Perfect Fit T76-200 Use and Care Manual
Contents
1. Operation Before operating this water heater be sure to read and follow the instructions on the label pictured below and all other labels on the water heater as well as the warnings printed in this manual Failure to do so can result in unsafe operation of the water heater resulting in property damage bodily injury or death Should you have any problems reading or following the instructions in this manual STOP and get help from a qualified person Lighting Instructions for the Xtreme Unit Only 1 LIGHTING PROCEDURE Lighting procedures are outlined on the label pictured below This label is also located on the water heater near the thermostat NOTE The Gas Valve supplied with this water heater may vary from the one pictured on the label below but the Lighting Instructions are the same for all types of valves supplied with this model water heater NOTE This unit contains a ceramic burner chamber When this chamber is heated for the first time the binders will burn off causing a light colored smoke to appear near the bottom of the unit This generally last for 30 45 minutes This is normal operation and does not indicate a need for alarm or service FOR YOUR SAFETY 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 A This appliance is equipped with an ignition f you cannot reach your gas supplier call d2. DO NOT use any phone in your building Leave the house immediately and make sure your fami ly and pets leave also Leave the doors open for ventilation and contact the gas supplier a qualified service agency or the fire department Keep the area clear until the service call has been made the leak is corrected and a qualified agency has determined the area to be safe A WARNING Both LP and natural gas have an odorant added to help detection Some people may not physically be able to smell or recognize this odorant If unsure or unfamiliar about the smell associated with LP or natural gas ask the gas supplier Other conditions such as Odorant Fade which causes the odorant to fade or diminish in intensi ty can also hide or camouflage a gas leak 7 DANGER Water heaters utilizing Liquefied Petroleum gas LP are different from natural gas models A natural gas heater will not function safely on LP gas and vice versa No attempt should ever be made to convert a heater from natural gas to LP gas To avoid possible equipment damage personal injury or fire DO NOT connect this water heater to a fuel type not in accordance with unit data plate Propane for propane units Natural gas for natural gas units These units are not certified for any other type fuel A WARNING LP appliances should not be installed below grade for example in a basement if such installation is prohibited by federal state and or local laws rules
3. Before operation re install the inlet plate to the blower PRESSURE SWITCH Inspect the inlet to the pressure switch and the tubing for debris or blockage Clean out the tubing peri odically to prevent buildup of debris LUBRICATION The blower motor bearings should be lubri cated 2 places with 2 or 3 drops of SAE 20 oil approximately every six months See Figure 11 Not required on Xtreme mod els 1 This water heater is equipped with a combination thermo stat temperature limiting device ECO that should be checked annually by qualified service personnel Figure 11 Lubrication Points 13 A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation VERIFY PROPER OPERATION AFTER SERVICING 2 The Temperature and Pressure Relief Valve must be free to operate properly Check at least once a year by lifting the handle fully and allowing several gallons of water to flush through the discharge line Make certain the discharged water is directed to a suitable drain DANGER Before manually operating the relief valve make certain no one will be exposed to the danger of coming in contact with the hot water released by this valve The water may be hot enough to cre ate a SCALD hazard The water released should be directed to a suitable drain to prevent injury or damage NOTE If the temperature and pressure relief v
4. always be installed in the recirculation line to prevent cold water from entering Factory designed Equa Flow Manifolds and Jacketed Insulated Storage Tanks are available WATER CONNECTIONS This water heater may be connect ed individually in multiples with others or with an external hot water storage tank Inlet water connections are made to the lower coupling on the heater and outlet water connections are made to the upper coupling or if desired on models so equipped the optional top connections may be utilized Each water heater is supplied with the necessary components Dif fuser tubes di electric nipples or a combination of both to make the water connections that will ensure proper performance The components are supplied in a box enclosed in the Damper Assembly package provided with each heater If special instructions are re quired for any specific water heater they will be included in the box Cap or plug unused connections Use only clean new galvanized steel copper or approved plastic pipe for water connections Local codes or regulations shall govern the exact type of material to be used The installation of unions on the inlet and outlet water lines and a shut off valve in at least the cold water inlet line is recom mended so the water heater may be easily disconnected for ser vicing Dielectric unions are not required for protection of water heater When this water heater is supplying general purpose hot
