure 69 3 Disconnect the electric connection by unplugging the transformer from the wall outlet Figure 69 4 Using a phillips head screwdriver remove the two 2 screws at the air intake chamber screen Note save screws for reinstallation later Figure 70 5 Remove the air intake chamber screen by lifting upward Figure 70 6 Take note of the wire position routing around the fan inside of the air intake chamber as this wire positioning will need to be duplicated upon installation of the new fan inside the intake chamber box 7 Remove the 2 screws securing the old fan inside the chamber Note save these screws for reinstallation later Figure 70 8 Lift the old fan up and outward to remove from the air intake chamber Figure 70 9 Locate the male to female electrical connection with close pin lock on wiring harness the white connection approximately 12 from fan 10 To separate the electrical connection of the fan and wiring harness press down on the back portion of the close pin lock of the electrical connection while pulling the connection in the opposite directions Figure 68 HOTTER Figure 69 AIR INTAKE CHAMBER
18. look inside the burner chamber to fully understand the correct positioning of the burner assembly and burner manifold tab It may be necessary to use a flashlight to ensure correct placement Care must be taken so as to not damage any electrical wiring components or the air pressure ng as you are installing the new inner door manifold burner assembly Extra caution should be taken to ensure that electrical wiring air hose fiberglass insulation nor any other object is between door gasket and combustion chamber shield Installing New Inner Door Manifold Burner Assembly 11 12 13 14 15 16 17 18 Insert the manifold burner assembly in the burner chamber compartment making sure that the tip of burner manifold tab engages in the slot of the bracket Figure 86 The tip end of the burner manifold MUST be placed in the slotted portion under the condensation pan to obtain proper installation Figure 86 After confirming no material of any type are between door gasket and combustion chamber shield align the screws on the inner door with the screw holes on the combustion chamber and bet with 1 4 nut driver or 1 4 socket amp ratchet Figure 85 After tightening the inner door screws visually inspect area around door gasket and skirt for spaces or gaps The door asket MUST be sealed completely in order or the water heater to perform proper 3 DO NOT OPERATE THE WATER HEATER IF THE DOOR GASKET DOES
19. 21 Upon verifying proper operation of the water heater replace the manifold cover outer door 40 INNER DOOR MANIFOLD BURNER ASSEMBLY REMOVAL REPLACEMENT Important Use only factory authorized replacement parts If you lack the necessary skills to properly perform the installation you should not proceed but get help from a qualified service technician PE Tools required 3 4 Open End Wrench or Crescent f HH i Wrench Phillips Head Screwdriver Ratchet with 1 4 pine To oen mm socket or 1 4 Nut Driver OO HOTTER KW COOLER Electronic Control Display Figure 81 Figure 82 Removing Old Inner Door Manifold Burner Assembly 1 Set the gas control valve thermostat to its lowest setting by pressing the COOLER and HOTTER buttons together at the same time holding for 1 second Then press the COOLER button to the lowest setting Figure 81 6 OFF 2 Turn gas control switch to the OFF position x located right side of the gas control valve ON OFF thermostat and turn off the gas supply to the unit SR SWITCH Figure 82 3 Disconnect the electric connection by unplugging the transformer from the wall outlet Figure 82 4 Remove the manifold cover outer door from the unit by depressing on the lower portion and pulling outward 5 Unplug all
20. BOTTOM VIEW BURNER ORIFICE in SCREWS Reinstalling The Inner Door Manifold Burner Assembly 17 18 19 20 21 22 23 24 25 Insert the manifold burner assembly in the burner chamber compartment making sure that the tip of burner manifold tab engages in the slot of the bracket Figure 107 The tip end of the burner manifold MUST be placed in the slotted portion under the condensation pan to obtain proper installation Figure 107 After confirming no material of any type are between door gasket and combustion chamber shield align the screws on the inner door with the screw holes on the combustion chamber and tighten with 1 4 nut driver or 1 4 socket amp ratchet Figure 106 After tightening the inner door screws visually inspect area around door gasket and skirt for spaces or gaps The door gasket MUST be sealed completely in order for the water 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 natural gas Upon tightening with the fingers and confirming it has not been cross threaded tighten nut with an 3 4 open end wrench or crescent wrench Figure 110 Reconn
21. BOX 37 POWER IGN HEATING CLEAN VAC LOCK CHECK SC EER St ep Electronic Control Display COOLER OFF ON OFF SWITCH SCREEN Installing the Fan in the Air Intake Chamber Box Figure 71 11 Plug the electrical connections of the new fan into the wiring harness Align the electrical connections in such a position as to ensure the locking portions of the connections are on the same side Gently push the electrical connectors together until the snap lock on the wiring harness engages the angular lock on the fan connector Do Not use undue force in pushing SHES i ea these connectors together Figure 71 Note ITIS SNAP LOCKER Connectors are designed in such a manner if the connection is not properly aligned they will not lock together 12 Place the new fan inside the air intake chamber box It is imperative that the square portion of Figure 72 the fan air outlet be placed inside the raised square portion of the air intake chamber of the fan compartment Figure 72 13 Ensuring the new fan is properly aligned in the air INSTALL THE FAN USING THE intake chamber secure the fan in place using the TWO SCREWS REMOVED 2 screws removed in step 7 Figure 72 EARLIER 14 Route the wiring inside the fan box to the outer edge of the fan in such a manner to ensure it will not be pinched or damaged upon installation of the air inta
22. EACH CT er A OUTLET OUTDOOR AIR DUCTS CONFINED z gt SPACE me 1 SQ INCH PER 2000 BTUH 100 SQ INCH MINIMUM EACH ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS Figure 6 ALTERNATIVE OPENING LOCATION 1 SQ INCH PER 3000 BTUH 100 SQ INCH MINIMUM EACH CONFINED SPACE ALL AIR FROM OUTDOORS USING A SINGLE PERMANENT OPENING Figure 7 Vent Pipe System This water heater must be properly vented for the removal of exhaust gases to the outside atmosphere Correct installation of the vent pipe system is mandatory for the proper and efficient operation of this water heater and is an important factor in the life of the unit The vent pipe must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition The vent pipe installation must not be obstructed so as to prevent the removal of exhaust gases to the outside atmosphere U L recognized fuel gas and carbon monoxide CO detectors are recommended in all applications and should be installed using the manufacturer s instructions and local codes rules or regulations Vent Pipe Size It is important that you follow the guidelines in these instructions for sizing a vent pipe system If a transition to a larger vent size is required the vent transition connection must be made at the draft hood outlet DO NOT reduce the vent size to les
23. burner The gas control valve has an inlet filter built into its body to prevent impurities in the gas system from contaminating the internal valves and a LED diagnostic light located in the lower right hand corner of the valve to display any micro computer fault experienced by the control On the bottom of the control is where electrical connections to the other component parts are attached along with the gas supply manifold tube to the main burner The gas control valve thermostat of this water heater is suitable for use on Natural gas only Figure 12 Gas Control Valve Thermostat On Off Switch Le located on Bottom View the right side S as TT a I ololo amag JOL Temperature Probe z High Limit Probe i 1 8 Pin Systems y Connector fc 5 Pin Communications Manifold Tube gt a Connector 3 Pin Ignitor l i Connector Power Supply E Pressure SEN 2 Pin Power Transformer Switch Fan Connector FV Sensor Connector Connector Igniter Flame Sense Connector Control Display Anode Rod Connector KNOW THE WATER HEATER S COMPONENT PARTS Burner Manifold Door Assembly The burner manifold door assembly consists of several components such as main burner burner orifice manifold tube and flame sense hot surface ignite
24. but less than 10 seconds to enter the Temperature Scale Selection mode In this mode the currently active temperature scale indicator F or C will start to flash When in this mode a button press of either the red up arrow or the blue down arrow button will cause the control to toggle the temperature scale between F and C Figure 22 Once the selection has been made the user may exit this mode by again pressing the two temperature adjustment buttons at the same time for more than two 2 seconds but less than five 5 seconds The control will also time out five 5 seconds after the last button press and return to the normal operational mode Fault Code Diagnostics The control system of this water heater monitors inputs and outputs When the system determines a fault condition is present it will show the fault on the display Depending on the fault the system may continue to operate or enter a timed lockout Lockout time varies depending on the fault When the lockout time expires if the fault has been corrected the system will attempt normal operation Fault Code Retrieval The system will display the last eight 8 fault codes The system will display how many days ago each fault occurred up to 14 days Note A 14 indicates that the fault occurred 14 or more days ago Interrupting the power restarts the date code at 00 User must enter Field Service Mode to view information Current water tempe
25. door with the screw holes on the combustion chamber and tighten with 1 4 nut driver or 1 4 socket amp ratchet Figure 97 After tightening the inner door screws visually inspect area around door gasket and skirt for spaces or gaps The door gasket MUST be sealed completely in order for the water 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 natural gas Upon tightening with the fingers and confirming it has not been cross threaded tighten nut with an 3 4 open end wrench or crescent wrench Figure 100 Reconnect all the electrical connections to the bottom of the gas control valve thermostat gently pushing each connector up snapping into place Figure 100 Reconnect the electrical flag terminals and air pressure tubing to pressure switch Figure 101 Turn on the electrical and the gas supplies to the water heater Plug in the electric connection from the transformer to the electric outlet Figure 94 Restart the water heater by following the directions on the Lighting and Operating Instructions label located on the front of the water heater As the burner is heating view flames through vie
26. electrical wiring or pra the air pressure hose Figure 107 Figure 105 MANIFOLD TUBE Removing Old Burner Orifice 11 12 Burner may be hot wait until burner has cooled off After noting the position of the condensation drain hole on the top of the burner Turn the inner door manifold burner assembly upside Using a phillips head screwdriver remove the 2 screws attaching the burner to the manifold pipe saving screws for reinstallation later Figure 108 Using a ratchet with 1 2 socket remove the burner s old orifice Note the burner orifices have different threads dependent upon the gas type Right handed treads for natural gas Figure 109 Installing New Burner Orifice 13 14 15 Using a ratchet with 1 2 socket install the new burner orifice Note the burner orifices have different threads dependent upon the gas type Right handed treads for natural gas turn clockwise to install and Left handed threads for propane gas turn counterclockwise to install Figure 109 Care MUST be taken to ensure the burner is installed correctly on the inner door manifold assembly Position the new burner upside down with the orientation of the burner s condensation drain as shown in illustration Figure 108 Align the screw holes on the inner door manifold assembly Using the two screws removed in step 11 installed the new
27. proper draft for the water heater is established under all conditions of operation CAUTION DO NOT common vent this water heater with any power vented appliance The following figures are examples of vent pipe system installations and may or may not be typical for your specific application Consult the National Fuel Gas Code NFPA 54 ANSI Z223 1 current edition and the guidelines set forth by prevailing local codes 2 FT Minimum Above y Any Object Within 3 FT EA 10 FT Horizontally Minimum 4 Support Strap e Maintain n see 1 Type B Double Clearance T _ Maintain I Vent Specified Connector Clearance Slope Up 1 4 Inch Per Foot Minimum Venting Gas Vent System With Type B Double Wall Vent Pipe Figure 9 Consult the table found in the National Fuel Gas Code NFPA 54 ANSI Z223 1 current edition to determine the minimum height from roof to lowest discharge opening A Maintain Manufacturer s Specified Minimum Clearance Listed Vent Cap T___ Maintain Specified Support Strap Clearance Maintain 4 GER Clearance TI L a d I Vent Connector Connector Slope Up Unused Chimney Flue Or Masonry Enclosure 1 4 Inch Per Foot Minimum Venting Th
