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GPH-90N
User Manual
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State GPH-90N User Manual

Service Instructions
GAS WATER HEATERS
HEAT ENGINE REPLACEMENT
This instruction has been prepared to acquaint you with the service of your gas-fi red water heater. It is your responsibility to ensure that your water heater is properly installed and maintained.
Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and/or property damage. Thoroughly read and understand all instructions before you attempt to install, operate or service this heater.
Remove panels to gain access:
Door opening
Unlock the door by rotating the lock counter-clockwise
1. with a wide, slot screwdriver. Release the top and bottom door pins by prying the pins
2. out, using a small screwdriver. Open the door (the door remains fastened to the left
3. side panel).
Remove the top casing (front)
Use a screwdriver to remove the six screws securing
1. the top casing. Lift up and remove casing top (front).
2.
Remove the fl exible venting
Unwrap the insulation covering to expose the front elbow
1. of the venting. Loosen the gear clamps securing the venting.
2.
Top Casing (Front)
Door Lock
Access To Door Pins
3.
Remove the fl exible elbow from the top of the heat engine.
Remove the right side panel
1.
Use a screwdriver to remove the screw from the bottom, front of the right side panel.
2.
Remove the three screws from the right side panel towards the rear of the unit.
3.
Remove the screw from the top of the unit.
4.
Push the panel back and lift out.
To Remove:
Disconnect the electrical power to the water heater.
1. Close the shutoff valve on the gas supply line to the
2. water heater. Close the shutoff valves on both the hot-water and cold-
3. water lines. Drain the tank following the instructions in the “Draining
4. The Tank” section in the Operating Manual. Disconnect the hoses from the heat engine (top is water
5. outlet and bottom is water inlet). Disconnect the gas line from the heat engine.
6. Carefully disconnect the wire harnesses from the heat
7. engine.
Screws
Screws
To p Casing (Front)
0610 1 319172-000 Rev. 00
Screws
Nut
Nut
0610 2 319172-000 Rev. 00
8.
Remove the 4 nuts holding the heat engine to the tank. (Requires 1/2” wrench, socket or nut-driver.) It may be necessary to remove part of the venting system to access some nuts.
9.
Remove the heat engine.
To Install:
Assemble the new heat engine to the tank.
1. Reconnect the hoses to the heat engine.
2. Reconnect the gas line.
3. Open the shutoff valves on both the hot-water and cold-
4. water lines. Open the shutoff valve on the gas supply line.
5. Fill the tank following the instructions in the “Filling The
6. Water Heater” section in the Operating Manual. Carefully reconnect the wire harnesses.
7. Reassemble the side panel in the reverse order.
8.
Reassemble the fl exible venting in the reverse order.
9. Re-fi t the insulation around the exhaust elbows.
10. Reassemble the top casing in the reverse order.
11. Reconnect the electrical power to the water heater.
12. Restart the water heater following the “Lighting
13. Instructions” found in the Operating Manual.
Nut
Nut
0610 3 319172-000 Rev. 00
0610 4 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
CIRCULATION PUMP REPLACEMENT
This instruction has been prepared to acquaint you with the service of your gas-fi red water heater. It is your responsibility to ensure that your water heater is properly installed and maintained.
Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and/or property damage. Thoroughly read and understand all instructions before you attempt to install, operate or service this heater.
Secure the Ground Lug with the screw.
To Remove:
1.
Disconnect the electrical power to the water heater.
2.
Close the shutoff valves on both the hot-water and cold­water lines.
3.
Close the shutoff valve on the gas supply line to the water heater.
4.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
5.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
6.
Open the door (the door remains fastened to the left side panel).
7.
Remove the ten screws that secure the front cover of the heat engine. Remove the front cover of the Heat Engine.
8.
Remove the two screws securing the circuit board and partially extract it.
9.
Carefully disconnect the Circulating Pump wiring harness plug from the circuit board.
10.
Drain the tank following the instructions in the “Draining The Tank” section in the Operating Manual.
11.
Disconnect the lower hose from the Water Inlet fi tting on the left hand side of the Heat Engine Cabinet.
12.
Remove the two mounting screws for Water Inlet (suction side) of the pump.
13.
Remove the two screws on the discharge side (copper piping) of the pump.
14.
Remove the remaining four Circulating Pump mounting screws; two located at the bottom of the Heat Engine Cabinet, and two located at the Water Inlet.
15.
Remove the pump.
7. Carefully reconnect the wiring harness plug to the circuit
8. board. Slide the circuit board into its proper position and secure
9. using the two screws. Reassemble the front cover of the Heat Engine.