5. area of the covering material must be used in determining the size of the openings mentioned above Protective screening for the openings MUST NOT be smaller than inch 64 cm mesh to resist clogging by lint or other debris For additional information regarding combustion and ventilation air supply requirements refer to the latest edition of the Ameri can National Standard National Fuel Gas Code ANSI Z223 1 FOR INSTALLATIONS IN CANADA While the requirements for U S installations outlined above are generally true in Canada precise requirements for combustion and ventilation air supplies are detailed in the CAN CGA B149 In stallation Codes under Venting Systems and Air Supply for Ap pliances To ensure that the water heater is properly installed those requirements must be followed Introduction Large exhaust fans can lower the air pressure inside a building or room and interfere with proper venting and operation Com mercial kitchens or other locations that must maintain a high flow of exhaust air should have the water heater installed in a sepa rate room with combustion and ventilation air supplied directly from outside as described above F CORROSIVE ATMOSPHERES The heater should not be in stalled near an air supply containing halogenated hydrocarbons For example the air in beauty shops dry cleaning establishments photo processing labs and storage areas for liquid and powdered bleaches or swim pool chemi
6. directly on the flue outlet collar DO NOT substitute any other size or type of draft hood Before proceeding with installation verify that the part number on the draft hood flue damper assembly matches that called for on label near connector If not see your distributor or the store from where the water heater was purchased A Place the draft hood flue damper assembly on the flue outlet of the water heater with the drive motor to the left front Rotate as necessary to position where the plug on the end of the wire har ness can freely engage in the receptacle of the drive motor 3 8 Maximum Length Damper Mounting Screw Additional screws located at 90 intervals around Damper Base Damper Mounting Pd Insert Polarized Plug into re ceptacle on Drive Motor after Damper Draft Hood Assem bly is secured to water heater Note Damper MUST be in open position when water heater main burner is operating Figure 3 Installing Damper Draft Hood Assembly B Mark a spot on top pan through the hole in support bracket at the rear of the drive motor Refer to Figure 3 C Remove the draft hood flue damper assembly and drill a hole through the spot for securing it with sheet metal screw D Reinstall the draft hood flue damper assembly and secure it with a sheet metal screw through the support bracket Also install three 3 3 8 95 cm maximum length self drilling screws s
7. it is recommended that a qualified person or serviceman perform the work A CAUTION Hydrogen gas can be produced in a hot water system served by this water heater that has not been used for a long period of time generally two weeks or more HYDROGEN GAS IS EXTREMELY FLAMMABLE To dissipate such gas and to reduce risk of injury it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance connected to the hot water system If hydrogen is pre sent there will probably be an unusual sound such as air escap ing through the pipe as the water begins to flow Do not smoke or use an open flame near the faucet at the time it is open A WARNING When this water heater is supplying general purpose hot water requirements for individuals a thermostatically controlled mixing valve for reducing point of use water temperature is recommend ed Contact a licensed plumber or the local plumbing authority for further information Outlet water temperature will vary during normal operating cy cles Reliable temperature readings should be taken shortly after main burner cycles off during a period of little or no use 3 GAS MANIFOLD PRESSURE With the gas valve supplied with this water heater main burner ignition occurs at a low or step manifold pressure which will then automatically build up to its normal operating level On the Power Assist Burner and Xtreme uni
8. or combustible materials any where near or in the vicinity of a water heater Be sure to read and follow the warning label pictured below and other labels on the water heater as well as the warnings printed in this manual Failure to do so can result in prop erty damage bodily injury or death DANGER Failure to properly vent the water heater to the outdoors as outlined in the Venting Section of this manual can result in unsafe operation of the water heater To avoid the risk of fire explosion or asphyxiation from carbon monoxide never operate this water heater unless it is properly vented and has an adequate air supply for proper operation Be sure to inspect the vent system for proper installation at initial start up and at least annually there after Refer to Maintenance section of this manual for more information regarding vent system inspections A DANGER FLAMMABLES Flammable Vapors A Vapors from flammable liquids will explode and catch fire causing death or severe burns Do not use or store flammable products such as gasoline solvents or adhesives in the same room or area near the waiter heater Keep flammable products 1 far away from heater 2 in approved containers 3 tightly closed and 4 out of children s reach Water heater has a main burner and pilot flame The pilot flame 1 which can come on at any time and 2 will ignite flammable vapors Vapors 1 cannot be seen 2 ar