28. 8 25 X Temp Rise X 1 0 divided by BTU H Input BTU Output GPH X 8 25 X Temp Rise X 1 0 GPH BTU H Input X Eff divided by Temp Rise X 8 25 One cubic foot of Natural Gas contains about 1000 BTU of heat One therm is equal to 100 000 BTU One cubic foot of Propane Gas contains about 2500 BTU of heat One gallon of Propane gas contains about 91 250 BTU of heat One pound of Propane gas contains about 21 600 BTU of heat 54 GENERAL INFORMATION One pound of gas pressure is equal to 27 7 inches water column pressure Inches of Water Column X 036091 PSI Inches of Water Column X 073483 Inches of Mercury Hg Centimeters Inches X 2 54 MM millimeters Inches X 25 4 Meters Inches X 0254 Doubling the diameter of a pipe will increase its flow capacity approximately 5 3 times Construction Tank is constructed of steel The inside of the tank is constructed of a glass lining bonded to the steel This prevents water to metal contact and rusting of the tank An anode rod will be installed within the tank The hex head plug end of the anode is visible on the top of the water heater This metal rod offers secondary protection of the tank against corrosion where the application of glass is not possible threaded tank openings These areas will have small areas of water to metal contact All water heaters will contain at least one thermostat to operate the heater and one high limit to prevent water temperatures ap
29. ER A A SA POWER SUPPLY TRANSFORMER CONNECTOR HEX HEA SCREWS PROTECTOR POWER SUPPLY TRANSFORMER E OS F i i ELECTRICAL FLAG GROUND y TERMINALS SCREW d WIRE CONNECTOR PROTECTOR TRANSFORMER Installing the New Transformer 10 Insert the wiring connector that goes to the gas control valve thermostat through the wire protector ay ELECTRICAL GROUND on the side of the transformer box Figure 44 FLAG TERMINALS SCREW 11 Attach the two 2 flag terminal connectors to the transformer by aligning and pressing down Figure 44 12 Position the new transformer inside the transformer box where the wiring connections are nearest their exit points Figure 44 13 Align the holes of the transformer mounting bracket to the hole of the transformer box and B Q attach using the 2 hex head screws Note HEX HEA POWER SUPPLY Figure 44 take care not to pinch any wiring between the SCREWS WIRE TRANSFORMER transformer and the transformer box see PROTECTOR Figure 44 14 Insert the ground wire connector through the ground screw and tighten in p
30. FETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life BEFORE OPERATING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A This appliance does not have a pilot It is equipped with e lf you cannot reach your gas supplier call the an ignition device that will automatically light the fire department burner Do not try to light the burner by hand C Use only your hand to push in the electronic display BEFORE OPERATING smell all around the appliance buttons and gas control switch Never use tools area for gas Be sure to smell next to the floor because If the control buttons will not push in don t try to some gas is heavier than air and will settle on the floor repair them call a qualified service technician Force WHAT TO DO IF YOU SMELL GAS or attempted repair may result in a fire or explosion Do not try to light any appliance D Do not use this appliance if any part has been Do not touch any electric switch under water Immediately contact a qualified do not use any phone in your building installer or service agency to replace a flooded Immediately call your gas supplier from a neighbor s water heater Do not attempt to repair the unit phone Follow the gas supplier s instructions It must be replaced OPERATING INSTRUCTIONS SE d K 7 OFF ON OFF SWITCH GAS CONT
31. FF YES LOST YES LESS THAN 4 TIMES GAS VALVE CLOSES Is PRESSURE SWITCH PROVEN CLOSED WITHIN 5 SECONDS WAIT FOR PRESSURE SWITCH TO CLOSE NO DISPLAY ERROR NUMBER 6 YES YES Is REQUEST FOR HEAT SATISFIED COMBUSTION FAN OFF AFTER POST GAS VALVE OFF NO PURGE DELAY 23 Please Note The control continually monitors internal circuits and external sensors Error codes noted above and those for self diagnostic faults can be found on pages 20 through 22 EXTERNAL INSPECTION AND CLEANING Cleaning the Air Intake Chamber Screen Atleast twice annually the air intake chamber screen should be inspected for any dust or debris that may have accumulated on the louvers NOTE If the water heater is located in an area that is subjected to lint pet hair or dirt it may be necessary to check the air intake chamber screen more frequently e Use a vacuum cleaner with a hose attachment to remove any dust or debris that may have accumulated on the screen Cleaning the Combustion Chamber and Air Diverter Assembly Follow procedure outlined in Removing Inner Door Manifold Burner Assembly page 41 e Use a vacuum cleaner shop vac to remove all loose debris in the combustion chamber Use compressed air to clear any dust or debris that may have accumulated on the air diverter assembly e Reassemble following the procedure under Installing In
32. 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 natural gas Upon tightening with the fingers and confirming it has not been cross threaded tighten nut with an 3 4 open end wrench or crescent wrench Figure 87 Reconnect all the electrical connections to the bottom of the gas control valve thermostat gently pushing each connector up snapping into place Figure 87 Reconnect the electrical flag terminals and air pressure tubing to pressure switch Figure 88 Turn on the electrical and the gas supplies to the water heater Plug in the electric connection from the transformer to the electric outlet Figure 82 Restart the water heater by following the directions on the Lighting and Operating Instructions label located on the front of the water heater Test gas connections by brushing on an approved nonconcorrosive leak detection solution Upon verifying proper operation of the water heater replace the manifold cover outer door Figure 85 1 4 HEX HEAD SCREW Figure 86 INNER DOOR MANIFOLD BURNER ASSEMBLY
33. R button to the lowest setting Figure 45 Turn gas control switch to the OFF position located right side of the gas control valve thermostat and turn off the gas supply to the unit Figure 46 Disconnect the electric connection by unplugging the transformer from the wall outlet Figure 46 Remove the manifold cover outer door from the unit by depressing on the lower portion and pulling outward Unplug the 3 wire pressure switch fan sensor electrical connection of the wiring harness from the gas control valve thermostat by depressing the lower portion of the snap clip to open and pulling down the connector Figure 47 Using a phillips head screwdriver remove the 2 screws of the air intake chamber screen Note save screws for reinstallation later Figure 48 Remove the air intake chamber screen by lifting upward and outward Figure 48 Please take note of the wire position routing around the fan inside the air intake chamber as this wire positioning will need to be duplicated upon installation of the fan in the new intake chamber box Remove the 2 screws securing the fan inside the chamber Note save these screws for reinstallation later Figure 48 10 Lift the fan up and outward to remove from the air intake chamber Figure 48 11 Locate the male to female electrical connection with close pin lock on wiring harness the white connection approximately 12 from fan Figure 48 12 To sep
34. ROL 1 STOP Read the safety information above on the label 8 Turn on all electrical power to the appliance Set the ON OFF switch on the gas control to the Set the ON OFF switch on the gas control to the ON postition ON position ae e Set the Electronic Display to the lowest Set the Electronic Display to the desired setting by first setting by first pressing the COOLER Q and pressing the COOLER and HOTTER QO but HOTTER A buttons ALI and holding for 1 tons together and holding for 1 second Then press second Then press the COOLER Q button to the HOTTER button until the desired setting the lowest setting is reached Set the ON OFF switch on the gas control to the OFF position A DANGER l Hotter water increases the This appliance is equipped with a device risk of scald injury Consult the instruction which automatically lights the burner manual before changing temperature DO NOT TRY TO LIGHT THE BURNER BY HAND 10 If the appliance will not operate follow the instruc 7 Wait five 5 minutes to clear out any gas tions TO TURN OFF GAS TO APPLIANCE and If you then smell gas STOP Follow B in call your technician or gas supplier the safety information above on this label If you WARNING TURN OFF ALL don t smell gas go to the next step ELECTRIC POWER BEFORE SERVICING BEER TO TURN OFF GAS TO APPLIANCE ae 1 Set the Electronic Display to the lowest setting by first i pressing the COOLER an
35. S Do Not Extend A Vent Beyond Edge a Of Chimney Vent Connector fe a Slope Up 1 4 Inch Per Foot Minimum TFT Vi Au v e E Chimney Termination Vent System Figure 8 Do not reduce the vent to less than the draft hood outlet diameter Do not terminate the vent connector in a chimney that has not been certified for this purpose Some local codes may prohibit the termination of vent connectors in a masonry chimney Vertical Exhaust Gas Vent Vertical exhaust gas vents must be installed with U L listed type vent pipe according to the vent manufacturer s instructions and the terms of its listing It must be connected to the water heaters draft hood by a listed vent connector or by directly originating at the draft hood opening Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer s instructions Gas vents must be supported to prevent damage joint separation and maintain clearances to combustible materials IMPORTANT This gas vent must be terminated in a vertical position to facilitate the removal of the burnt gases An unused chimney flue or masonry enclosure may be used as a passageway for the installation of a gas vent NOTE The chimney flue or masonry enclosure size may be too large to allow proper venting Common combined venting is allowable with vertical type B vent systems and lined masonry chimneys as long as
36. SERVICE HANDBOOK FOR STANDARD RESIDENTIAL HIGH EFFICIENCY ATMOSPHERIC VENT FVIR GAS WATER HEATERS MODELS GAHH 40 100 GAHH 50 100 GP 6 40YPC T 100 GP 6 50YPC T 100 PCG6240T403NOV 100 PCG250T403NOV 100 PCG2J4040T3NOV 100 PCG2J5040T3NOV 100 12 40GPC T 100 12 50GPC T 100 PCG2J4040T3NOV 100 PCG2J5040T3NOV 100 Xe Smith CE Printed in U S A 10 10 318181 000 ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED IF YOU ARE UNSUCCESSFUL CONTACT A O SMITH WATER HEATERS RESIDENTIAL TECHNICAL ASSISTANCE AT 1 800 527 1953 OR WWW HOTWATER COM SERVICE HANDBOOK Your safety and the safety of others is extremely important in the servicing of this water heater Many safety related messages and instructions have been provided in this handbook and on the water heater to warn you and others of a potential hazard Read and obey all safety messages and instructions throughout this handbook It is very important that the meaning of each safety message is understood by you and others who service this water heater The information contained in this handbook is designed to answer commonly faced situations encoun tered in the operation of the standard Residential Gas product line and is not meant to be all inclusive If you are experiencing a problem not covered in this handbook please contact the Technical Infor
37. UE PRESSURE OR SUDDEN FORCE SUCH AS HAMMERING OR BEATING ON THE AIR CHAMBER BOX WITH ANY OBJECT REINSTALL Figure 79 INCLUDING YOUR HANDS WILL DAMAGE THE EN CHAMBERGASKET AIR INTAKE CHAMBER BOX AND RESULT IN IAN Y FAILURE OF THE HEATER S OPERATION 15 Install the air intake chamber box by rotating NEW AIR INTAKE the top of the air intake chamber box from left to CHAMBER BOX right only a few inches in both directions while pressing on the bottom portion of the air intake chamber box When properly installed the air intake chamber box will be in place against the water heater s side aligning with the screw holes Figure 80 Figure 80 16 Secure the air intake chamber box to the water heater s side by reusing the 4 screws removed in step 6 Figure 80 ROTATE FROM 17 Reattach the air pressure tubing to the air SS pressure switch by pushing the tubing onto the connector until the end of the tubing pushes to the AND shoulder of the connector 18 Check the air hose tubing connection to the PUSH INWARD gt j pressure switch to ensure the tubing has not loosened up or pulled off 19 Turn on the electrical and the gas supplies to the water heater Plug in the electric connection from the transformer to the electric outlet Figure 75 20 Restart the water heater by following the directions on the Lighting and Operating Instructions label located on the front of the water heater
