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GPH-90N
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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
Carefully reconnect the Gas Valve wiring harness plug
7. to the circuit board. Slide the circuit board into its proper position and secure
8. using the two screws. Open the shutoff valves on both the hot-water and cold-
9. water lines. Fill the tank with water.
10. Reconnect the gas line.
11. Reconnect the electrical power to the water heater.
12. Open the shutoff valve on the gas supply line to the
13. water heater. Use a approved water and soap solution to check the for
14. gas leaks. Repair as required. Reassemble the front cover of the Heat Engine.
15. Close and lock the door.
16. Restart the water heater following the “Lighting
17. Instructions” found in the Operating Manual.
Heat Engine Cabinet
Screw (4)
Screw & Washer (5)
Burner Orifi ce Plate
Gas Line Extension
Spark Generator
Gas Valve
O-ring
O-ring
Gas Inlet
Screw &
Screw (2)
Fitting
Washer (4)
0610 20 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
ECO SWITCH 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.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
3.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
4.
Open the door (the door remains fastened to the left side panel).
5.
Remove the ten screws that secure the front cover of the heat engine. Remove the front cover of the Heat Engine.
6.
Carefully disconnect the two wire leads to the ECO switch.
7.
Remove the two screws securing the ECO switch.
8.
Remove the ECO switch.
Door Lock
Door Pins
To Install:
Secure the new ECO switch using the two screws.
1. Carefully reconnect the two wire leads to the ECO
2. switch. Reassemble the front cover of the Heat Engine.
3. Close and lock the door.
4. Reconnect the electrical power to the water heater.
5. Restart the water heater following the “Lighting
6. Instructions” found in the Operating Manual.
0610 21 319172-000 Rev. 00
Heat Engine Cabinet
Screw (2)
ECO
Transformer
0610 22 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
POWER CORD 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.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
3.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
4.
Open the door (the door remains fastened to the left side panel).
5.
Remove the ten screws that secure the front cover of the heat engine. Remove the front cover of the Heat Engine.
6.
Remove the two screws securing the circuit board and partially extract it.
7.
Carefully disconnect the Power Cord wiring harness plug from the circuit board.
8.
Remove the two screws securing the Ground Lugs.
9.
Remove the two screws securing the Power Cord to the Heat Engine Cabinet.
10.
Remove the Power Cord.
Door Lock
Door Pins
To Install:
Secure the new Power Cord to the Heat Engine Cabinet
1. with the two screws. Secure the Ground Lugs with the two screws.
2. Carefully reconnect the Power Cord wiring harness plug
3. to the circuit board. Slide the circuit board into its proper position and secure
4. using the two screws. Reassemble the front cover of the Heat Engine.
5. Close and lock the door.
6. Reconnect the electrical power to the water heater.
7. Restart the water heater following the “Lighting
8. Instructions” found in the Operating Manual.
9.
0610 23 319172-000 Rev. 00
Screw-Ground Lug (2)
Heat Engine Cabinet
Screw (2)
Power Cord
0610 24 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
TRANSFORMER 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.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
3.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
4.
Open the door (the door remains fastened to the left side panel).
5.
Remove the ten screws that secure the front cover of the heat engine. Remove the front cover of the Heat Engine.
6.
Remove the two screws securing the circuit board and partially extract it.
7.
Carefully disconnect the Transformer wiring harness plugs from the circuit board.
8.
Remove the four screws securing the Transformer to the Heat Engine Cabinet.
9.
Remove the Transformer.
Door Lock
Door Pins
To Install:
Secure the new Transformer to the Heat Engine Cabinet
1. with the four screws. Carefully reconnect the Transformer wiring harness plugs
2. to the circuit 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. Reconnect the electrical power to the water heater.
6. Restart the water heater following the “Lighting
7. Instructions” found in the Operating Manual.
8.
0610 25 319172-000 Rev. 00
Heat Engine Cabinet
Transformer
Screw (4)
0610 26 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
FLAME ROD 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.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
3.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
4.