9. water requirements for use by individuals a thermostatically controlled mixing valve is recommended to reduce the risk of scald injury Contact a licensed plumber or the local plumbing authority for fur ther information Thermometer s should be installed so that they indicate the tem perature of the water at or near the outlet of the water heater and storage tank s if provided See Fig 4 or 5 on page 6 WIRING A polarized 120V 50 60 Hz power supply with suit able disconnect means must be connected to the black and white leads provided The current draw by the Standard Burner Unit is 0 3 Amps 1 5 Amps on the Power Assist Burner unit and 2 5 amps on the Xtreme unit The water heater when installed must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 in the United States or CSA C22 1 Electrical Code in Canada Refer to Fig 12 13 14 15 or 16 on pages 22 24 of this manual for water heater internal wiring diagrams Operation Before operating this water heater be sure to read and follow the instructions on the label pictured below and all other labels on the water heater as well as the warnings printed in this manual Failure to do so can result in unsafe operation of the water heater resulting in property damage bodily injury or death Should you have any problems reading or following the instructions in this manual STOP and
10. Commercial Gas Water Heater USE amp CARE MANUAL WITH INSTALLATION INSTRUCTIONS FOR THE CONTRACTOR MULTI FLUE COMMERCIAL MODELS Standard Burner Unit Power Assist Burner Unit LISTED Refer to page 9 for an important note regarding initial Start up of this unit CERTIFIED The Power Assist Burner and Xtreme Units use a system that requires a blower to deliver the air for combustion A Recognize this symbol as an Indication of Important A Do Not Destroy this Manual Please read carefully and Safety Information keep in a safe place for Future Reference NOTICE This water heater is designed for use in a commercial application and the installation and maintenance of it should be per formed by a qualified licensed service personnel If the foregoing assumption is not appropriate then we recommend that you obtain and retain our Residential Use amp Care Manual CALIFORNIA PROPOSITION 65 WARNING This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING If the information in these instructions are not followed exactly a fire or explosion may result A causing property damage personal injury or death A FOR YOUR SAFETY e Immediately call your gas supplier from a neigh bor s phone Follow the gas supplier s instructions Do not store or use gasoline or other flammable vapors o
11. HTS THE PILOT DO NOTTRY TO LIGHT THE PILOT BY HAND GAS CONTROL KNOB CLOCK WISE N TO OFF 6 WAIT FIVE 5 MINUTES TO CLEAR OUT ANY GAS IF YOU THEN SMELL GAS STO P FOL LOW B IN THE SAFETY INFORMATION ABOVEON THIS LABEL IF YO U DONT SMELL GAS GO TO NEXT STEP TURN THE GAS CONTROL KNOB COUNTER CLOCKWISE TO ON TURN ON ALL ELECTRIC POWER TO THE APPLIANCE S ET THERMOSTAT TO SIR ED SETTING I NSTALL OUTER COVER IF THE APPLIANCE WILL NOT OPERATE FOL LOW THE INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE AND CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLIER TO TURN OFF GAS TO APPLIANCE SET THE THERMOSTA T TO LOWEST SETTING 3 TURN THE GAS CONTROL KNOB CLOCK TURN OFF ALL ELECTRIC POWER TO THE WISE NTO OFF APPLIAN CE IF SERVI CE IS TO BE PERFORMED Operation SAFETY PRECAUTIONS Do turn off manual gas shut off valve if water heater has been sub jected to over heating fire flood physical damage or if gas supply fails to shut off Do Not turn on water heater unless it is filled with water Do Not turn on water heater if cold water supply shut off valve is closed Do Not store or use gasoline or other flammable vapors and liq uids such as adhesives or paint thinner in vicinity of this or any other appliance If such flammables must be used open doors and windows for ventilation and all gas burning appliances in vicinity should be shut off including their pilot lights t
12. LVE CONNECTION DIAGRAM SCHEMATIC NOTE If any of the original wire as supplied with this appliance must be replaced it MUST be replaced with 18 GA 600V 105 C wire or its equivalent unless otherwise noted A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dan gerous operation VERIFY PROPER OPERATION AFTER SERVICING Figure 12 Diagrams for units supplied with Honeywell VR8304P Gas Valve and Honeywell S8600M Ignition Control NORMAL OPERATION SEQUENCE L1 INDICATED BY BOXED NUMERALS L2 DAMPER MOTOR LED E im INDICATORS 120V POWER THERMOSTAT THERMOSTAT PILOT VALVE e AND POWER LED LIMIT T ECO MAIN VALVE ANY REPLACEMENT WIRE MUST BE RATED FOR 250 C CONTROL PILOT ELECTRODE ASS Y IGNITION 2 IGN GAS VALVE CONNECTION DIAGRAM SCHEMATIC NOTE If any of the original wire as supplied with this appliance must be replaced it MUST be replaced with 18 GA 600V 105 C wire or its equivalent unless otherwise noted A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dan gerous operation VERIFY PROPER OPERATION AFTER SERVICING Figure 13 Diagrams for units supplied with Robertshaw 7000 DERHC S7C or 7000BDER S7C Gas Valve and Honeywell S8600M Ignition Control Wiring and Schematic Diagrams NORMAL OPERATION SEQUENCE INDICATED BY B