38. WITH ANY OBJECT INCLUDING YOUR HANDS WILL DAMAGE THE AIR INTAKE CHAMBER BOX AND RESULT IN FAILURE TO THE HEATER S OPERATION Figure 49 AIR INTAKE CHAMBER BOX REMOVAL ROTATE FROM LEFT TO RIGHT AND PULL OUTWARD Figure 50 RUBBER WIRE PROTECTOR WIRE HARNESS INSIDE WIRE CHANNELING AIR PRESSURE TUBING KI CONNECTION R Figure 51 nol DH H H w NEW AIR INTAKE CHAMBER BOX Figure 52 AIR INTAKE CHAMBER BOX INSTALLATION ROTATE FROM LEFT TO RIGHT AND PUSHINWARD wb II m REAR SIDE OF THE AIR INTAKE CHAMBER BOX REINSTALL CHAMBER GASKET 32 25 Install the air intake chamber box by rotating the top of the air intake chamber box from left to Figure 53 right only a few inches in both directions while pressing on the bottom portion of the air intake chamber box When properly installed the air j H i i SECURE WITH intake chamber box will be in place against the S OREWS REMOVED water heater s side aligning with the screw holes EARLIER 26 Secure the air intake chamber box to the water heater s side by reusing the 4 screws removed in step 13 Figure 53 Figure 54 Installing the Fan in the Air Intake Chamber Box 27 Plug the electr
39. arate the electrical connection of the fan and wiring harness press down on the back portion of the close pin lock of the electrical connection while pulling the connection in the opposite directions 13 Using a phillips head screwdriver remove the 4 screws securing the air intake chamber box to the water heater s side also keeping these screws in a safe place for reinstallation later Figure 48 Figure 45 HOTTER Figure 46 Figure 48 AIR INTAKE CHAMBER BOX POWER IGN HEATING CLEAN VAC LOCK CHECK SC BER Ge Kc Electronic Control Display COOLER e OFF ON OFF SWITCH RUBBER WIRE PROTECTOR SWITCH FAN FV SENSOR CONNECTOR SCREEN 14 15 16 17 18 Rotate the top of the air intake chamber box from left to right only a few inches in both directions while pulling outward at the bottom removing the air intake chamber box from the combustion chamber pipe saving the air intake chamber gasket for reinstallation Figure 49 Unplug the air pressure tubing from the back of the old air intake chamber box Figure 50 The wire harness goes through the rubber wire protector in the back of the air intake chamber box Figure 50 Reach inside the air intake chamber box and push on the center of the rubber wire protector pushing it and the wiring harness wires to the outside of the air intake chamber box R
40. 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 on the top of the burner is toward the back as shown in the illustration Figure 108 Installation Caution Must Be Taken 16 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 manifold tab Figure 107 It may be necessary to use a flashlight to ensure correct placement Care must be taken so as to not damage any electrical wiring components or the air pressure tubing as you are installing the new inner door manifold burner assembly Extra caution should be taken to ensure that electrical wiring air hose fiberglass insulation nor any other object is between door gasket and combustion chamber shield Figure 106 1 4 HEX HEAD SCREW Figure 107 INNER DOOR MANIFOLD BURNER ASSEMBLY Figure 108 BURNER S CONDENSATION DRAIN ORIENTATION OF SCOOP TO BE ON THE SAME SIDE AS THE VIEW PORT e E BURNER S TIP END TAB TOP VIEW VIEW PORT BURNER S CONDENSATION DRAIN pe A d
41. d the lower control must be replaced Turn power off for 10 to 20 seconds then THMSTR and SHORT Flashing The self diagnostic test has on again to clear this error code detected the temperature sensor x thermistor inside the immersion This part of the control cannot be probe is shorted replaced or serviced Ifthe error code cannot be cleared the lower control must be replaced A 7 R Press and release each of the All Segments Flashing The self diagnostic check has temperature adjustment buttons Ifthe detected one or both of the above action does not clear the error the temperature adjustment buttons control will continue to regulate the water are stuck temperature at the last setting However settings will no longer be adjustable the upper control should be replaced Check the wire that runs from the power P ANODE and OPEN Flashing No current to Power Anode anode to the upper control Check the wire for damage and to ensure that the connectors are fully seated into the mating connectors on both ends Check that the tank is full of water Never use this water heater unless it is completely full of water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater Cycle power to the water heater OFF and ON to reset Turn the power off for 10 to 20 seconds P ANODE Flashin
42. d HOTTER O but 2 SSC GER switch on the gas control to the tons together and holding for 1 second Ther press ELECTRONIC DISPLAY the COOLER button to the lowest setting 3 Turn off all electrical power to the appliance if service is to be performed Figure 20 16 ADJUSTING THE TEMPERATURE ON THE ELECTRONIC CONTROL DISPLAY Adjusting the Temperature Set Point The thermostat of this water heater has been factory set at its lowest position It is adjustable and must be reset to the desired temperature setting to reduce the risk of scald injury The electronic control display temperature should be set at approximately 120 F 49 C and this is the preferred starting point see Figure 21 Some states have a requirement for a lower setting If you need hotter water follow directions for temperature adjustment but beware of the warnings in this section Pressing the COOLER button decreases temperature and pressing the HOTTER button increases the temperature To avoid any unintentional changes in water temperature settings the control has a tamper resistant feature for changing the temperature setting To change the temperature setting follow these instructions 1 Unlock the temperature indicators by holding down both COOLER and HOTTER temperature adjustment buttons at the same time for one second See Figure 21 The temperature indicators will light up and will only
43. e COOLER button to the lowest setting Figure 74 2 Turn gas control switch to the OFF position located right side of the gas control valve OFF thermostat and turn off the gas supply to the unit x ON OFF Figure 75 SWITCH 3 Disconnect the electric connection by unplugging the transformer from the wall outlet Figure 75 4 Remove the manifold cover outer door from the unit by depressing on the lower portion and pulling outward 5 Remove the air pressure tubing from the air pressure switch by pulling downward on the tubing at the connection to the air pressure switch Figure 76 Figure 76 6 Usinga phillips head screwdriver remove the 4 screws securing the air intake chamber box to the water heater s side Note keep these screws in a safe place for reinstallation later Figure 77 7 Rotate the top of the air intake chamber box from left to right only a few inches in both directions while pulling outward at the bottom removing the air intake chamber box from the combustion chamber pipe saving the air intake chamber gasket for reinstallation Figure 77 8 Upon removal of the air intake chamber box locate the air pressure tubing at the back of the air Figure 77 intake chamber box and unplug the tubing Note the routing of the air pressure tubing through the Figure 75 ROTATE FROM wate
44. e a flashlight to ensure correct CONDENSATION DRAIN placement Care must be taken so as to not ae yj damage any electrical wiring components or the TOP VIEW air pressure tubing as you are installing the new inner door manifold burner assembly SE ir Extra caution should be taken to ensure pater RART eech that electrical wiring air hose fiberglass AN insulation nor any other object is between TWO SCREWS LA 3B _ door gasket and combustion chamber shield gr fe BURNER S CONDENSATION DRAIN J BOTTOM VIEW Reinstalling The Inner Door Manifold Burner Assembly 15 Insert the manifold burner assembly in the burner Figure 100 chamber compartment making sure that the tip of burner manifold tab engages in the slot of the bracket Figure 98 The tip end of the burner manifold MUST k f IMPORTANT be placed in the slotted portion under the WHEN BRUSHING ONAN TIE da condensation pan to obtain proper installation LEAK DETECTION SOLUTION Li ZZZ SE DO NOT SPLASH SOLUTION Figure 98 ONTO ELECTRICAL CON j NECTIONS Wa Hd A ee PRESSURE A SWITCHIFAN 7 FV SENSOR CONNECTOR e A TRANSFORMER FLAME dh CONNECTOR sense TTT DISPLAY ANODE POWER SUPPLY SS Uewer 1 N Il CONNECTOR H ROD CONNECTOR e 16 After confirming no material of any type are 17 18 19 20 21 22 23 between door gasket and combustion chamber shield align the screws on the inner
45. e chamber as this wire positioning will need to be duplicated Figure 60 pressure upon installation of the new wiring harness SIA Figure 62 DT 11 Using a phillips head screwdriver remove the 4 E A Sud screws securing the air intake chamber box to the An mo Jolo oa water heater s side also keeping these screws in Ve a safe place for reinstallation later Figure 61 12 Rotate the top of the air intake chamber box from left to right only a few inches in both directions while pulling outward at the bottom removing an PRESSURE TUBING amp WIRING the air intake chamber box from the combustion HARNESSELAG TERMINALS chamber pipe saving the air intake chamber gasket for reinstallation Figure 61 FV SENSOR Replacing the Wiring Harness Figure 61 13 Locate the male to female electrical connection AIR INTAKE liana with close pin lock on wiring harness located on CHAMBER BOX the right side of fan Figure 62 REMOVAL 14 To separate the electrical connection of the fan ROTATE EROM and wiring harness press down on the back portion of the close pin lock of the electrical connection while pulling the connection in the AND opposite directions jia 15 The wire harness goes through the rubber wire Ree tyra Al 7 Na E protector in the back of the air intake chamber box HI H D
46. e sensor is making good contact with the burner flame ensure flame is steady Ensure the flame sensor is clean use ultra fine steel wool or Scotch Brite pad to clean the flame sensor Turn the power off for 10 20 seconds then on again to clear this error code Replace the lower control if the error code persists CONTROL DISPLAY TROUBLESHOOTING CONTROL DISPLAY STATUS PROBLEM SOLUTION 1 Clean the screen on the combustion air P SW OPEN and CLEAN SCREEN Flashing The air pressure switch contacts intake chamber Turn the power OFF for remain open longer than 11 10 to 20 seconds then ON again to clear seconds after the combustion fan the error code If the problem persists is energized Ensure the pressure switch sensing tube is in good condition and securely connected at both ends Ensure the inner door to the combustion chamber is secure and the gasket is properly sealing Check operation of the air intake chamber fan and pressure switch A Turn off power to the water heater B Remove the tubing from the pressure switch and the wires from both terminals of the pressure switch Connect a digital manometer to the open end of the tubing from the air intake chamber Turn on the power to the water heater and when the fan turns on measure the pressure reading in the tubing If the pressure reading reaches the 22 WC make point of the pressure switch turn off pow
47. e time holding for 1 second Then press the COOLER button to the lowest setting Figure 36 2 Turn gas control switch to the OFF position located right side of the gas control valve thermostat and turn off the gas supply to the unit Figure 37 3 Disconnect the electric connection by unplugging the transformer from the wall outlet Figure 37 4 Remove the manifold cover outer door from the K Ss unit by depressing on the lower portion and pulling ON OFF outward SWITCH 5 Remove the air pressure tubing from the air pressure switch by pulling downward on the tubing at the connection to the air pressure switch Figure 38 6 Remove the two 2 electrical flag terminals from the switch by pulling outward and off of the switch Figure 39 7 Usinga phillips head screwdriver remove the 2 screws securing the pressure switch to the water heater s side keep these screws in a safe place A for reinstallation later Figure 39 Installing the Pressure Switch 8 Secure the new pressure switch to the water heater s side by reusing the 2 screws removed in step 7 Figure 39 9 Reattach the two 2 electrical flag terminals by pushing the flag terminals onto the switch Figure 39 10 Reattach the air pressure tubing to the air Figure 39 pressure switch by pushing the tubing onto the connector until the end of the tubing pushes to the should