10. Close and lock the door.
11. Open the shutoff valve on the gas supply line to the
12. water heater. Reconnect the electrical power to the water heater.
13. Restart the water heater following the “Lighting
14. Instructions” found in the Operating Manual.
Access To
Door Pins Door Lock
To Install:
Assemble the new pump to the Heat Engine Cabinet
1. using the four screws. Reassemble the copper piping to the pump (discharge
2. side). Reassemble the Water Inlet fi tting to the Heat Engine
3. Cabinet. Reconnect the lower hose to the Water Inlet fi tting.
4. Open the shutoff valves on both the hot-water and cold-
5. water lines. Fill the tank following the instructions in the “Filling The
6. Water Heater” section in the Operating Manual.
0610 5 319172-000 Rev. 00
Heat Engine Cabinet
Screw­Ground Lug
Circuit Board
Circulation Pump
Screws­Water Inlet
Copper Piping
Water Inlet Fitting
Screws­Pump Mounting
0610 6 319172-000 Rev. 00
Screws­Pump Mounting
Screws-Pump Discharge
Service Instructions
GAS WATER HEATERS
BLOWER MOTOR REPLACEMENT
This instruction has been prepared to acquaint you with the service of your gas-fi red water heater. It is your responsibility to ensure that your water heater is properly installed and maintained.
Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and/or property damage. Thoroughly read and understand all instructions before you attempt to install, operate or service this heater.
To Remove:
Access To
1.
Disconnect the electrical power to the water heater.
2.
Close the shutoff valve on the gas supply line to the water heater.
3.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
4.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
5.
Open the door (the door remains fastened to the left side panel).
6.
Remove the ten screws that secure the front cover of the heat engine. Remove the front cover of the Heat Engine.
7.
Remove the two screws securing the circuit board and partially extract it.
8.
Carefully disconnect the Blower Motor wiring harness plug from the circuit board.
9.
Remove the three screws securing the Blower Motor.
10.
Remove the Blower Motor.
Door Lock
Door Pins
To Install:
Assemble the new Blower Motor using the three
1. screws. Carefully reconnect the wiring harness plug to the circuit
2. board. Slide the circuit board into its proper position and secure
3. using the two screws. Reassemble the front cover of the Heat Engine.
4. Close and lock the door.
5. Open the shutoff valve on the gas supply line to the
6. water heater. Reconnect the electrical power to the water heater.
7. Restart the water heater following the “Lighting
8. Instructions” found in the Operating Manual.
0610 7 319172-000 Rev. 00
Heat Engine Cabinet
Circuit Board
Blower Motor
Mounting Screw (3)
0610 8 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
CIRCUIT BOARD REPLACEMENT
This instruction has been prepared to acquaint you with the service of your gas-fi red water heater. It is your responsibility to ensure that your water heater is properly installed and maintained.
Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and/or property damage. Thoroughly read and understand all instructions before you attempt to install, operate or service this heater.
To Remove:
Access To
1.
Disconnect the electrical power to the water heater.
2.
Close the shutoff valve on the gas supply line to the water heater.
3.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
4.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
5.
Open the door (the door remains fastened to the left side panel).
6.
Remove the ten screws that secure the front cover of the heat engine. Remove the front cover of the Heat Engine.
7.
Remove the two screws securing the circuit board.
8.
Carefully disconnect all the wiring harness plugs from the circuit board.
9.
Remove the circuit board.
Door Lock
Door Pins
To Install:
Carefully reconnect the wiring harness plugs to the
1. circuit board. Assemble the new circuit board to the Heat Engine
2. Cabinet and secure using the two screws. Reassemble the front cover of the Heat Engine.
3. Close and lock the door.
4. Open the shutoff valve on the gas supply line to the
5. water heater. Reconnect the electrical power to the water heater.
6. Restart the water heater following the “Lighting
7. Instructions” found in the Operating Manual.
0610 9 319172-000 Rev. 00
Heat Engine Cabinet
Circuit Board
Mounting Screw (2)
0610 10 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
DISPLAY PANEL REPLACEMENT
This instruction has been prepared to acquaint you with the service of your gas-fi red water heater. It is your responsibility to ensure that your water heater is properly installed and maintained.
Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and/or property damage. Thoroughly read and understand all instructions before you attempt to install, operate or service this heater.
To Remove:
Access To
1.
Disconnect the electrical power to the water heater.
2.
Close the shutoff valve on the gas supply line to the water heater.
3.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
4.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
5.
Open the door (the door remains fastened to the left side panel).
6.
Carefully disconnect all the wiring harness plugs from the Display Panel.
7.
Remove the four screws securing the Display Panel.
8.
Remove the Display Panel.