13. OPERATION If the water heater is to remain idle for an extended period 60 days or more the heater should be turned off The water heater and piping should be drained if they might be subjected to freezing temperatures It is recommended that the water heater s operation is thoroughly checked by a qual ified service technician before itis placed back in service NOTE Refer to Hydrogen Gas caution notation on page 10 Length of Pipe Feet 14 System Sentinel Diagnostic System The System Sentinel Diagnostic system on this water heater provides the user or service technician with a visual representation of the operational status of the various sections of the water heater s control system A quick glance at the System Sentinel panel on the front of the heater will give an indication of where to begin trouble shooting of a non operational heater The LED s light emitting diodes on the panel are arranged from top to bottom based on their function in the normal sequence of operation and their function is explained as follows POWER When illuminated this green LED indicates that 120VAC power is being supplied to the heater the On OFF switch is func tioning and the 24V transformer is functioning properly Refer to Section 1 of Troubleshooting Guide THERMOSTAT IGNITION PILOT VALVE MAIN VALVE THERMOSTAT When illuminated this red LED indicates that the ther mostat is f
14. OXED NUMERALS notions i ore hoe POWER THERMOSTAT IGNITION PILOT VALVE ECO s R LED MAIN VALVE IGNITION CONTROL CONTROL ANY REPLACEMENT WIRE aa MUST BE RATED FOR 250 C IGNITION 4 IGN PILOT SCHEMATIC ELECTRODE ASS Y M CONNECTION DIAGRAM NOTE If any of the original wire as supplied with this appliance must be replaced it MUST be replaced with 18 GA 600V 105 C wire or its equivalent unless otherwise noted GAS VALVE A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dan gerous operation VERIFY PROPER OPERATION AFTER SERVICING Figure 14 Diagrams for units supplied with Honeywell VR8304M Gas Valve and Honeywell S8600M Ignition Control NORMAL OPERATION SEQUENCE INDICATED BY BOXED NUMERALS 120V BLOWER LED INDICATORS POWER THERMOSTAT IGNITION THERMOSTAT d PILOT VALVE AND ECO MAIN VALVE IGNITION CONTROL IGNITION 3 IGN CONTROL T ANYREPLACEMENTWIRE SCHEMATIC MUST BE RATED FOR 250 C PILOT ELECTRODE ASS Y GAS VALVE CONNECTION DIAGRAM NOTE If any of the original wire as supplied with this appliance must be replaced it MUST be replaced with 18 GA 600V 105 C wire or its equivalent unless otherwise noted A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dan gerous operation VERIFY PROPER OPERATION AFTE
15. R SERVICING Figure 15 Diagrams for units supplied with Robertshaw 7000 DERHC S7C or 7000BDER S7C Gas Valve and Honeywell S8600M Ignition Control Wiring and Schematic Diagrams NORMAL OPERATION SEQUENCE INDICATED BY BOXED NUMERALS 120V 3 THERMOSTAT HL Omm HIGH LIMIT pues BL 2 W 1 ANY REPLACEMENT WIRE MUST BE RATED FOR 250 C CONNECTION DIAGRAM SCHEMATIC NOTE If any of the original wire as supplied with this appliance must be replaced it MUST be replaced with 18 GA 600V 105 C wire or its equivalent unless otherwise noted CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dan gerous operation VERIFY PROPER OPERATION AFTER SERVICING Figure 16 Diagrams for units supplied with Robertshaw 7000 DERHC Gas Valve and Honeywell S8600M Ignition Control 24 Supplement Sheet Commercial Beat Duty Gas Water Heater Supplements the following Use amp Care Man
16. RVICE The inlet gas pressure to the water heater must not exceed 10 5 w c 2 6 kPa for Natural gas and 13 0 w c 3 2 kPa for L P gas Note The Power Assist Burner Unit uses only Natural Gas and should follow the guidelines stated in the previous sentence for inlet gas pressure For purposes of input adjustment the minimum inlet gas pressure with main burner on is shown on the rating plate Check to see if high orlow gas pressure is present and then contact the gas company for correction The gas line should be of adequate size to prevent undue pressure drop Sizing based upon Table 1 on pg 14 is recommended No additional allowance is necessary for an ordinary number of fit tings A ground joint union and manual shutoff valve should be installed in the gas line near the water heater so that the burner assembly may be easily removed The shut off valve must be readily ac cessible for turning on or off See Fig 4 or 5 on page 6 Installation NOTES 1 Heater s Outlet Piping must have upward slope otherwise use Circulator 2 If Vertical Tank is used follow same lay out 3 Figure depicts the Power Assist Burner but all burner systems applies 4 The gas supply piping must be adequate ly supported and aligned to minimize loads forces on the water heater s gas valve and burner system Hot Outlet Storage Tank To Gas Supply Temperature amp Pressure Relief Valve See Local Code Manual G