48. ect all the electrical connections to the bottom of the gas control valve thermostat gently pushing each connector up snapping into place Figure 110 Reconnect the electrical flag terminals and air pressure tubing to pressure switch Figure 111 Turn on the electrical and the gas supplies to the water heater Plug in the electric connection from the transformer to the electric outlet Figure 103 Restart the water heater by following the directions on the Lighting and Operating Instructions label located on the front of the water heater As the burner is heating view flames through 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 any solution onto any electrical connections Figure 110 Upon verifying proper operation of the water heater replace the manifold cover outer door Figure 110 IMPORTANT WHEN BRUSHING ON AN APPROVED NONCORROSIVE lt LEAK DETECTION SOLUTION DO NOT SPLASH SOLUTION ONTO ELECTRICAL CON NECTIONS MANIFOLD TUBE POWER SUPPLY TRANSFORMER CONNECTOR Figure 111 PRESSURE SWITCH 49 TER FLAME Il SENSE Il CONNECTOR GAS CONTROL VALVE THERMOSTAT LI TRA PA PRESSURE e SWITCHIFAN FV SENSOR CONNECTOR f U N TTT DISPLAY ANODE IF ROD CONNECTOR
49. emove the wiring harness from the wire channeling in the back center of the air intake chamber box The old air intake chamber box is now separated and can be discarded Figure 50 Installing the Air Intake Chamber Box 19 20 21 22 23 24 Insert the fan wiring harness wire through the back and into the fan box compartment by threading the connector through the opening and insert in approximately 6 inches of wiring up to the rubber wire protector Figure 50 Push the rubber wire protector into place in the back of the air intake chamber box Note the rubber wire protector must be positioned properly and locked into place around both sides of the air intake chamber box Figure 50 Position the wiring harness wire in the wiring channeling molded down the back center of the air intake chamber box Figure 50 Connect the air pressure tubing to the fitting on the air intake chamber box and route tubing in molded inlaid of the air intake chamber box Figure 50 Reinstall the air intake chamber gasket removed in step 14 on the back lower portion of the new air intake chamber box Figure 51 Install the new air intake chamber box to the combustion chamber pipe Using a small amount of soapy water will help Do not get any water or soapy water on any electrical connections or gas control components see Figure 52 NOTE UNDUE PRESSURE OR SUDDEN FORCE SUCH AS HAMMERING OR BEATING ON THE AIR CHAMBER BOX
50. emporarily release both temperature adjust buttons and within 2 seconds press both temperatures adjust buttons again until all the display icons are on steady Release the two temperature adjust buttons The system will clear the fault perform a reset and normal operation will be restored 19 ELECTRONIC CONTROL DISPLAY TROUBLESHOOTING OWER IGN HEATING CLEAN VAC LOCK CHECK SCREEN BH SE ECO LDO SW THMSTR E _P SW OPEN SHORT ELECTRONIC CONTROL DISPLAY Please check guidelines below For your safety water heater service should be performed only by a qualified service person Read the GENERAL SAFETY INFORMATION supplied by the water heater manufacturer CONTROL DISPLAY STATUS PROBLEM POWER Flashing HEATING and SHORT Flashing HEATING and OPEN Flashing HEATING OPEN and SHORT Flashing ECO and OPEN Flashing Communication Error The system has detected a communication error between the upper and lower controls The self diagnostic tests have found a problem with an internal circuit Ignition flame failure The water heater has reached the maximum number of retries and is currently locked out for one hour Cycle the power to the water heater off and on to reset Weak flame sensor current Water temperature in the tank has exceeded 185 F 85 C and has activated the ECO 20 SOLUTION Check t
51. er of the connector Figure 38 See 11 Turn on the electrical and the gas supplies to the SWITCH water heater Plug in the electric connection from the transformer to the electric outlet Figure 37 12 Restart the water heater by following the directions on the Lighting and Operating Instructions label located on the front of the water heater 13 Upon verifying proper operation of the water AR PRESSURE heater replace the manifold cover outer door TUBING TERMINALS TRANSFORMER REMOVAL REPLACEMENT Important Use only factory authorized replacement parts If you lack the necessary skills to properly perform the installation you should not proceed but get help from a qualified service technician Tools required Ratchet with 5 16 Socket or 5 16 Nut Driver Phillips Head Screwdriver Removing the Transformer 1 Set the gas control valve thermostat to its lowest setting by pressing the COOLER and HOTTER buttons together at the same time holding for 1 second Then press the COOLER button to the lowest setting Figure 40 2 Turn gas control switch to the OFF position located right side of the gas control valve thermostat and turn off the gas supply to the unit Figure 41 3 Disconnect the electric connection by unplugging the trans
52. er screen Figure 56 32 Reattach the 3 wire wiring harness connector to the gas control valve Figure 47 33 Check the air hose tubing connection to the pressure switch to ensure the tubing has not INSTALL THE AIR INTAKE loosen up or pulled off CHAMBER SCREEN 34 Turn on the electrical and the gas supplies to the water heater Plug in the electric connection from the transformer to the electric outlet Figure 46 35 Restart the water heater by following the directions on the Lighting and Operating Instructions label located on the front of the water heater 36 Upon verifying proper operation of the water heater replace the manifold cover outer door Figure 56 33 WIRING HARNESS REMOVAL REPLACEMENT Important Use only factory authorized replacement parts If you lack the necessary skills to properly perform the installation you should not proceed but get help from a qualified service technician GC GER ES Figure 57 C F Tools required Phillips Head Screwdriver H a Removing the Air Intake Chamber Box oo 1 Set the gas control valve thermostat to its lowest HOTTER ke tJ COOLER setting by pressing the COOLER and HOTTER buttons together at the same time holding for 1 second Then press the COOLER button to the lowest setting Figure 57 Figure 58 Tur
53. er to the water heater and reconnect tubing to the pressure switch If pressure reading does not reach the 22 WC make point check the system and tubing for restrictions and cleanliness Attach leads of ohmmeter or continuity tester to the terminals of the pressure switch Turn on power to the water heater and when the air intake fan comes on check for continuity across the pressure switch contacts If switch contacts remain open no continuity while the fan is in operation replace the pressure switch Turn off power to the water heater 7 P SW and SHORT Flashing The air pressure switch contacts e S i Locate the pressure switch wiring remain closed for more than 5 S odia ensure pressure switch wiring is correct seconds when they should be open and not jumped Remove wires to both terminals on pressure switch Check pressure switch contacts with an ohmmeter for continuity A If pressure switch contacts show continuity closed circuit replace the pressure switch If pressure switch contacts show open circuit and all wiring is correct replace the lower control Check all wiring to the hot surface ignitor IGN Flashing Open ignitor circuit Check the 3 pin Molex ignitor assembly plug and receptacle on the lower control for a good connection Repair or replace parts if necessary Check resistance of the ignitor with an ohmmeter on the ignitor assembly plug Replace ignitor if re
54. former from the wall outlet Figure 41 4 Remove the manifold cover outer door from the heater by depressing on the lower portion and pulling outward 5 Unplug the power supply transformer connector from the bottom of the gas control valve by pressing the snap connector and pulling downward Figure 42 NOTE The transformer is located inside the transformer box adjacent to the gas control thermostat valve 6 Using a phillips head screwdriver remove the transformer box from the side of the water heater by removing the single screw securing it to the water heater s side Note keep screw in a safe place for reinstalling later 7 Using a phillips head screwdriver remove the ground screw from the inside of the transformer box Note save the screw for reinstallation later see Figure 43 8 Take note of the position of the transformer use a 5 16 nut driver or a ratchet with a 5 16 socket to remove the 2 hex head screws on the front of the transformer box Note save the screws for reinstallation later see Figure 43 9 Unplug the two flag terminal electrical connections on the transformer and pull the wiring and connector through the wire protector Figure 43 Figure 42 GAS CONTROL J VALVE THERMOSTAT POWER SUPPLY TRANSFORMER CONNECTOR Figure 40 HOTTER COOLER Figure 41 OFF ON OFF SWITCH Figure 43 a ELECTRICAL GROUND FLAG TERMINALS SCREW Es 7 TRANSFORM
55. fter turning off the hot water faucet check for water leaks around powered anode rod and immediately correct any if found 13 Upon determining there s no water leak at the newly installed powered anode rod reconnect the electrical plug connector to the top of the anode male terminal 14 Plug the electric transformer in the wall outlet and turn the gas supply back on to the gas control valve thermostat 15 Turn the gas control switch to the ON position located on the side of the gas control valve thermostat see Figure 35 16 To restart the water heater follow the directions on the Lighting and Operating Instructions label located on the front of the water heater near the gas control valve thermostat 17 Upon verifying proper operation of the water heater replace the manifold cover outer door Teflon is a registered trademark of E I Du Pont De Numours and Company Figure 34 k 27 OFF ON OFF SWITCH PRESSURE SWITCH REMOVAL REPLACEMENT Important Use only factory authorized replacement parts If you lack the necessary skills to properly perform the installation you should not proceed but get help from a qualified service technician Figure 36 Tools required Phillips Head Screwdriver Removing the Pressure Switch 1 Set the gas control valve thermostat to its lowest COOLER setting by pressing the COOLER and HOTTER buttons together at the sam
56. g Power Anode circuit failure then on again to clear the error code If the error code persists or cannot be cleared replace the upper control TROUBLESHOOTING FLOWCHART APPLY POWER TO APPLIANCE NO REQUEST FOR HEAT PRESENT YES WAIT FOR PRESSURE SWITCH TO OPEN DISPLAY ERROR NUMBER 7 IS PRESSURE SWITCH PROVEN OPEN WITHIN 5 SECONDS YES COMBUSTION FAN ON Is PRESSURE SWITCH PROVEN CLOSED WITHIN 11 SECONDS WAIT FOR PRESSURE NO SWITCH TO CLOSE DISPLAY ERROR NUMBER 6 YES PREPURGE COMBUSTION FAN OFF PROVEN OPEN WITHIN 3 MINUTE AUTOMATIC RESET TIME DELAY WAIT FOR PRESSURE SWITCH TO OPEN DISPLAY ERROR NUMBER 7 Is PRESSURE SWITCH 5 SECONDS YES ONE HOUR AUTOMATIC RESTART TIME DELAY TURN OFF COMBUSTION FAN NO Is IGNITOR DISPLAY ERROR CODE OKAY NUMBER 8 YES IGNITOR ON FOR WARM UP TIME GAS VALVE OPENS COMBUSTION FAN ON YES INTERPURGE TURN OFF COMBUSTION FAN AFTER POST PURGE DISPLAY ERROR 3 COMBUSTION FAN OFF YES Is PRESSURE SWITCH PROVEN CLOSED WITHIN 5 SECONDS WAIT FOR PRESSURE SWITCH TO CLOSE DISPLAY ERROR NUMBER 6 BURNER LIGHTS NO LESS AND IS SENSED DURING TRIAL GAS VALVE CLOSES THAN 3 TRIES FOR OR IGNITION IGNITION YES NO IGNITOR TURNS O
57. gure 60 33 Connect the air pressure tubing to the pressure switch Figure 60 AND 34 Attach the 3 wire wiring harness connector to the gas control valve Figure 59 35 Check the air hose tubing connection to the pressure switch to ensure the tubing has not loosened up or pulled off Figure 60 36 Turn on the electrical and the gas supplies to the water heater Plug in the electric connection from the transformer to the electric outlet Figure 58 37 Restart the water heater by following the directions on the Lighting and Operating poner label located on the front of the water eater 38 Upon verifying proper operation of the water heater replace the manifold cover outer door Figure 65 INSTALL THE AIR INTAKE CHAMBER SCREEN Figure 67 ROTATE FROM LEFT TO RIGHT PUSH INWARD 36 AIR INTAKE CHAMBER FAN REMOVAL REPLACEMENT Important Use only factory authorized replacement parts If you lack the necessary skills to properly perform the installation you should not proceed but get help from a qualified service technician Tools required Phillips Head Screwdriver Removing the Fan from the Air Intake Chamber 1 Set the gas control valve thermostat to its lowest setting by pressing the COOLER and HOTTER