Door Lock
Door Pins
To Install:
Assemble the new Display Panel to the door using the
1. four screws. Carefully reconnect the wiring harness plugs to the
2. Display Panel. Close and lock the door.
3. Open the shutoff valve on the gas supply line to the
4. water heater. Reconnect the electrical power to the water heater.
5. Restart the water heater following the “Lighting
6. Instructions” found in the Operating Manual.
0610 11 319172-000 Rev. 00
Door
Display Panel
Screws (4)
0610 12 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
INLET THERMISTOR REPLACEMENT
This instruction has been prepared to acquaint you with the service of your gas-fi red water heater. It is your responsibility to ensure that your water heater is properly installed and maintained.
Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and/or property damage. Thoroughly read and understand all instructions before you attempt to install, operate or service this heater.
To Remove:
Access To
1.
Disconnect the electrical power to the water heater.
2.
Close the shutoff valve on the gas supply line to the water heater.
3.
Close the shutoff valves on both the hot-water and cold­water lines.
4.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
5.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
6.
Open the door (the door remains fastened to the left side panel).
7.
Remove the ten screws that secure the front cover of the heat engine. Remove the front cover of the Heat Engine.
8.
Carefully disconnect the wire harness plug leading to thermistor.
9.
Drain the tank following the instructions in the “Draining The Tank” section in the Operating Manual.
10.
Remove the retaining screw for the inlet thermistor “(using an offset right angle Phillips screwdriver)”.
11.
Remove the thermistor.
Door Lock
Door Pins
To Install:
Secure the new thermistor in place with the retaining
1. screw. Open the shutoff valves on both the hot-water and cold-
2. water lines. Fill the tank with water. Check for leaks and repair as
3. required. Carefully reconnect the wiring harness plug to the
4. thermistor. Reassemble the front cover of the Heat Engine.
5. Close and lock the door.
6. Open the shutoff valve on the gas supply line to the
7. water heater. Reconnect the electrical power to the water heater.
8. Restart the water heater following the “Lighting
9. Instructions” found in the Operating Manual.
0610 13 319172-000 Rev. 00
Heat Engine Cabinet
Inlet Thermistor
Internal Flow Valve
Retaining Screw
0610 14 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
INTERNAL FLOW VALVE REPLACEMENT
This instruction has been prepared to acquaint you with the service of your gas-fi red water heater. It is your responsibility to ensure that your water heater is properly installed and maintained.
Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and/or property damage. Thoroughly read and understand all instructions before you attempt to install, operate or service this heater.
To Remove:
Disconnect the electrical power to the water heater.
1. Close the shutoff valve on the gas supply line to the
2. water heater. Close the shutoff valves on both the hot-water and cold-
3. water lines. Unlock the door by rotating the lock counter-clockwise
4. with a wide, slot screwdriver. Release the top and bottom door pins by prying the pins
5. out, using a small screwdriver. Open the door (the door remains fastened to the left
6. side panel). Remove the ten screws that secure the front cover of
7. the heat engine. Remove the front cover of the Heat Engine. Carefully disconnect the three wire harness plugs leading
8. to fl ow valve. Two are for Flow Valve control, one is for the Inlet Thermistor.
Access To
Door Pins Door Lock
9.
Drain the tank following the instructions in the “Draining The Tank” section in the Operating Manual.
10.
Remove the two screws that fasten the copper piping to the Circulation Pump (discharge side).
11.
Remove the two screws from the fl ange on the outlet side of the fl ow valve and remove the clamp.
12.
Remove the two screws fastening the fl ow valve mounting bracket to the Heat Engine Cabinet.
13.
Remove the two screws fastening the copper piping to the fl ow valve mounting bracket.
14.
Remove the two screws fastening the fl ow valve to the mounting bracket.
15.
Remove the Internal Flow Valve.
To Install:
Secure the new Internal Flow Valve to the mounting
1. bracket with the two fl ow valve mounting screws. Secure the copper piping to the fl ow valve mounting
2. bracket using the two copper piping mounting screws. Secure the mounting bracket with two screws.
3. Secure the piping for the outlet side of the fl ow valve with
4. the clamp and two screws. Secure the copper piping to the Circulation Pump
5. (discharge side) with two screws. Carefully reconnect the three wire harness plugs.
6. Open the shutoff valves on both the hot-water and cold-
7. water lines. Fill the tank following the instructions in the “Filling The
8. Water Heater” section in the Operating Manual. Reassemble the front cover of the Heat Engine.
9. Close and lock the door.
10. Open the shutoff valve on the gas supply line to the
11. water heater. Reconnect the electrical power to the water heater.