Open the door (the door remains fastened to the left side panel).
5.
Remove the ten screws that secure the front cover of the heat engine. Remove the front cover of the Heat Engine.
6.
Carefully disconnect the wire leading to the Flame Rod.
7.
Remove the two screws securing the Flame Rod.
8.
Remove the Flame Rod and Gasket. Ensure old gasket is completely removed and no material remains.
Door Lock
Door Pins
To Install:
Secure the new Flame Rod and Gasket with the two
1. screws. Carefully reconnect the wire leading to the Flame Rod.
2. Reassemble the front cover of the Heat Engine.
3. Close and lock the door.
4. Reconnect the electrical power to the water heater.
5. Restart the water heater following the “Lighting
6. Instructions” found in the Operating Manual.
0610 27 319172-000 Rev. 00
Heat Engine Cabinet
Gasket
Screw (2)
Flame Rod
0610 28 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
SPARK GENERATOR 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.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
3.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
4.
Open the door (the door remains fastened to the left side panel).
5.
Remove the ten screws that secure the front cover of the heat engine. Remove the front cover of the Heat Engine.
6.
Remove the two screws securing the circuit board and partially extract it.
7.
Carefully disconnect the Spark Generator wiring harness plug from the circuit board.
8.
Remove the screw securing the Ground Lugs.
9.
Remove the screw securing the Spark Generator.
10.
Remove the two screws securing the Electrode assembly. It may be necessary to remove the Power Cord to gain access to the two screws.
11.
Carefully disconnect the wire harness from the Spark Generator.
12.
Remove the Spark Generator, Electrode assembly and Gasket. Ensure old gasket is completely removed and no material remains.
Door Lock
Door Pins
To Install:
Carefully reconnect the wire harness to the new Spark
1. Generator. Secure the Electrode assembly and Gasket with the
2. two screws. Secure the Spark Generator with the screw.
3. Secure the Ground Lugs with the screw.
4. Carefully reconnect the Spark Generator wiring harness
5. plug to the circuit board. Slide the circuit board into its proper position and secure
6. using the two screws. Reassemble the front cover of the Heat Engine.
7. Close and lock the door.
8. Reconnect the electrical power to the water heater.
9. Restart the water heater following the “Lighting
10. Instructions” found in the Operating Manual.
0610 29 319172-000 Rev. 00
Screw-Ground Lug
Heat Engine Cabinet
Gasket
Electrode
Screw (2)
Screw
Spark Generator
0610 30 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
HILIMIT TEMPERATURE SWITCH 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.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
3.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
4.
Open the door (the door remains fastened to the left side panel).
5.
Remove the ten screws that secure the front cover of the heat engine. Remove the front cover of the Heat Engine.
6.
Remove the two screws securing the circuit board and partially extract it.
7.
Carefully disconnect the HiLimit wiring harness plug from the circuit board.
8.
Cut the plug off.
9.
Remove the HiLimit Temperature Switch.
Door Lock
Door Pins
To Install:
Extract one pin from the new plug, feed the new HiLimit
1. Temperature Switch around the heat exchanger and re­insert the pin into the plug. Carefully reconnect the HiLimit wiring harness plug to
2. the circuit 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. Reconnect the electrical power to the water heater.
6. Restart the water heater following the “Lighting
7. Instructions” found in the Operating Manual.
0610 31 319172-000 Rev. 00
Heat Exchanger
HiLimit Temperature Switch
Heat Engine Cabinet
0610 32 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
INLET WATER FILTER 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 valves on both the hot-water and cold­water lines.
3.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
4.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
5.
Open the door (the door remains fastened to the left side panel).
6.
Drain the tank following the instructions in the “Draining The Tank” section in the Operating Manual.
7.
Unscrew the Water Inlet Filter.
Door Lock
Door Pins
To Install:
Install the new Water Inlet Filter.