17. alve on the water heater discharges periodically this may be due to ther mal expansion in a closed water system Contact the water supplier or local plumbing inspector on how to correct this DO NOT plug the relief valve outlet D TANK Good maintenance requires that the tank be cleaned of deposits Unless the water supply is soft 0 to 5 grains hardness scale or lime deposits will accumulate in the tank Hard water scale is deposited at an increasingly high rate in proportion to in creased water temperature Accumulation of these deposits may reduce efficiency and shorten the life of the water heater Any new installation should have a tank inspection program set up initially for frequent inspection The first inspection should be within a six month period Once the scaling tendencies have been established the inspection program can be modified to suit the water conditions Cleaning should be performed if the scale has accumulated above the drain valve opening A wet dry shop vac with a nozzle fashioned from 1 and or 3 4 polyethylene pipe makes a good tool for scraping and removing scale TO CLEAN OR INSPECT TANK 1 Shut off gas valve and drain tank 2 Remove tank clean out cover on jacket and with pocket knife cut and remove a circular plug of insulation the full size of jack et opening 3 Loosen nut on seal plate assembly enough to twist yoke side ways Hold assembly securely and push inward then remove fro
18. an 5 minutes 125 F 11 2 to 2 minutes 130 F About 30 seconds About 10 seconds Less than 5 seconds Less than 3 seconds About 11 2 seconds About 1 second Table courtesy of Shriners Burn Institute TIME TEMPERATURE RELATIONSHIPS IN SCALDS The temperature of the water in the heater can be regulated by setting the temperature dial on front of the thermostat To comply with safety regulations the thermostat was set at its lowest setting before water heater was shipped from the factory The illustration below illustrates the thermostat and how to adjust the water tem perature To adjust the water temperature insert a small straight screwdriver into slotted screw in hole in front of thermostat and turn wheel to desired setting Thermostat is adjustable up to 180 F CAUTION Hotter water increases the risk of SCALDING Honeywell White Rodgers NOTE Each water heater will contain one 1 of the above ther mostats Refer to actual unit to determine which one DANGER There is a Hot Water SCALD Potential if the thermostat is set too high NOTE When this water heater is supplying general purpose hot water requirements for use by individuals a thermostatically con trolled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury Contact a licensed plumber or the local plumbing authority for further infor mation Introductio
19. as Shut Off Recirculation Loop Thermostat Ground Joint Union Air Gap 6 Sediment Trap Discharge Pipe to Suitable Open Drain Figure 4 Typical Gravity Circulating System NOTES 1 Figure depicts the Standard Burner but all burner systems applies 2 The gas supply piping must be adequately supported and aligned to minimize loads forces on the water heater s gas valve and burner system Temperature amp Pressure Relief Valve See Local Code Cold Shut Off Inlet Valve Recirculation Loop Recirculator Temperature amp Pressure Relief Valve Circulator Circulator may be wired to run continuously without the Control Air Gap 6 Discharge Pipe to Suitable Open Drain Temperature amp Pressure Relief Valve See Local Code Optional Return Outlet Check Valve Cold Water Inlet Shut Off Valve Manifolds Check Valve Discharge Line to Suitable Open Drain Figure 5 Typical Forced Circulation Tank System with Factory Supplied Jacketed amp Insulated Storage Tanks 6 Installation A sediment trap must be installed at the bottom of the gas line See Fig 4 or 5 on page 6 The pipe compound used should be resistant to the action of liq uefied petroleum gases LEAK TESTING The water heater and its gas connections MUST be leak tested at normal operating pressure before it is placed in operation Turn ON the manual gas s
20. ations of 2000 feet Factory prepared high altitude models are available and are specif ically rated for installations at elevations up to 5000 feet Refer to rating plate on front of water heater for model number and alti tude specifications A WARNING 7 EMERGENCY SHUTDOWN Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance A WARNING DO NOT use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appli ance and to replace any part of the control system and any gas control which has been under water If the water heater has been subjected to fire or physical damage turn off gas at the manual gas control shut off valve Do not op erate the water heater again until it has been checked out by a qualified service technician Maintenance Properly maintained this water heater will provide years of depend able trouble free service It is strongly suggested that a regular rou tine maintenance program be established and followed by the owner It is further recommended that a periodic inspection of the blower thermostat burner relief valve internal flueway draft hood damper assembly and venting system should be made by service technicians qualified in gas appliance repair 1 ROUTINE PREVENTIVE MAINTENANCE A BURNERS Visually inspect the main burner flame and the pilo