58. harness Align the electrical connections in AIR PRESSURE TUBING i such a position as to ensure the locking portions of the connections are on the same side Gently push the electrical connectors together until the snap lock on the wiring harness engages the angular lock on the fan connector Do Not use Figure 64 OUTE WIRNE HARNES undue force in pushing these connectors together THROUGH OPENING AT Figure 62 Note Connectors are designed in BOTTOM OF JACKET such a manner if the connection is not properly aligned they will not lock together 24 Route the wiring inside the fan box to the outer edge of the fan in such a manner to ensure it will not be pinched or damaged upon installation of the air intake screen Figure 62 WIRE HARNESS INSIDE WIRE CHANNELING CONNECTION 25 Install the air intake chamber screen ensuring that the prongs of the lower portion of the air intake chamber screen are in place in the holding slots Using the 2 screws removed in step 8 secure the air intake chamber screen Figure 65 26 Check the air pressure tubing to the fitting on the of the air intake chamber box and route tubing in molded inlaid of the air intake chamber box Figure 63 27 Reinstall the air intake chamber gasket remo
59. he 5 conductor data cable that runs between the upper and lower controls Check that the wiring is not broken and the connectors on both ends are properly seated in the mating connectors Replace the upper control if the error code does not clear cycle power to the water heater Off and On to reset Replace the lower control if the problem persists Turn the power off for 10 to 20 seconds then on again to clear the error code If the error code persists or cannot be cleared replace the lower control Gas supply is turned off pressure too low Ensure supply and manifold gas pressures are within requirements in the installation manual Manifold gas pressure is non adjustable if pressure is off by more than 0 3 W C 75 Pa replace the lower control Low supply voltage should be 115 125 VAC Ensure flame sensor is making good contact with the burner flame ensure flame is steady Ensure the flame sensor is clean use ultra fine steel wool or Scotch Brite pad to clean the flame sensor Ensure the hot surface ignitor is positioned to provide consistent ignition Check for any cracks in the ignitor assembly ceramic insulators replace ignitor assembly if damaged Check resistance of the ignitor at room temperature 77 F 25 C at the plug end Replace ignitor if the resistance is not within 1 72 to 2 4 ohms at room temperature Ensure flam
60. he tank completely with water Purge the water lines of any excess air by opening a hot water faucet allowing the water to flow for a minimum of 3 minutes allowing the tank to fill completely 15 16 17 18 19 Using the two 2 phillips head screws removed earlier in step 10 reattach the air pressure switch orientation with pressure tubing connector to the down side to the front of the water heater Reattach the electrical flag terminal to the pressure switch Reattach the pressure tubing Figure 118 Reinstall the transformer box to the front of the water heater by using the one 1 phillips head screw removed earlier in step 9 Figure 118 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 natural gas Upon tightening with the fingers and confirming it has not been cross threaded tighten nut with an 3 4 open end wrench or crescent wrench Figure 119 Reconnect all the electrical connections to the bottom of the gas control valve thermostat gently pushing each connector up snapping into place Figure 119 20 21 22 Teflon is a registered trademark of E I Du Pont De Numours and Company 51 Figure 116 GAS SHUT OFF GROUND JOINT UNION DI Figure 117 GAS CONTROL VALVE THERMOSTAT
61. ial powered anode rod Unlike conventional magnesium or aluminum anode rods used in water heaters the powered anode does not deteriorate and is less likely to contribute to the occurrence of Smelly Rotten Egg Water Figure 17 CAUTION DO NOT USE AN EXTENSION CORD TO CONNECT THE TRANSFORMER TO AN ELECTRICAL OUTLET CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING Power Supply Transformer WATER HEATER OPERATION The figure below shows the water heater s sequence of operation when a call for heat is initiated The gas control valve thermostat will attempt to light the burner three times If the flame sense rod in the burner manifold assembly does not detect ignition the control will enter lockout mode indicated by the electronic control display s flashing of the appropriate status code SEQUENCE OF OPERATION Call for heat indicated by flashing of display screen status codes Gas valve thermostat will open for 4 second trial for ignition and fan will turn on Gas valve thermostat will do a relay check relay clicks will be heard Main burner flame is detected by flame sense rod Air intake fan and main burner will continue to operate until water temperature inside the tank reaches temperature set point Display will show temperature set point du
62. ical connections of the fan into the wiring harness Align the electrical connections in such a position as to ensure the locking portions of the connections are on the same side Gently push the electrical connectors together until the CENT PUSH THE ELECTRICAL snap lock on the wiring harness engages the CONNECTORS TOGETHER UNTIL angular lock on the fan connector Do Not use IT IS SNAP LOCKED undue force in pushing these connectors together Figure 54 Note Connectors are designed in such a manner if the connection is not properly aligned they will not lock together 28 Replace the fan inside the air intake chamber Figure 55 box It is imperative that the square portion of the fan air outlet be placed inside the raised square portion of the air intake chamber fan compartment Figure 55 INSTALL THE FAN USING THE TWO SCREWS REMOVED 29 Ensuring the fan is properly aligned in the air EARLIER intake chamber secure the fan in place using the 2 screws removed in step 9 Figure 55 30 Route the wiring inside the fan box to the outer edge of the fan in such a manner to ensure it will not be pinched or damaged upon installation of the air intake screen Figure 55 31 Install the air intake chamber screen ensuring that the prongs of the lower portion of the air intake chamber screen are in place in the holding slots Using the 2 screws removed in step 6 secure the air intake chamb
63. ire partition Itis recommended but not mandatory that a minimum 12 inches of vertical vent pipe be installed on the draft hood prior to any elbow in the vent system IMPORTANT Existing vent systems must be inspected for obstructions corrosion and proper installation Chimney Connection IMPORTANT Before connecting a gas vent to a chimney make sure the chimney passageway is clear and free of obstructions The chimney must be cleaned if previously used for venting solid fuel appliances or fireplaces Also consult local and state codes for proper chimney sizing and application or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition e The connector must be installed above the extreme bottom of the chimney to prevent potentially blocking the flue gases COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS e The connector must be firmly attached and sealed to prevent it from falling out e To aid in removing the connector a thimble or slip joint may be used e The connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney 2 FT Minimum Above Any Object 3 FT Within 10 FT Horizontally Minimum Support Strap Seal Maintain te ae SA Clearance 7 AT S
64. ke screen Figure 72 15 Install the air intake chamber screen ensuring that the prongs of the lower portion of the air intake chamber screen are in place in the holding slots Using the 2 screws removed in step 4 secure the air intake chamber screen Figure 73 16 Turn on the electrical and the gas supplies to the water heater Plug in the electric connection from the transformer to the electric outlet Figure 69 17 Restart the water heater by following the directions on the Lighting and Operating Instructions label located on the front of the water AMBER SCRERIC sia heater 18 Upon verifying proper operation of the water heater replace the manifold cover outer door Figure 73 38 PRESSURE TUBING REMOVAL REPLACEMENT Important Use only factory authorized replacement f Figure 74 parts If you lack the necessary skills to properly perform the installation you should not proceed but get help from a qualified service technician APR N SI Tools required Phillips Head Screwdriver f HH i OO HOTTER TW H COOLER Electronic Control Display Removing the Air Intake Chamber Box 1 Set the gas control valve thermostat to its lowest setting by pressing the COOLER and HOTTER buttons together at the same time holding for 1 second Then press th
65. lace with a phillips PERETE o head screwdriver Figure 44 TRANSFORMER 3 15 Using the screw removed in step 6 reattach the CONNECTOR ELECTRICA transformer box to the water heater s side FLAG 16 Reattach the power supply transformer connector SEN K TERMINALS to the bottom of the gas control valve thermostat by aligning and pushing upward Figure 42 17 Plug the electric transformer in the wall outlet and WIRE turn the gas supply back on to the gas control SERATA A TRANSFORMER valve thermostat Figure 41 18 Turn the gas control switch to the ON position Figure 41 19 To restart the water heater follow the directions on the Lighting and Operating Instructions label located on the front of the water heater near the gas control valve thermostat 20 Upon verifying proper operation of the water heater replace the manifold cover outer door 30 AIR INTAKE CHAMBER BOX REMOVAL REPLACEMENT Important Use only factory authorized replacement parts If you lack the necessary skills to properly perform the installation you should not proceed but get help from a qualified service technician Tools required Phillips Head Screwdriver Removing the Air Intake Chamber Box 1 N A a 6 7 8 9 Set the gas control valve thermostat to its lowest setting by pressing the COOLER and HOTTER buttons together at the same time holding for 1 second Then press the COOLE
66. lectrical connections from the bottom of the gas control valve thermostat Figure 114 8 Using a 3 4 open end wrench or a crescent wrench remove the manifold tube from the gas control valve thermostat turning counterclockwise natural gas Grasp the manifold tube and push down slightly to free the manifold tube from the gas control valve thermostat Figure 114 9 Using a phillips head screwdriver remove the transformer box from the front of the water heater by removing the one 1 screw at the top of the transformer box save screw for reinstallation later Figure 115 10 Disconnect the two 2 electrical flag connectors from the pressure switch also disconnect the air pressure tubing Using a phillips head screwdriver remove the pressure switch from the water heater s front by removing the two 2 screws securing it save screws for reinstallation later Figure 115 Figure 112 COOLER OFF ON OFF SWITCH Figure 114 IMPORTANT WHEN BRUSHING ON AN APPROVED NONCORROSIVE LEAK DETECTION SOLUTION DO NOT SPLASH SOLUTION ONTO ELECTRICAL CON NECTIONS GAS CONTROL VALVE THERMOSTAT U Mit CX PRESSURE e SwWITCHIEAN Li 4 FV SENSOR POWER SUPPLY lIGNITER NIT CONNECTOR TRANSFORMER G FLAME 3 CONNECTOR SENSE TT BISPLAY ANODE CONNECTOR ROD CONNECTOR Figure 115 PRESSURE SWITCH
67. ling it off of the power anode control display terminal Figure 29 Installing the Electronic Control Display 6 Plug the power anode electrical wire terminal onto the power anode connector terminal Figure 29 7 Insert the electronic control display electrical connector into the electronic control display electrical connection by aligning the connector pins note orientation of the connector pins and pressing down ensuring the electrical connector snap is locked into place Figure 29 8 Install the electronic control display onto the front of the water heater by squeezing both sides of the electronic control display inserting the prongs into the water heater s slots please note the orientation of the electronic control display and the routing the wiring inside so as not be pinched between the display and the water heater s front Figure 28 9 Turn on the electrical and the gas supplies to the water heater Plug in the electric connection from the transformer to the electric outlet Figure 27 Restart the water heater by following the directions on the Lighting and Operating Instructions label located on the front of the water heater 10 Figure 26 Figure 29 COOLER OFF ON OFF SWITCH TO REMOVE OR TO INSTALL SQUEEZE BOTH SIDES OF THE CONTROL DISPLAY ELECTRONIC CONTROL DISPLAY ELECTRICAL CONNECTION
68. ma tion Center listed on the back of this handbook for further assistance Additional information is also available on the web site listed on the back of this handbook This handbook is intended for use by licensed plumbing professionals and reference should be made to the Installation Instructions and Use amp Care Guide accompanying the product This handbook contains supplemental information to the Installation Instructions and Use amp Care Guide When servicing residential water heaters it is essential that you return the unit to a safe condition before you leave the site All original components must be re installed and all safety measures must be implemented In addition the recommended water temperature setting is 120 F IMPORTANT It is recommend that on every service call an inspection amp cleaning of the air intake chamber screen and combustion chamber and air diverter assembly be performed See page 24 Tools Required for servicing gas models e phillips head screw driver 3 8 7 16 amp 3 4 inch open end wrenches e 3 16 inch Allen wrench e 1 1 16 inch 6 point socket for anode removal e 5 16 nut driver e pliers e electrical multimeter with alligator leads e digital or analog manometer gas pressure gauge e Teflon tape e hose to drain tank Digital manometer shown Teflon is a registered trademark of E I Du Pont De Numours and Company AWARNING Read and understand instr