1. Close the drain valve.
2. Open the shutoff valves on both the hot-water and cold-
3. water lines. Fill the tank following the instructions in the “Filling The
4. Water Heater” section in the Operating Manual. Close and lock the door.
5. Reconnect the electrical power to the water heater.
6. Restart the water heater following the “Lighting
7. Instructions” found in the Operating Manual.
0610 33 319172-000 Rev. 00
Heat Engine Cabinet
Water Inlet Filter
Water Inlet Fitting
0610 34 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
HOSE (HEAT ENGINE TO STORAGE TANK) REPLACEMENT
This instruction has been prepared to acquaint you with the service of your gas-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:
Remove Door
Disconnect the electrical power to the water heater.
1. Unlock the door by rotating the lock counter-clockwise
2. with a wide, slot screwdriver. Release the top and bottom door pins by prying the pins
3. out, using a small screwdriver. Open the door (the door remains fastened to the left
4. side panel). Carefully disconnect all the wiring harness plugs from
5. the Display Panel. Carefully remove the door hinge pins from their retaining
6. fi ngers.
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 left side panel
Use a screwdriver to remove the screw from the bottom,
1. front of the left side panel. Remove the three screws from the left side panel towards
2. the rear of the unit. Remove the screw from the top of the unit.
3. Push the panel back and lift out.
4.
To Remove:
1.
Close the shutoff valves on both the hot-water and cold­water lines.
2.
Drain the tank following the instructions in the “Draining The Tank” section in the Operating Manual.
3.
Unscrew the fi tting at both ends of the hose assembly(s). The upper hose is the (hot) water outlet from the heat engine. The lower hose is the (cold) water inlet to the heat engine.
4.
Remove the hose assembly(s).
To Install:
Install the new hose assembly(s).
1. Tighten the fitting at both ends of the hose
2. assembly(s). Close the drain valve.
3. Open the shutoff valves on both the hot-water and cold-
4. water lines. Fill the tank following the instructions in the “Filling The
5. Water Heater” section in the Operating Manual. Check for leaks and repair as required.
6. Reassemble the side panel in the reverse order.
7. Reassemble the door in the reverse order.
8. Carefully reconnect the wiring harness plugs to the
9. Display Panel. Reassemble the top casing in the reverse order.
10. Reconnect the electrical power to the water heater.
11. Restart the water heater following the “Lighting
12. Instructions” found in the Operating Manual.
0610 35 319172-000 Rev. 00
Screws
To p Casing (Front)
Screws
Top Casing (Front)
Door Lock
Access To Door Pins
Screws
0610 36 319172-000 Rev. 00
Upper Hose Assembly (Hot)
Heat Engine Outlet Fitting
Heat Engine Inlet Fitting
Lower Hose Assembly (Cold)
Drain Valve
0610 37 319172-000 Rev. 00
0610 38 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
TANK 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.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
3.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
4.
Open the door (the door remains fastened to the left side panel).
5.
Carefully disconnect the Tank Thermistor wiring harness plug from the Display Panel located on the door.
6.
Carefully disconnect the Tank Thermistor wiring harness plug from the Heat Engine Cabinet.
7.
Loosen the screw on the Tank Thermistor bracket and remove the bracket.
8.
Remove the Tank Thermistor.
Door Lock
Door Pins
To Install:
Install the new Tank Thermistor.
1. Reinstall the Tank Thermistor bracket around the
2. thermistor and tighten the screw. Carefully reconnect the Tank Thermistor wiring harness
3. plug to the Heat Engine Cabinet. Carefully reconnect the Tank Thermistor wiring harness
4. plug to the Display Panel. Close and lock the door.
5. Reconnect the electrical power to the water heater.
6. Restart the water heater following the “Lighting
7. Instructions” found in the Operating Manual.
0610 39 319172-000 Rev. 00
Thermocouple
Screw
Bracket
Thermocouple
0610 40 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
EXHAUST VENT HIGH-TEMPERATURE SWITCH 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.
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. Carefully disconnect the two wires from the High-
2. temperature Switch. Remove the two screws securing the High-temperature
3. Switch to the Condensate Trap. Remove the High-temperature Switch.
4.