21. cals often contain such hydrocar bons The air there may be safe to breathe but when it passes through a gas flame corrosive elements are released that will shorten the life of any gas burning appliance Propellants from common spray cans or gas leaks from refrigeration equipment are highly corrosive after passing through a flame The limited warranty is voided when failure of water heater is due to a corro sive atmosphere Reference is made to the limited warranty for complete terms and conditions Installation WARNING The manufacturer s warranty does not cover any damage or defect caused by installation or attachment or use of any special attachment such as energy saving devices other than those authorized by the manufacturer into onto or in conjunction with the water heater The use of such unauthorized devices may shorten the life of the water heater and may endanger life and property The manufacturer disclaims any responsibility for such loss or injury resulting from the use of such unauthorized devices 1 INSPECT SHIPMENT for possible damage The manufacturer s responsibility ceases upon delivery of goods to the carrier in good condition Any claims for damage shortage in shipments or non delivery must be filed immediately against carrier by consignee 2 DRAFT HOOD The combination draft hood flue damper as sembly designed for and shipped with this water heater must be installed without alteration
22. de Section 1 the POWER LED Is the POWER LED Illuminated Is the ON OFF Switch in Power is being supplied to the ON position the heater the ON OFF Switch is functioning and the 24V AC Transformer is functioning Is 120 VAC power present at the Check circuit breaker or fuse and field connec branch circuit connections to Black tion of branch circuit wiring to leads of switch wire of the switch and White wire of Repair or replace as required Is POWER LED the transformer now illuminated Is 120 VAC power present between Replace Switch then verify that the Black and White wires to the power is present Is POWER LED transformer now illuminated Is 24 VAC power present between the Replace Transformer then verify Yellow and Gray wires from the trans that power is present Is POWER former LED now illuminated The System Sentinel Panel is defec tive and must be replaced A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation VERIFY PROP ER OPERATION AFTER SERVICING 16 System Sentinel Troubleshooting Guide Section 2 the THERMOSTAT LED No Is the THERMOSTAT LED Illuminated YES Ensure that power is being supplied to the Thermostat is calling for heat water heater Refer to Section 1 the and 24 VAC power is being sup POWER LED in this Troubleshooting
23. e heavier than air 3 go a long way on the floor and 4 can be carried from other rooms to the pilot flame by air currents are at least 18 above the floor This will reduce but not eliminate the risk of vapors being ignited by the main burner or pilot flame Installation Do not install water heater where flammable products will be stored or used unless the main burner and pilot flames Read and follow water heater warnings and instructions If owners manual is missing contact the retailer or manufacturer DANGER LIQUEFIED PETROLEUM MODELS Propane or LP gas must be used with great caution It is heavier than air and will collect first in lower areas making it hard to detect at nose level Make sure to look and smell for LP leaks before attempting to light appliance Use a soapy solution to check all gas fittings and connections Bubbling at a connection indicates a leak that must be corrected When smelling to detect an LP leak be sure to sniff near the floor too Gas detectors are recommended in LP applications and their installation should be in accordance with the manufacturer s recommendations and or local laws rules regulations or customs It is recommended that more than one method be used to detect leaks in LP applications IF LP GAS IS PRESENT OR SUSPECTED DO NOT attempt to find the cause yourself DO NOT try to light any appliance DO NOT touch any electrical switch
24. e must not exceed 150 psi 160 psi for ASME models the maximum working pressure as marked on front of the water heater The Btu h rating of the relief valve must equal or exceed the Btu h input of the water heater as marked on its rating plate Connect the outlet of the relief valve to a suitable open drain The discharge line must pitch downward from the valve to allow com plete draining by gravity of the relief valve and discharge line and be no smaller than the outlet of the valve The end of the discharge line should not be threaded or concealed and should be protect ed from freezing No valve of any type restriction or reducer cou pling should be installed in the discharge line Local codes shall govern the installation of relief valves 6 THERMAL EXPANSION Determine if a check valve exists in the inlet water line It may have been installed in the cold water line as a separate back flow preventer or it may be part of a pressure reducing valve water meter or water softener A check valve located in the cold water inlet line can cause what is referred to as a closed water system A cold water inlet line with no check valve or back flow prevention device is re ferred to as an open water system As water is heated it expands in volume and creates an increase in the pressure within the water system This action is referred to as thermal expansion In an open water system ex panding water which exceeds the capacity o