12. Restart the water heater following the “Lighting
13. Instructions” found in the Operating Manual.
0610 15 319172-000 Rev. 00
Heat Engine Cabinet
Screw (2)
Screw (2)
Screws­Valve Mounting
Clamp
Mounting Bracket
Internal Flow Valve
Screws­Pipe Mounting
0610 16 319172-000 Rev. 00
Screw (2)
Copper Piping
Service Instructions
GAS WATER HEATERS
OUTLET THERMISTOR REPLACEMENT
This instruction has been prepared to acquaint you with the service of your gas-fi red water heater. It is your responsibility to ensure that your water heater is properly installed and maintained.
Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and/or property damage. Thoroughly read and understand all instructions before you attempt to install, operate or service this heater.
To Remove:
Access To
1.
Disconnect the electrical power to the water heater.
2.
Close the shutoff valve on the gas supply line to the water heater.
3.
Close the shutoff valves on both the hot-water and cold­water lines.
4.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
5.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
6.
Open the door (the door remains fastened to the left side panel).
7.
Remove the ten screws that secure the front cover of the heat engine. Remove the front cover of the Heat Engine.
8.
Carefully disconnect the wire harness plug leading to thermistor.
9.
Drain the tank following the instructions in the “Draining The Tank” section in the Operating Manual.
10.
Remove the two screws from the fl ange on the return fi tting and remove the clamp.
11.
Remove the thermistor.
Door Lock
Door Pins
To Install:
Secure the new thermistor in place with the clamp and
1. two screws. Open the shutoff valves on both the hot-water and cold-
2. water lines. Fill the tank with water. Check for leaks and repair as
3. required. Carefully reconnect the wiring harness plug to the
4. thermistor. Reassemble the front cover of the Heat Engine.
5. Close and lock the door.
6. Open the shutoff valve on the gas supply line to the
7. water heater. Reconnect the electrical power to the water heater.
8. Restart the water heater following the “Lighting
9. Instructions” found in the Operating Manual.
0610 17 319172-000 Rev. 00
Outlet Thermistor
Screw (2)
Return Fitting
Heat Engine Cabinet
Clamp
0610 18 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
GAS VALVE REPLACEMENT
This instruction has been prepared to acquaint you with the service of your gas-fi red water heater. It is your responsibility to ensure that your water heater is properly installed and maintained.
Failure to follow the instructions in this service instruction sheet may result in serious bodily injury and/or property damage. Thoroughly read and understand all instructions before you attempt to install, operate or service this heater.
To Remove:
Disconnect the electrical power to the water heater.
1. Close the shutoff valve on the gas supply line to the
2. water heater. Close the shutoff valves on both the hot-water and cold-
3. water lines. Unlock the door by rotating the lock counter-clockwise
4. with a wide, slot screwdriver. Release the top and bottom door pins by prying the pins
5. out, using a small screwdriver. Open the door (the door remains fastened to the left
6. side panel). Remove the ten screws that secure the front cover of
7. the heat engine. Remove the front cover of the Heat Engine. Remove the two screws securing the circuit board and
8. partially extract it. Carefully disconnect the Gas Valve wiring harness plug
9. from the circuit board. Disconnect the gas line from the heat engine.
10. Remove the two screws that secure the Gas Inlet
11. Fitting. Remove the four screws that secure the Burner Orifi ce
12. Plate. One of these screws also secures the Spark Generator. Pull the Gas Valve Assembly away from the heat
13. engine. Carefully disconnect the wire harness from the Gas
14. Valve Assembly. Remove the fi ve screws and washers securing the Burner
15. Orifi ce Plate to the Gas Valve. Remove the four screws and washers that secure the
16. Gas Line Extension to the Gas Valve. Remove the Gas Valve.
17.
To Install:
Fasten the Gas Line Extension to the new Gas Valve
1. with the four screws and washers. Ensure the O-ring is undamaged and properly positioned. Secure the Burner Orifi ce Plate to the Gas Valve with
2. fi ve screws and washers. Carefully reconnect the wire harness to the Gas Valve
3. Assembly (green wire pair to the lower right solenoid, yellow & black pair wire to the lower left solenoid, black & white pair to the top right side solenoid and black & brown pair to the top left side solenoid). Install the Gas Valve Assembly into the heat engine,
4. ensuring the Assembly is seated properly between the Orifi ce Plate and the heat engine. Secure the Orifi ce Plate with four screws. Ensure the
5. Spark Generator is properly secured. Secure the Gas Inlet Fitting with two screws. Ensure the
6. O-ring is undamaged and properly positioned.
Access To
Door Pins Door Lock
0610 19 319172-000 Rev. 00
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