To Install:
Remove the right side panel
Use a screwdriver to remove the screw from the bottom,
1. front of the right side panel.
Top Casing (Front)
Door Lock
Access To Door Pins
Screws
Secure the new High-temperature Switch with the two
1. screws. Carefully reconnect the two wires to the High-temperature
2. Switch. Reassemble all the casing panels in the reverse order.
3. Close and lock the door.
4. Reconnect the electrical power to the water heater.
5. Restart the water heater following the “Lighting
6. Instructions” found in the Operating Manual.
Screws
Screws
To p Casing (Front)
0610 41 319172-000 Rev. 00
VENTING
EXHAUST ELBOW
BARBED FITTING
HIGH TEMPERATURE SWITCH
DRAIN PAN - ROUTE TO SUITABLE DRAIN
CONDENSATE TRAP
CONDENSATE TUBE -
SLOPE TO SUITABLE DRAIN
NOTE: THE CONDENSATE TUBE MUST BE BELOW EXHAUST ELBOW.
0610 42 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
DRAIN 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:
Access To
1.
Disconnect the electrical power to the water heater.
2.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
3.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
4.
Open the door (the door remains fastened to the left side panel).
5.
Close the shutoff valves on both the hot-water and cold­water lines.
6.
Drain the tank following the instructions in the “Draining The Tank” section in the Operating Manual.
7.
Remove the Drain Valve.
Door Lock
Door Pins
To Install:
Use only Tefl on tape or an approved pipe sealant on
1. the threads. Install the new Drain Valve.
2. Open the shutoff valves on both the hot-water and cold-
3. water lines. Fill the tank following the instructions in the “Filling The
4. Water Heater” section in the Operating Manual. Check for leaks and repair as required.
5. Close and lock the door.
6. Reconnect the electrical power to the water heater.
7. Restart the water heater following the “Lighting
8. Instructions” found in the Operating Manual.
0610 43 319172-000 Rev. 00
Drain Valve
0610 44 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
TEMPERATURE & PRESSURE RELIEF 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 valves on both the hot-water and cold-
2. water lines. Drain the tank following the instructions in the “Draining
3. The Tank” section in the Operating Manual. Disconnect the discharge piping from the Temperature
4. & Pressure Relief Valve. Remove the Temperature & Pressure Relief Valve.
5.
To Install:
Use only Tefl on tape or an approved pipe sealant on
1. the threads. Install the new Temperature & Pressure Relief Valve.
2. Open the shutoff valves on both the hot-water and cold-
3. water lines. Fill the tank following the instructions in the “Filling The
4. Water Heater” section in the Operating Manual. Check for leaks and repair as required.
5. Close and lock the door.
6. Reconnect the electrical power to the water heater.
7. Restart the water heater following the “Lighting
8. Instructions” found in the Operating Manual.
0610 45 319172-000 Rev. 00
Temperature & Pressure Relief Valve
Discharge Piping
0610 46 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
CONDENSATE TRAP REPLACEMENT
This instruction has been prepared to acquaint you with the service of your gas-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:
To Remove:
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 right side panel
Use a screwdriver to remove the screw from the bottom,
1. front of the right side panel. Remove the three screws from the right side panel
2. towards the rear of the unit. Remove the screw from the top of the unit.
3. Push the panel back and lift out.
4.
1.
Disconnect the electrical power to the water heater.
2.
Loosen the lower gear clamp that secures the venting system to the exhaust elbow.
3.
Lift the venting system away from the exhaust elbow.
4.
Remove the condensate tube from the condensate trap.
5.
Remove the two screws that secure the High-temperature Switch.
6.
Remove the two screws that secure the Condensate Trap Assembly.
7.
Remove the Condensate Trap Assembly (it could be a snug fi t).
8.
Remove the exhaust elbow gasket.
9.
Remove the barbed fi tting (if installed).
To Install:
Re-install the barbed fi tting (if required).
1. Ensure the gasket is placed correctly onto the exhaust
2. elbow prior to assembly. Install the new Condensate Trap Assembly.