25. eater may still be used until a replacement Damper Assembly can be installed by following these steps Turn off power to the water heater at the main power switch located on the side of the control enclosure Order a replacement Damper Assembly With power still off Relay is defective and must be replaced Pressure switch is defective and must be replaced pressure switch remove Damper Drive Motor cover and move the Service Switch located to the right of the the motor from the NORMAL position to the SERVICE position Using a stan dard flat screwdriver rotate the slotted white knob located below the motor counter clockwise until the damper blade is in the open fully vertical position Replace cover and turn power on at the main power switch located on the side of the control enclosure The heater should now attempt its firing sequence Denotes these boxes are for use with the Power Assist Burner amp Xtreme models only A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation VERIFY PROP ER OPERATION AFTER SERVICING 18 System Sentinel Troubleshooting Guide Section 4 the PILOT VALVE LED No Is the PILOT VALVE LED Illuminated YES The Ignition Control Module is in the Ignition sequence and is pro viding 24 VAC power to the ECO Energy Cut Off De
26. ecommended that a suitable catch pan ade quately drained be installed under the water heater The pan MUST NOT restrict the flow of combustion air flow to bottom of water heater NOTE Auxiliary catch pan installation MUST conform to the applicable local codes RESTAURANTS If the water heater is to be installed in a restau rant or other location where the floor is frequently cleaned it must be elevated to provide at least six inches 15 cm of clearance from the floor to comply with NSF International recommendations A factory designed leg extension kit is available for this purpose from the distributor or store where the water heater was purchased Currently unavailable for GX90 models COMBUSTION amp VENTILATION AIR Proper operation of the water heater requires air for combustion and ventilation If the water heater is installed in a building of conventional frame ma sonry or metal construction and there are no other appliances installed that require an air supply infiltration air is normally ad equate for proper combustion and ventilation and an outside air supply for the water heater may not be required However if the water heater is installed in a confined space or the building is of unusually tight construction then an outside air supply must be provided Provisions for Combustion and Ventilation air must com ply with the applicable codes and standards as defined in the Local Installation Regulations sectio
27. evice which automatically lights the pilot DO the fire department NOT try to light the pilot by hand BEFORE OPERATING smell all around the C Useonly your hand to turn thegas control knob 1 2 REMOVE OUTER COVER USING A SLOTTED GAS VALVE 3 TURN OFF ALL ELECTRIC POWER TO THE 9 4 appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions Never use tools If the knob will notturn by hand don try to repair it calla qualified service technician Force or attempted repair may result in afireor explosion Do not use this appliance if any part has been under water Immediately call a qualified ser vice technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP READTHE SAFETY INFORMATION 5 TURN THE ABOVE ON THIS LABEL SCREWDRIVER NSERT INTO SLOT IN CENTER OF DIAL TURN DIAL COUNTERCLOCKWIS E fK TO THE LOWEST SETTING THERMOSTAT TEMPERATURE ADJUSTMENT NOTE Thermostat shown with cover removed APPLIANCE THIS APPLIANCE IS EQUIPPED WITH AN 10 IGNITION DEVICE WHICH AUTOMATICALLY LIG
28. f the water heater flows back into the city main where the pressure is easily dissi pated A closed water system however prevents the expanding water from flowing back into the main supply line and the result of thermal expansion can create a rapid and dangerous pressure increase in the water heater and system piping This rapid pressure increase can quickly reach the safety setting of the relief valve causing it to operate during each heating cycle Thermal expansion and the resulting rapid and repeated ex pansion and contraction of components in the water heater and piping system can cause premature failure of the relief valve and possibly the heater itself Replacing the relief valve will not correct the problem The suggested method of controlling thermal expansion is to install an expansion tank in the cold water line between the water heater and the check valve The expansion tank is designed with an air cush ion built in that compresses as the system pressure increases thereby relieving the over pressure condition and eliminating the re peated operation of the relief valve Other methods of controlling ther mal expansion are also available Contact your installing contractor water supplier or plumbing inspector for additional information re garding this subject If a recirculation line is installed the return connection should be made to a tee close to the inlet connection on the water heater A check valve should
29. get help from a qualified person Lighting Instructions for the Standard and Power Assist Units Only 1 LIGHTING PROCEDURE Lighting procedures are outlined on the label pictured below This label is also located on the water heater near the thermostat NOTE The Gas Valve supplied with this water heater may vary from the one pictured on the label below but the Lighting Instructions are the same for all types of valves supplied with this model water heater pg N FOR YOUR SAFETY 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 A This appliance is equipped with an ignition f you cannot reach your gas supplier call device which automatically lights the pilot DO the fire department NOT try to light the pilot by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions C Use only your hand to turn the gas control knob Never use tools If the knob will not turn by hand don t try to repair it call a qualified service technician Force or attempt