69. n gas control switch to the OFF position located right side of the gas control valve thermostat and turn off the gas supply to the unit Figure 58 3 Disconnect the electric connection by unplugging Electronic Control Display N the transformer from the wall outlet Figure 58 7 OFF 4 Remove the manifold cover outer door from the e unit by depressing on the lower portion and pulling j ON OFF outward SWITCH 5 Unplug the 3 wire pressure switch fan sensor electrical connection of the wiring harness from the gas control valve thermostat by depressing the lower portion of the snap clip to open and pulling down the connector Figure 59 6 Unplug the electric flag terminals and air pressure tubing from the pressure switch Figure 60 7 Remove the FV sensor by depressing the snap lock to open the FV sensor cover slide the FV CS Aero sensor out of the cover and unplug the electrical Ta flag terminals connections Note place the FV sensor in a safe place as it will be reinstalled later Figure 60 8 Using a phillips head screwdriver remove the 2 screws of the air intake chamber screen Note Figure 59 nits KA PRESSURE save screws for reinstallation later Figure 62 3 d ech SWITCH EAN 9 Remove the air intake chamber screen by lifting en UN d RE upward and outward Figure 62 8 10 Please take note of the wire position routing around the fan inside the air intak
70. ner Door Manifold Burner Assembly page 42 24 Figure 24 Figure 25 ASSEMBLY LF ea INNER DOOR MANIFOLD BURNER Air Intake Chamber Screen TI A gt COMBUSTION CHAMBER ASSEMBLY ELECTRONIC CONTROL DISPLAY REMOVAL REPLACEMENT Important Use only factory authorized replacement parts If you lack the necessary skills to properly perform the installation you should not proceed but get help from a qualified service technician Removing the Electronic Control Display 1 Set the gas control valve thermostat to its lowest setting by pressing the COOLER and HOTTER buttons together at the same time holding for 1 second Then press the COOLER button to the lowest setting Figure 26 2 Turn gas control switch to the OFF position located right side of the gas control valve thermostat and turn off the gas supply to the unit Figure 27 3 Disconnect the electric connection by unplugging the transformer from the wall outlet Figure 27 4 Remove the electronic control display by squeezing in both sides of the display and removing from the slots in the water heater s front Figure 28 5 Unplug the electronic control display electrical connector from the back of the electronic control display by depressing the locking snap and pulling out of the electronic control display electrical connection also remove the power anode wire connector by pul
71. nit Figure 103 SE 3 Disconnect the electric connection by unplugging the transformer from the wall outlet Figure 103 4 Remove the manifold cover outer door from the unit by depressing on the lower portion and pulling outward 5 Unplug all the electrical connections from the bottom of the gas control valve thermostat Figure 104 SSES 6 Disconnect the electrical flag terminals and air pressure tubing to the pressure switch Figure 105 IMPORTANT 7 Using a 3 4 open end wrench or a crescent WHEN BRUSHING ON AN wrench remove the manifold tube from the gas LEAK DETECTION SOLUTION Lai SSe l GAS CONTROL i control valve thermostat turning counterclockwise ONTO ELECTRICAL CON natural gas Grasp the manifold tube and push Gd o D I down slightly to free the manifold tube from the eB Uf IM TEE gas control valve thermostat Figure 104 MANIFOLD TUBE E d ge FV SENSOR Ai POWER SUPPLY IGNITERI UU CONNECTOR 8 Use a 1 4 nut driver or 1 4 socket amp ratchet to TRANSFORMER FLAME dr loosen the 2 hex head screws on the inner door CONNECTOR SENSE T DISPLAY ANODE 2 CONNECTOR IM ROD CONNECTOR so the inner door manifold burner assembly can be removed Figure 106 9 Remove inner door manifold burner assembly by grasping the manifold and pulling straight back Care should be taken when inner door and burner assembly passes through jacket opening that it does not damage any of the
72. nnections Figure 120 Upon verifying proper operation of the water heater replace the manifold cover outer door Figure 120 IMPORTANT WHEN BRUSHING ON AN e APPROVED NONCORROSIVE A E GAS CONTROL LEAK DETECTION SOLUTION ps VALVE THERMOSTAT DO NOT SPLASH SOLUTION ONTO ELECTRICAL CON NECTIONS 1 ur SH IT PRESSURE MANIFOLD TUBE j PJ J XX SWITCH FAN J FV SENSOR POWER SUPPLY i N SONNECTOR TRANSFORMER FLAME l CONNECTOR I sense 17 DISPLAY ANODE CONNECTOR ROD CONNECTOR CHECKING THE GAS SUPPLY PRESSURE Checking the Gas Supply Pressure Gas pressure checks are done with flowing gas using a gas pressure gauge capable of reading 5 GAS CONTROL pressure in inches of water column GAS CONTROL H sii VALVE Ne x THERMOSTAT THERMOSTAT e Supply gas pressure checks are measured before the gas control valve thermostat and e Manifold main burner gas pressure is measured at the pressure tap on the side of the gas control valve thermostat Use an allen wrench to remove the plug then attach the gas gauge NOTE Desired gas pressures will be noted on the gas valve label located on the gas control valve thermostat supply gas pressure is under desired pressure requirement i USE AN ALLEN as close to the water heater as possible WRENCH TO REMOVE AND REPLACE PLUG PRESSURE e CONNECTED at PRESSURE TAP Figure 121 increase supply ga
73. nse Reset Sequence Flammable liquids such as gasoline solvents adhesives LP gases Figure 23 etc and other substances emit flammable vapors which can be ignited by a gas water heater s hot surface igniter or main burner The resulting flashback and fire can cause serious burns to anyone in the area This water heater is equipped with a FV sensor for detecting the presence of flammable vapors When the sensor detects those vapors the unit will shut down and not operate Even though this water heater is a flammable vapors ignition resistant water heater and designed to de reduce the chances of flammable vapors being ignited gasoline and NZA FV Sensor other flammable substances should never be stored or used in the L same vicinity or area containing a gas water heater or other open flame or spark producing appliance Should the FV Sensor of this water heater detect the presence of flammable vapors the following FV Sense Reset Sequence must be entered into the Electronic Control Display NOTE BEFORE RESETTING THE FVIR SENSE IN THE ELECTRONIC CONTROL DISPLAY THOROUGHLY INSPECT THE AREA AND REMOVE THE SOURCE OF THE FLAMMABLE VAPORS 1 Manual reset is accomplished by first turning off the power to the water heater for at least 10 seconds 2 Then while pressing the two temperature adjustment buttons on the display turn the switch on the gas control valve thermostat to the on position All the display icons will start to flash T
74. on air Flashing remain open longer than 5 i intake chamber retest seconds after the combustion fan A is energized If the problem persists Cycle power to the water heater OFF and ON to reset Check all wiring to the flammable vapor FV SENSE and OPEN Flashing Flammable Vapor Sensor is open sensor Remove the connectors from the flammable vapor sensor and measure the resistance of the sensor with an ohmmeter A If the reading taken is more than 1 7 million ohms replace the flammable vapor sensor B If the reading taken is less than 1 7 million ohms and the wiring from the control to the sensor is good replace the lower control Check all wiring to the flammable vapor FV SENSE and SHORT Flashing Flammable Vapor Sensor is sensor shorted Remove the connectors from the flammable vapor sensor and measure the resistance of the sensor with an ohmmeter A If the reading taken is less than 2000 ohms replace the flammable vapor sensor B If the reading taken is more than 2000 ohms and the wiring from the control to the sensor is good replace the lower control Turn power off for 10 to 20 seconds then THMSTR and OPEN Flashing The self diagnostic test has on again to clear this error code detected the temperature sensor thermistor inside the immersion This part of the control cannot be probe is open replaced or serviced If the error code cannot be cleare
75. pening to which Her connect The minimum dimension of rectangular air ducts cannot be less than three inches The size of each of the two openings is determined by the method in which the air is to be provided Refer to the table below to calculate the minimum free area for each opening Louvers and Grilles In calculating free area for ventilation and combustion air supply openings consideration must be given to the blocking effect of protection louvers grilles and screens These devices can reduce airflow which in turn may require larger openings to achieve the required minimum free area Screens must not be smaller than 1 4 mesh If the free area through a particular design of louver or grille is known it should be used in calculating the specified free area of the opening If the design and free area are not known it can be assumed that most wood louvers will allow 20 25 of free area while metal louvers and grilles will allow 60 75 of free area Louvers and grilles must be locked open or interconnected with the equipment so that they are opened automatically during equipment operation Keep louvers and grilles clean and free of debris or other obstructions Minimum Free Area of Permanent Openings for Ventilation and Combustion Air Supply All Air from Outdoors Only Based on total BTUH input rating for all utilizing equipment within the confined space Minimum Free Area Reference Opening Source Per Opening sq in
76. peration of the water wi d X Se DD Fiame Sense heater replace the manifold cover outer door LEE BURNER REMOVAL REPLACEMENT Important Use only factory authorized replacement parts If you lack the necessary skills to properly perform the installation you should not proceed but get help from a qualified service technician Tools required 3 4 Open End Wrench or Crescent g HH F Wrench Phillips Head Screwdriver Ratchet with 1 4 0 KR socket or 1 4 Nut Driver Gem ES OSH oe OO HOTTER KW COOLER Removing the Inner Door Manifold Burner Assembly Electronic Control Display 1 Setthe gas control valve thermostat to its lowest setting by pressing the COOLER and HOTTER buttons together at the same time holding for 1 second Then press the COOLER button to the lowest setting Figure 93 2 Turn gas control switch to the OFF position located right side of the gas control valve thermostat and turn off the gas supply to the unit Figure 94 Figure 93 POWER IGN HEATING CLEAN VAC LOCK CHECK SC Figure 94 OFF 3 Disconnect the electric connection by unplu ging the transformer from the wall outlet Figure 94 ON OFF 4 Remove the manifold cover outer door from the MR SWITCH dui oy depresso on the lower portion and pulling outward 5 Unplug all the electrical connections from the bottom of the gas control valve thermostat Figure 95
77. proaching the steam level 55 ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED IF YOU ARE UNSUCCESSFUL CONTACT AO SMITH WATER HEATERS RESIDENTIAL TECHNICAL ASSISTANCE AT 1 800 527 1953 OR WWW HOTWATER COM 56
78. r See figure below for the complete list of components Figure 13 Figure 13 Main Burner Scoop side to be placed on the same side as Flame Sense Hot Surface Igniter Assembly Flame Sense T gt Hot Surface Ss Igniter Assembly i ix GE Door Gasket DO NOT operate the water heater without the burner orifices installed Figure 14 Air Intake Chamber Fan The small fan at the top of the air intake chamber gt les on the side of the water heater is used to draw in O LE Sil Air intake necessary combustion air for the efficient operation W ani _ ofthe main burner The fan pressurizes the sealed combustion chamber which in turn allows the flue cl 2 baffle inside the center flue tube to slow down the pala hot exhaust gases so heat can be extracted into the Fan water before exiting into the vent system The air intake chamber fan runs for about 5 seconds to pre purge the combustion chamber before the beginning LI of an ignition sequence when there is a call for Air intake heat The fan will continue to operate while the main SSES burner is in operation and for about 5 seconds after the temperature set point has been achieved The air intake chamber screen covering the fan should be inspected and cleaned periodically to assure it is not limiting air flow into the chamber Figure 14 Figure 15 Pressure Switch A pressure switch in the con