3. Secure the Condensate Trap Assembly with the two
4. screws. Secure the High-temperature Switch with the two
5. screws. Connect the condensate tube to the condensate trap.
6. Reposition the venting into the vent coupler.
7. Tighten the lower gear clamp to secure the venting
8. system to the exhaust elbow. Reassemble the right side panel.
9. Reassemble the casing top (front).
10. Close and lock the door.
11. Reconnect the electrical power to the water heater.
12. Restart the water heater following the “Lighting
13. Instructions” found in the Operating Manual.
0610 47 319172-000 Rev. 00
Top Casing (Front)
Door Lock
Access To Door Pins
Screws
Screws
To p Casing (Front)
Screws
High-temperature Switch
Screw (2)
Venting System
Vent Coupling
Gasket
Gear Clamp
Barbed Fitting
0610 48 319172-000 Rev. 00
Condensate Trap
Exhaust Elbow
Condensate Tube
Service Instructions
GAS WATER HEATERS
ANODE 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:
Remove the top casing (front).
1.
Use a screwdriver to remove the six screws securing the top casing.
2.
Lift up and remove casing top (front).
To Remove:
Disconnect the electrical power to the water heater.
1. Close the shutoff valve on the cold-water line.
2. Follow the instructions in the “Draining The Tank” section
3. in the Operating Manual to drain approximately 5 gallons (20 litres) of water from the tank. Close the drain valve.
4. Disconnect the hot-water piping from the Hot Water
5. Outlet Nipple/Anode. Remove the Hot Water Outlet Nipple/Anode.
6.
To Install:
Screws
To p Casing (Front)
Screws
Use only Tefl on tape or an approved pipe sealant on
1. the threads. Install the new Hot Water Outlet Nipple/Anode.
2. Reconnect the hot-water piping to the Hot Water Outlet
3. Nipple/Anode. Open the shutoff valve on the cold-water line.
4. Fill the tank following the instructions in the “Filling The
5. Water Heater” section in the Operating Manual. Check for leaks and repair as required.
6. Reassemble the casing top (front).
7. Close and lock the door.
8. Reconnect the electrical power to the water heater.
9. Restart the water heater following the “Lighting
10. Instructions” found in the Operating Manual.
0610 49 319172-000 Rev. 00
Hot Water Outlet Nipple/Anode
0610 50 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
DIP TUBE 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:
Remove the top casing (front)
1.
Use a screwdriver to remove the six screws securing the top casing.
2.
Lift up and remove casing top (front).
To Remove:
Disconnect the electrical power to the water heater.
1. Close the shutoff valve on the cold-water line.
2. Follow the instructions in the “Draining The Tank” section
3. in the Operating Manual to drain approximately 5 gallons (20 litres) of water from the tank. Close the drain valve.
4. Disconnect the cold-water piping from the Cold Water
5. Inlet Nipple/Dip Tube. Remove the Cold Water Inlet Nipple/Dip Tube.
6.
To Install:
Screws
To p Casing (Front)
Screws
Use only Tefl on tape or an approved pipe sealant on
1. the threads. Install the new Cold Water Inlet Nipple/Dip Tube.
2. Reconnect the cold-water piping to the Cold Water Inlet
3. Nipple/Dip Tube. Open the shutoff valve on the cold-water line.
4. Fill the tank following the instructions in the “Filling The
5. Water Heater” section in the Operating Manual. Check for leaks and repair as required.
6. Reassemble the casing top (front).
7. Close and lock the door.
8. Reconnect the electrical power to the water heater.
9. Restart the water heater following the “Lighting
10. Instructions” found in the Operating Manual.
0610 51 319172-000 Rev. 00
Cold Water Inlet Nipple/Dip Tube
0610 52 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
MAIN BAFFLE 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:
Remove the top casing (front)
1.
Use a screwdriver to remove the six screws securing the top casing.
2.
Lift up and remove casing top (front).
Remove the top casing (rear).
1.
Use a screwdriver to remove the two screws securing the top casing.
2.
Lift up and remove casing top (rear).
Screws
To p Casing (Rear)
Screws
Remove the fl exible venting
1.
Unwrap the insulation covering the venting.
2.
Loosen the gear clamps securing the venting.
3.
Remove the fl exible venting.
To Remove:
Disconnect the electrical power to the water heater.
1. Remove the main baffl e.
2.
To Install:
Install the new main baffl e.
1. Reassemble the fl exible venting to the heat engine and
2. the storage tank. Re-fi t the insulation around the exhaust elbows.
3. Reassemble the top casing.
4. Reconnect the electrical power to the water heater.
5. Restart the water heater following the “Lighting
6. Instructions” found in the Operating Manual.
To p Casing (Front)
0610 53 319172-000 Rev. 00
Top Casing
Screw (8)
Main Baffl e
Insulation
Flexible Venting
0610 54 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
CONDENSATION BAFFLE 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 right side panel
Use a screwdriver to remove the screw from the bottom,
1. front of the right side panel.
Top Casing (Front)
Door Lock
Access To Door Pins
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. Loosen the upper gear clamp that secures the venting
2. system to the vent coupler. Lift the venting system out of the vent coupler.
3. Remove the drain tubing from the condensate trap.
4. Carefully disconnect the two wires from the High-
5. temperature Switch. Remove the two screws that secure the exhaust
6. elbow. Remove the exhaust elbow (it could be a snug fi t).
7. Remove the exhaust elbow gasket.
8. Remove the Condensation Baffl e.
9.
To Install:
Install the new Condensation Baffl e.
1. Ensure the gasket is placed correctly onto the exhaust
2. elbow prior to assembly.
Screws
Screws
To p Casing (Front)
0610 55 319172-000 Rev. 00
Screws
Secure the exhaust elbow with the two screws.
3. Carefully reconnect the two wires to the High-temperature
4. Switch. Connect the drain tubing to the condensate trap.
5. Reposition the venting into the vent coupler.
6. Tighten the upper gear clamp to secure the venting
7. system to the vent coupler. Reassemble the right side panel.
8. Reassemble the casing top (front).
9. Close and lock the door.
10. Reconnect the electrical power to the water heater.
11.
Venting System
Restart the water heater following the “Lighting
12. Instructions” found in the Operating Manual.
Vent Coupling
Gear Clamp
Condensation Baffl e
Gasket
Screw
0610 56 319172-000 Rev. 00
Exhaust Elbow
Condensate Trap
Condensate Tube
Service Instructions
GAS WATER HEATERS
TANK 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:
Remove Door
Disconnect the electrical power to the water heater.
1. Unlock the door by rotating the lock counter-clockwise
2. with a wide, slot screwdriver. Release the top and bottom door pins by prying the pins
3. out, using a small screwdriver. Open the door (the door remains fastened to the left
4. side panel). Carefully disconnect all the wiring harness plugs from
5. the Display Panel. Carefully remove the door hinge pins from their retaining
6. fi ngers.
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.
Top Casing (Front)
Door Lock
Access To Door Pins
Screws
Remove the top casing (rear)
Use a screwdriver to remove the two screws securing
1. the top casing. Lift up and remove casing top (rear).
2.
Remove the right side panel
Use a screwdriver to remove the screw from the bottom,
1. front of the right side panel. Remove the three screws from the right side panel
2. towards the rear of the unit. Remove the screw from the top of the unit.
3. Push the panel back and lift out.
4.
Remove the left side panel
Use a screwdriver to remove the screw from the bottom,
1. front of the left side panel. Remove the three screws from the left side panel towards
2. the rear of the unit. Remove the screw from the top of the unit.
3. Push the panel back and lift out.
4.
Remove the rear panel
Use a screwdriver to remove the four screws on the
1. back side Lift off the panel.
2.
To p Casing (Rear)
Screws
To p Casing (Front)
0610 57 319172-000 Rev. 00
Screws
Remove additional components:
To Install:
Remove the casing bracket
1.