79. r heater s opening near the bottom Remove LEFT TO RIGHT otk the old air pressure tubing Figures 76 amp 77 SCREWS 9 Connect the new air pressure tubing into the back of the air intake chamber box by pushing it on the ous connector Figure 78 10 Route the new air pressure tubing through the water heater s opening near the bottom Note mirrors the position of the old tubing Figures 77 PULL OUTWARD e JI A CHAMBER GASKET Installing the Air Intake Chamber Box 8 Figure 78 RUBBER WIRE 11 Check the position the wiring harness wire in the PROTECTOR wiring channeling molded down the back center of the air intake chamber box Figure 78 12 Connect the air pressure tubing to the fitting on WIRE HARNESS INSIDE the bottom of the air intake chamber box and route WIRE CHANNELING il tubing in molded inlaid of the air intake chamber ir box Figure 78 I CHAMBER BOX 13 Reinstall the air intake chamber gasket removed AIR PRESSURE TUBING gt in step 7 on the back lower portion of the air CONNECTION DI A intake chamber box Figure 79 14 Install the air intake chamber box to the combustion chamber pipe Using a small amount of soapy water will help Do not get any water or soapy water on any electrical connections or gas control components see Figure 80 NOTE UND
80. rature measured at gas valve thermostat will also be displayed in Field Service mode Entering Field Service Mode Ta 2 di Press and hold both temperature adjust buttons Figure 22 Hold both buttons as control passes from the set point display to Temperature Scale Selection menu Continue to hold buttons until CHECK icon is displayed then release buttons This will take 10 to 15 seconds The display will show the current water temperature POWER icon CHECK icon and will flash any current fault icons The backlight will always be displayed while in the Field Service Mode 18 USING THE ELECTRONIC CONTROL DISPLAY Reviewing Fault Codes 1 Press the red up arrow button one time 2 The display will show either EO or E1 3 If EO is shown there are no faults By pressing the up arrow button again the display will exit the Field Service mode or the control will exit automatically after no button is pressed for five 5 seconds 4 If E1 is shown the control will flash the icons of the most recent fault 5 Pressing the red up arrow button again will shown how many days ago the fault occurred and continue to flash the corresponding fault icons 6 Interpreting the day of the fault occurrence is as follows 00 would be today 01 would be yesterday up to 14 which would be 14 or more days ago 7 Continuing to press the up arrow button will scroll through all of the eight 8 most recent faults if they e
81. remain on for 30 seconds if no further buttons are pressed After 30 seconds the control will go back to Lock mode Lock mode indicates a temperature setting is locked into the control memory 2 Release both of the temperature adjustment buttons A To decrease the temperature press and release the COOLER button until the desired setting is reached B To increase the temperature press and release the HOTTER button until the desired setting is reached NOTE Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the heater Figure 21 Gas Control Valve Thermostat Settings IGN HEATING EAN VAC LOCK CHECK SCREEN d F Q c FV SENSE ECO LDOSW THMSTRI E EB PEN Sesal HOTTER lt H COOLER Electronic Control Display Water Time for 1st Time for Permanent Burns Temperature Degree Burn 2nd amp 3rd Degree F Less Severe Burns Most Severe Burns mo omashowertem 16 Liceo SSCS Table 2 17 USING THE ELECTRONIC CONTROL DISPLAY How to select or change the temperature scale from Fahrenheit F to Celsius C Gas Control Valve Thermostat Settings Figure 22 HOTTER Electronic Control Display The temperature scale defaults to Fahrenheit F To change to Celsius C press the two temperature adjustment buttons at the same time for more than five 5 seconds
82. ring call for heat Draft Blower is energized Gas valve thermostat is de energized and air intake fan continues for a post purge time of approximately 5 seconds System will verify pressure switch operation and start a 5 second pre purge then air Water heater returns to standby intake fan will turn off mode Ignitor will start a 12 second warm up period IGN will show on display 14 FILLING DRAINING AND FLUSHING THE WATER HEATER TANK It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during operation The water heater should be drained if being shut down during freezing temperatures To drain the tank perform the following steps ADANGER Hotwater discharge burn hazard Keep clear of relief valve discharge CA U T I O N unit e Read instruction manual for safe Fill tank with water before operation temperature setting lt Tamp tat re limiting Vaives are Improper installation and use may result available in property damage 1 Turn off the gas to the water heater at the manual gas shut off valve and turn off the electrical power to the gas control thermostat valve 2 Open a nearby hot water faucet until the water is no longer hot 3 Close the cold water inlet valve 4 Remove the outer door and connect a hose to the drain valve and terminate it to an adequate drain or external to the building Figure 19 5
83. rod electrical connector Figure 32 7 Remove the powered anode rod by using a ratchet and a 1 1 16 socket turning counterclockwise Figure 33 Note Figure 33 is shown exploded if the socket used is short well you may have to remove the top male connector first before removing the powered anode rod Figure 33 Figure 30 COOLER OFF ON OFF SWITCH Powered 26 Installing the Powered Anode Rod 8 Use Teflon tape or an approved pipe sealant on threads of the new powered anode rod 9 Prior to installing it will be necessary to use pliers to bend up approximately 90 the electrical male connector on the top of the powered anode rod The electrical connector should be bent upward in order to allow the 1 1 16 deep well socket to pass over the connector Note if using a short well socket the male connector must first be removed Figure 34 is shown exploded for clarity 10 Place the powered 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 Torque should be between 65 to 120 foot pounds 11 Open a nearby hot water faucet to purge air from the water line Fill water heater tank completely Note to assure the water heater tank is full Keep the hot water faucet open for 3 minutes after a constant flow of water is obtained 12 A
84. rough Chimney With Type B Double Wall Vent Pipe Figure 10 Maintain vent pipe clearance requirements to local state and or the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition NFPA 211 Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances states that these chimneys are intended to be installed in accordance with the installation instructions Vuen with each chimney support assembly inimum air space clearance to combustible materials should be maintained as marked on the chimney sections KNOW THE WATER HEATER S COMPONENT PARTS Electronic Control Display Upper Control The Electronic Control Display panel used on this water heater provides an easy to read eye level display for temperature adjustment fault code diagnostics and recall powered anode rod operation and setting the temperature scale for either Fahrenheit F or Celsius C Figure 11 Electronic Control Display Upper Control Gas Control Valve Thermostat Lower Control The gas control valve thermostat is where the incoming gas supply is connected to the water heater It is used in conjunction with the electronic control display to start or stop main burner operation There is an On Off switch located on the right hand side of the control The gas control valve thermostat is energized by a 24 VAC power supply transformer and uses a temperature sensing probe to open or close the flow of gas to the main
85. s pressure regulator setting and e increase supply gas piping size supply gas pressure is over desired pressure e add gas pressure regulator e reduce setting on existing regulator manifold gas pressure is more than 3 inch W C from values indicated on gas valve e ensure there is adequate supply gas pressure e ensure the main burner orifice is the correct size for the water heater model being tested e if the above tests have been performed and the results were correct replace the gas control valve 52 GAS WATER HEATER SIZING GUIDE Use the following information as a guide to approximate the correct size water heater for the residence e 40 gallon size 28 gallon draw for two bath residence or one bath with an automatic clothes washer e 50 gallon size 35 gallon draw for three bath residence or two baths with an automatic clothes washer e When a whirlpool tub is part of the home equipment it is suggested that the water heater storage tank capacity be selected based on the needs of the whirlpool tub This method of tank sizing will in most cases cancel all statements above concerning tank sizing e High flow or multiple shower head installations must be sized for at least a 20 minute draw Sa Stored 80gal 90ga 100ga 110ga 120ga 130ga 140ga 150 gal o zk q i E Stored s gal 71ga aset 89ga 98ga 108ga 117ga 125 gal 0 xk q EE 54 gal 59 gal 66 gal 74 gal 82 gal
86. s than the draft hood outlet diameter Vent Connectors 1 Type B Double wall U L Listed Vent Pipe 2 Single wall Vent Pipe Maintain the manufacturer s specified minimum clearance from combustible materials when using type B double wall vent pipe Vent connectors made of type B double wall vent pipe material may pes through walls or artitions constructed of combustible material if he minimum listed clearance is maintained Maintain a one inch minimum clearance from all combustible materials when using single wall vent pipe IMPORTANT Single wall vent pipe cannot be used for water heaters located in attics and may not pass through attic spaces crawl spaces or any confined or inaccessible location A single wall metal vent connector cannot pass through any interior wall When installing a vent connector please note the following e Install the vent connector avoiding unnecessary bends which create resistance to the flow of vent gases Install without dips or sags with an upward slope of at least 1 4 inch per foot e Joints must be fastened by sheet metal screws or other approved means It must be supported to maintain clearances and prevent separation of joints and damage e The length of the vent connector cannot exceed 5 of the vertical vent height e The vent connector must be accessible for cleaning inspection and replacement Vent connectors cannot pass through any ceiling floor firewall or f
87. side the building 2 All air from outdoors 12 MAXIMUM CLOSET n OR i OTHER CONFINED PERMANENT SPACE OPENINGS TO THE OUTSIDE OR ADDITIONAL ROOMS WITHIN THE BUILDING LI 12 MAXIMUM Figure 2 COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS All Air from Inside the Building When additional air is to be provided to the confined area from additional room s within the building the total volume of the room s must be of sufficient size to properly provide the necessary amount of fresh air to the water heater and other gas utilization equipment in the area Each of the two openings shall have a minimum free area of 1 square inch per 1 000 BTUH of the total input rating of all gas utilization equipment in the confined area but not less than 100 square inches for each opening CONFINED SPACE PERMANENT OPENINGS 1 SQUARE INCH 1000 BTUH MINIMUM 100 SQ IN FOR EACH OPENING Figure 3 All Air from Outdoors Outdoor fresh air can be provided to a confined area either directly or by he use of vertical and horizontal ducts The fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors Attic or crawl spaces cannot be closed and must be properly ventilated to the outside Ductwork must be of the same cross sectional area as the free area of the o
88. sistance is not within 1 72 and 2 40 ohms If above checks are good turn off power for 10 seconds and then back on If this error code will not clear and the ignitor resistance is within specifications replace the lower control FV SENSE Flashing Flammable Vapor Sensor has Do not touch any electrical switch do not use detected the presence of any phone in the building and do not try to flammable vapors and is in lockout light any appliance Smell around the water heater to ensure there are no gas leaks at the gas control valve or in the supply gas line or for any other type of flammable vapors in the area Carefully inspect the area surrounding the water heater for any substances such as gas oline paint paint thinners varnish or cleaners that could emit flammable vapors Remove anything that can potentially emit flammable vapors from the area and store it properly in a different location continued next page CONTROL DISPLAY TROUBLESHOOTING CONTROL DISPLAY STATUS PROBLEM SOLUTION FV SENSE Flashing 4 System must be manually reset by entering a Conti df special FVS reset sequence into the Electronic ONUNLUEG ITOMm Previous Pages Control Display See Electronic Control Display FV Sense Reset Sequence for instructions It is also recommended that the FV Sensor be replaced LDO SW OPEN and CLEAN SCREEN The air pressure switch contacts Clean the screen on the combusti