Use a Phillips screwdriver to remove the four screws holding the casing bracket to the tank.
Remove the fl exible venting
1.
Unwrap the insulation covering the venting.
2.
Loosen the gear clamps securing the venting.
3.
Remove the fl exible venting.
Remove the Heat Engine
1.
Close the shutoff valves on both the hot-water and cold­water lines.
2.
Close the shutoff valve on the gas supply line to the water heater.
3.
Drain the tank following the instructions in the “Draining The Tank” section in the Operating Manual.
4.
Disconnect the hoses from the heat engine (top is water outlet and bottom is water inlet).
5.
Disconnect the gas line from the heat engine.
6.
Remove the 4 nuts holding the heat engine to the tank. (Requires 1/2” wrench, socket or nut-driver.) It may be necessary to remove part of the venting system to access some nuts.
7.
Remove the heat engine.
Remove the water lines Disconnect the hot-water and the cold-water lines from the tank.
Remove the condensation trap
1.
Remove the venting to the unit.
2.
Use a Phillips screwdriver to remove the two screws holding the condensation trap to the tank.
3.
Remove the condensation trap by pulling it straight out.
Remove the baffl es
1.
Remove the large baffl e by pulling it straight up out of the top of the fl ue tube.
2.
Remove the small baffl e by pulling it straight out of the side of the fl ue tube.
1.
Fit the new tank in position. Hint: Screw a short length of 3/4” NPT pipe into the sides of the water heater to use as handles to move the water heater.
To Reassemble:
Reinstall the earthquake straps in the reverse order.
1. Reinstall the tank temperature sensor and clip in reverse
2. order. Install the large baffl e.
3. Install the small baffl e into the condensation trap by fi tting
4. the tabs into the slots inside the condensation trap and then install condensation trap and small baffl e into tank in reverse order. Reinstall the venting.
5. Connect the hot-water and cold-water lines to the tank.
6. Assemble heat engine to the tank.
7. Reconnect the gas line.
8. Reconnect the hoses to the tank.
9. Open the shutoff valves on both the hot-water and the
10. cold-water lines. Fill the tank following the instructions in the “Filling The
11. Water Heater” section of the Operating Manual. Carefully reconnect the wire harnesses.
12. Reinstall the fl exible venting in reverse order.
13. Re-fi t the insulation around the exhaust elbows.
14. Reinstall the casing bracket in reverse order.
15. Reassemble the rear panel in reverse order.
16. Reassemble the left side panel in reverse order.
17. Reassemble the right side panel in reverse order.
18. Reassemble the top casing (front and back) in reverse
19. order. Close and lock the door.
20. Open the shutoff valve on the gas supply line to the water
21. heater. Reconnect the electrical power to the water heater.
22. Restart the water heater following the “Lighting Instructions”
23. found in the Operating Manual.
Remove the tank temperature sensor
1.
Remove the clip and slide the sensor out.
Remove the earthquake straps
1.
Remove the bolts at the clamp that hold the two halves of the earthquake strap.
To Remove:
Lift tank out of position. Hint: Screw a short length of 3/4”
1. NPT pipe into the sides of the water heater to use as handles to move the water heater.
0610 58 319172-000 Rev. 00
0610 59 319172-000 Rev. 00
0610 60 319172-000 Rev. 00
Service Instructions
GAS WATER HEATERS
HEAT EXCHANGER 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 the ten screws that secure the front cover of
Remove panels to gain access:
Door opening
1.
Unlock the door by rotating the lock counter-clockwise with a wide, slot screwdriver.
2.
Release the top and bottom door pins by prying the pins out, using a small screwdriver.
3.
Open the door (the door remains fastened to the left side panel).
To Remove:
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.
Top Casing (Front)
Door Lock
0610 61 319172-000 Rev. 00
Access To Door Pins
Screws
5. the heat engine. Remove the front cover of the Heat Engine. Remove the two screws securing the circuit board and
6. partially extract it. Carefully disconnect the HiLimit temperature switch (2
7. thin red wires) and the Blower motor wiring harness plug from the circuit board. Carefully disconnect the (black) wire from the Spark
8. generator to the electrode. Remove the two screws securing the retaining clip that
9. holds in the copper tube to the fi tting on the left side of the heat engine. Remove the retaining clip.
10. Remove the two screws securing the retaining clip that
11. holds in the copper tube to the internal fl ow valve at the lower right side of the heat engine. Remove the retaining clip.
12. Carefully disconnect the blue wire from the Flame
13. sensor. Remove the two screws securing the ECO switch.
14. Remove the ECO switch.
15. Remove the four screws around the outside of the orifi ce
16. plate. One of these screws also secures the Spark generator, another one secures a ground lug. Remove the fi ve screws that secure the top portion of
17. the Gas valve to the burner chamber. Remove the four retaining screws that secure the heating
18. core to the Heat Engine Cabinet. There is one under the blower, one under the combustion chamber and one on each side at the top. Note: When removing the upper two screws support the core so that it will not drop. Remove the Heat exchanger assembly from the Heat
19. engine. Remove the exhaust gasket and ring.
20. Remove six screws securing the Combustion chamber
21. to the lower portion of Heat exchanger. Remove the Combustion chamber.
22. Remove the six screws securing the Draft hood to the
23. upper portion of Heat exchanger. Remove the Draft hood.
24. Carefully remove and retain (but do NOT cut!) the HiLimit
25. temperature switch from the heat exchanger. Ensure old (white) gasket is completely removed and
26. no material remains on the Draft Hood and Combustion chamber.
Screw (4) Heat Exchanger
Burner Orifi ce Plate
Screw (4) Orifi ce Plate
Heat Engine Cabinet
ECO Switch
Spark Generator
Screw & Washer (5) Gas Valve
Screw (2) Circuit Board
Screw (2) & Retaining Clip)
0610 62 319172-000 Rev. 00
Screw (2) & Retaining Clip)
Flame Rod
To Install:
Re-install the original HiLimit temperature switch.
1. Secure a new (white) gaskets in place on the Draft Hood
2. and Combustion Chamber. Reassemble the Draft Hood to the upper portion of heat
3. engine. Reassemble the Combustion chamber to the heat
4. exchanger. Reassemble the exhaust gasket and ring over the
5. exhaust vent. Re-install the Heat exchanger assembly to the Heat
6. Engine Cabinet. Carefully reconnect the HiLimit temperature switch (2
7. thin red wires) and the Blower motor wiring harness plug to the circuit board. Carefully reconnect the (black) wire from the Spark
8. generator to the electrode. Slide the circuit board into its proper position and secure
9. using the two screws. Reassemble the orifi ce plate to the combustion chamber.
10. One of these screws also secures the Spark generator, another one secures a ground lug. Reassemble the top portion of the Gas valve to the
11. burner chamber. Re-install the ECO switch.
12. Carefully reconnect the blue wire to the Flame sensor.
13. Reassemble the retaining clip that holds in the copper
14. tube to the internal fl ow valve at the lower right hand side of the heat engine. Reassemble the retaining clip that holds in the copper
15. tube to the fi tting on the left hand side of the heat engine. Open the shutoff valves on both the hot-water and cold-
16. water lines. Fill the tank following the instructions in the “Filling The
17. Water Heater” section in the Operating Manual. Check for leaks and repair as required.
18. Reassemble the front cover of the Heat Engine.
19. Close and lock the door.
20. Open the shutoff valve on the gas supply line to the
21. water heater. Reconnect the electrical power to the water heater.
22. Restart the water heater following the “Lighting
23. Instructions” found in the Operating Manual.
Screw (6) Draft Hood
Draft Hood
Heat Exchanger
Gasket (Combustion Chamber)
Combustion Chamber
Screw (6) Combustion Chamber
Gasket (Exhaust)
Ring
Gasket (Draft Hood)
HiLimit Temperature Switch
0610 63 319172-000 Rev. 00
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