89. sition located right side of the gas control valve thermostat and turn off the gas supply to the unit Figure 90 Figure 90 OFF 3 Disconnect the electric connection by unplugging ON OFF the transformer from the wall outlet Figure 90 SWITCH 4 Remove the manifold cover outer door from the unit by depressing on the lower portion and pulling outward 5 Remove the inner door manifold burner assembly See Removing Inner Door Manifold Burner Assembly page 41 Figure 91 6 Lift the retainer clip straight up from the back of the manifold component block using a flat blade screwdriver then remove the manifold component block from the manifold door Figure 92 7 Remove and keep the screw securing the flame Figure 91 sense hot surface igniter assembly Figure 92 INNER DOOR 8 Remove and discard the old flame sense hot aro surface igniter assembly 9 Route the new flame sense hot surface igniter connector wire through manifold burner door opening as shown in figure 92 Secure the assembly to the bracket ussing screw removed earlier 10 Reposition the manifold component block in the manifold door opening and secure it with the retainer clip 11 Install inner door manifold burner assembly see page 42 12 Restart the water heater by following the directions on the Lighting and Operating Instructions label located on the front of the water heater 13 Upon verifying proper o
90. ssembly upside Using a phillips head screwdriver remove the 2 screws attaching the burner to the manifold pipe Saving screws for reinstallation later Figure 99 Figure 97 1 4 HEX HEAD SCREW Installing New Burner 12 Care MUST be taken to ensure the burner is installed correctly on the inner door manifold assembly Position the new burner upside down with the orientation of the burner s condensation 1 drain as shown in illustration Figure 99 Figure 98 13 Align the screw holes on the inner door manifold assembly Using the two screws removed in step 11 installed the new burner to the inner door INNER DOOR manifold assembly rotate the assembly to visually MANIFOLDIBURNER check the top portion of the burner assembly and SATTA confirm the orientation of the condensation drain hole on the top of the burner is toward the back as shown in the illustration Figure 99 ARE RIDE BURNER S TIP END TAB Installation Caution Must Be Taken 14 Prior to installing the new inner door manifold burner assembly look inside the burner chamber Figure 39 to fully understand the correct positioning of the burner assembly and burner manifold tab It may BURNER S be necessary to us
91. ted to a set temperature per hour An example might be that a water heater has a recovery rate of 30 gallons of water per hour at 80 degree F Fahrenheit temperature rise Standby efficiency the water heater s ability to contain heat in the tank A minimum of tank water heat loss per hour is desired Sample temperature change Btu h loss square foot of tank surface R value Temperature rise is the increase in the temperature from its coldest inlet water temperature to the desired hot outlet setting Typically this is assumed to be 40 degrees entering water 120 degrees desired stored water or 80 degrees temperature rise Thermal efficiency is approximately the amount of generated BTU British Thermal Units which enters the water A percentage of the total BTU passes out through the vent piping Water cannot for all practical purposes be compressed Water expands when it is heated Formulas and Conversions BTU British Thermal Unit is the heat required to raise 1 pound of water 1 F 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
92. the electrical connections from the Figure 83 bottom of the gas control valve thermostat Figure 83 6 Disconnect the electrical flag terminals and air pressure tubing to the pressure switch Figure 84 E WHEN BRUSHING ON AN f gt PERI 7 Using a 3 4 open end wrench or a crescent APPROVED NONCORROSIVE iz ST GAS CONTROL wrench remove the manifold tube from the gas DO NOT SPLASH SOLUTION e VAIVEHERMOSTAT control valve thermostat turning counterclockwise Se ee seh TA o a mona TE ae RE D m gR T pressure own sli o free the manifold tube from the J 7 II S SWITCHIFAN gas Gre e Figure 83 Geen e N RZ NR POWER SUPPLY IGNITERI d N n H W TRANSFORMER FLAME H gt 8 Use a 1 4 nut driver or 1 4 socket amp ratchet to EMEC ro sense West anope loosen the 2 hex head screws on the inner door CONNECTOR lr ROD CONNECTOR so the inner door manifold burner assembly can be removed Figure 85 Figure 84 9 Remove inner door manifold burner assembly by grasping the manifold and pulling straight back Care should be taken when inner door and burner assembly passes through jacket opening that it PRESSURE does not damage any of the electrical wiring or SWITCH the air pressure hose Figure 86 MANIFOLD TUBE Installation Caution Must Be Taken 10 Prior to installing the new inner door manifold burner assembly
93. trol string of this water heater is used to verify there is an adequate flow of combustion air into the combustion chamber before and during main burner operation It is electrically connected to the gas control valve thermostat and controls the opening and closing of the gas valve If there is an insufficient air supply being delivered to the combustion chamber the pressure switch will not allow the water heater to operate Figure 15 Pressure 12 KNOW THE WATER HEATER S COMPONENT PARTS Flammable Vapor Cut Off Switch FV Sensor The water heater is equipped with a FV sensor for detecting the presence of flammable vapors e g spilled gasoline When the sensor detects those vapors the heater will shut down and not operate If flammable vapors are detected or the sensor is inoperative an icon will flash on the electronic control display and the heater will go into a lockout mode The water heater will not function again until the flammable vapors have been eliminated and the control is manually reset using a special Flammable Vapor sensor reset sequence Figure 16 Figure 17 Figure 18 Gas Control a Valve Thermostat D Y is 13 Figure 16 FV Sensor Power Anode Rod To protect the glass lined water tank from corrosion through electrolysis this water heater is equipped with a non sacrific
94. uction manual and safety messages before installing operating or servicing this water heater Failure to follow instructions and safety messages could result in death or serious injury Instruction manual must remain AWARNING Fire Hazard Fer continued protection against risk of fire Do not install water heater on carpeted floor Do not operate water heater if flood damaged with water heater Water temperature over 125 F d S A WA RN I N G A DANGER 52 C can cause severe burns 3 z instantly resulting in severe injury Explosion Hazard or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Overheated water can cause water tank explosion Properly sized temperature Feel water before bathing or s and pressure relief valve must showering ao be installed in opening Temperature limiting valves are provided available Read instruction manual for safe temperature setting AWARNING Install vent system in accordance with Fire or Explosion Harzard codes Do not operate water heater if flood Do not store or use gasoline or other flammable vapors and damaged liquids in the vicinity of this or any other appliance Heater should not be installed for High Avoid all ignition sources if you smell Natural or LP gas Altitude operation above 10 100 feet Do not expose water heater control to excessive gas 3 078 m
95. ue to chemical exposure and may reduce but not eliminate the presence of corrosive chemi cals in the air e beauty shops e photo processing labs buildings with indoor pools e water heaters installed in laundry hobby or craft rooms e water heaters installed near chemical storage areas e water softeners Combustion air must be free of acid forming chemicals such as sulfur fluorine and chlorine These elements are found in aerosol sprays de tergents bleaches cleaning solvents air freshen ers paint and varnish removers refrigerants and many other commercial and household products When burned vapors from these products form highly corrosive acid compounds These prod ucts should not be stored or used near the water heater air inlet or air intake path Combustion and ventilation air requirements are determined by the location of the water heater The water heater may be located in either an open unconfined area or in a confined area or small enclosure such as a closet or small room Confined spaces are areas with less than 50 cubic feet for each 1 000 BTUH of the total input for all gas using appliances Unconfined Space A water heater in an uncon fined space uses indoor air for combustion and requires at least 50 cubic feet for each 1 000 BTUH of the total input for all gas appliances The table below shows a few examples of the mini mum square footage area required for various BTUH inputs Table 1 BTUH Input
96. ved in step 12 on the back lower portion of the new air intake chamber box Figure 66 28 Install the new air intake chamber box to the combustion chamber pipe Using a small amount of soapy water will help Do not get any water or soapy water on any electrical connections or gas control components Figure 67 NOTE UNDUE PRESSURE OR SUDDEN FORCE SUCH AS HAMMERING OR BEATING ON THE AIR CHAMBER BOX WITH ANY OBJECT Figure 66 INCLUDING YOUR HANDS WILL DAMAGE THE AIR INTAKE CHAMBER BOX AND RESULT IN FAILURE TO THE HEATER S OPERATION 29 Install the air intake chamber box by rotating VE REINSTALL the top of the air intake chamber box from left to Jp CHAMBER GASKET right only a few inches in both directions while UT pressing on the bottom portion of the air intake chamber box When properly installed the air intake chamber box will be in place against the AIR INTAKE water heater s side aligning with the screw holes CHAMBER BOX Figure 67 30 Secure the air intake chamber box to the water heater s side by reusing the 4 screws removed in step 11 Figure 67 31 Plug in the electrical flag terminals into the air pressure switch Figure 60 32 Reinstall the FV sensor removed in step 7 by depressing the snap lock to open the FV sensor i cover route wiring through sensor cover plug the INSTALL SCREWS electrical flag terminals connections to the FV ct sensor and slide the FV sensor back inside and close the cover Fi
97. wport test the manifold tube connection at the gas control valve thermostat by brushing on an approved noncorrosive leak detection solution IMPORTANT Do Not splash any solution onto any electrical connections Figure 100 Upon verifying proper operation of the water heater replace the manifold cover outer door Figure 101 PRESSURE SWITCH 46 MANIFOLD TUBE BURNER ORIFICE REMOVAL REPLACEMENT Important Use only factory authorized replacement Figure 102 parts If you lack the necessary skills to properly 9 i perform the installation you should not proceed but get help from a qualified service technician ae pai Gen Tools required 3 4 Open End Wrench or Crescent f HH i Wrench Phillips Head Screwdriver Ratchet with 1 4 pine To oen mm socket or 1 4 Nut Driver Ratchet with 1 2 socket OO HOTTER k COOLER Electronic Control Display Removing the Inner Door Manifold Burner Assembly Figure 103 1 Set the gas control valve thermostat to its lowest setting by pressing the COOLER and HOTTER buttons together at the same time holding for 1 second Then press the COOLER button to the lowest setting Figure 102 2 Turn gas control switch to the OFF position located right side of the gas control valve OFF thermostat and turn off the gas supply to the u
98. xist and its days ago of occurrence 8 After the last fault is reached the display will retum to the first fault E1 to allow for the faults to be reviewed again Exiting Field Service Mode e There are three 3 methods to exit the Field Service Mode Manual Manual and Clear and Timed Exit 1 Manual exit is accomplished by pressing both the red up arrow and the blue down arrow buttons for one 1 second but less than five 0 seconds while in the Field Service Mode or by pressing the red up arrow button one 1 time after the E0 is displayed during fault review while in the Field Service Mode These methods will return the control to the standard operating mode and retain any fault codes stored in memory 2 Manual exit and fault clear is accomplished by pressing the red up arrow and the blue down arrow buttons for five 5 seconds while in the Field Service Mode This method will return the control to the standard operating mode and at the end of the five 5 seconds clear all faults stored in memory and initiate a software reset indicated by all the LCD segments coming on for five 5 seconds The temperature setting and scale etc will not be altered using this method of exit 3 Timed exit will occur while in the Field Service Mode if the control detects no button presses for a period exceeding five 5 minutes The control will automatically return to the normal operating mode and keep all fault data retained in memory FV Se

A.O. Smith PCG2J5040T3NOV 100 User's Manual

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