30. hut off valve near the water heater Use a soapy water solution to test for gas leaks at all connections and fittings Bubbles indicate a gas leak that must be corrected The water heater factory connections to the gas valve should also be leak tested after placing the water heater in operation A WARNING NEVER use open flame to test for gas leaks as bodily injury or property damage could result PRESSURE TESTING THE GAS SUPPLY SYSTEM The water heater and its manual gas shut off valve MUST be disconnected from the gas supply piping system during any high pressure test ing of that system at pressures in excess of 1 2 psi 14 w c 3 5 kPa The water heater MUST be isolated from the gas piping system by closing the manual gas shut off valve during any pressure test ing of the gas supply piping at pressures equal to or less than 1 2 psi 14 w c 3 5 kPa 5 RELIEF VALVE A new factory installed combination pressure and temperature relief valve complying with the Standard for Re lief Valves and Automatic Gas Shutoff Devices for Hot Water Sup ply Systems ANSI Z21 22 or Standard CAN1 4 4 Temperature Pressure Temperature and Pressure Relief Valves and Vacuum Relief Valves is provided with the water heater No valve is to be placed between the relief valve and the water heater For a cir culating tank installation the separate storage tank s must have similar protection The pressure rating of the relief valv
31. ings or local utility for qualified service as sistance Should your problem not be solved to your complete satisfaction you should then contact the Manufacturer s National Service De partment at one of the following address In The U S A Rheem Manufacturing Co Water Heater Division 2600 Gunter Park Drive Montgomery Alabama 36109 1413 Phone 1 800 432 8373 In CANADA Rheem Canada Ltd Lt e P O Box 2846 Hamilton ON L8N 3P3 Phone 1 800 268 6966 21 When contacting the manufacturer the following information should be made available Model and serial numbers of the water heater as shown on the rating plate attached to the jacket of the heater Address where water heater is located and can be seen Name and address of installer and any service agency who per formed service on the water heater Date of original installation and dates any service work was per formed Details of the problem as you can best describe them List of people with dates who have been contacted regarding your problem Wiring and Schematic Diagrams NORMAL OPERATION SEQUENCE Li INDICATED BY BOXED NUMERALS L2 LED f INDICATORS 4020V POWER THERMOSTAT Mene M ww PILOT VALVE POWER LED i ECO EE MAIN VALVE WHITE TRANSFORMER ANY REPLACEMENT WIRE MUST BE RATED FOR 250 C PILOT CONTROL ELECTRODE ASS Y IGNITION IGN GAS VA
32. instal lation of a gas fired water heater in a garage is not desirable A WARNING If a location in a garage is the only alternative the gas water heater should be installed so that the open flame of the pilot and main burner are no less than 18 inches above the garage floor The water heater must be located or protected so it is not subject to physical damage by moving vehicles or area flooding Raising the gas fired water heater will reduce BUT NOT eliminate the possibili ty of lighting the vapor of any flammable liquids which may be improperly stored or accidentally spilled C All models are certified for installation on combustible floors and in alcoves The minimum side and top clearance to walls and ceil ing for providing protection of combustible materials are shown on the water heater s rating label A front clearance of 18 inches 46 cm should be provided for adequate inspection and servic ing If the water heater must be installed on carpeting place a metal or wood panel beneath water heater extending beyond its full width and depth at least 3 inches 7 6 cm in all directions If the water heater is installed in an alcove the entire floor must be covered by the panel A CAUTION The water heater should not be located in an area where leakage of the tank or connections will result in damage to the area adja cent to it or to lower floors of the structure When such areas can not be avoided it is r
33. m tank 4 Remove as much built up scale from flue tubes and tank bot tom as practical Do not attempt to clean so thoroughly that the tool used damages the glass lining 5 Clean the seal plate and install a new gasket Wipe clean the interior surface of the tank that contacts the gasket Reinstall the seal plate and tighten in position Fill tank with water and check for leaks If no leaks are found install insulation plug and clean out cover on jacket and re light the water heater If chemical lime dissolving cleaners are preferred cautiously fol low the instructions supplied with the cleaner DO NOT use a muri atic or hydrochloric acid HCI base cleaner ANODE INSPECTION The water supply in certain areas con tains very aggressive elements In these areas periodic inspec TABLE 1 Maximum Capacity of Pipe in Cubic Feet of Gas per Hour for Gas Pressures of 0 5 psig or Less and a Pressure Drop of 0 3 Inch Water Column Based on a 0 60 Specific Gravity Natural Gas If 1 5 Specific Gravity L P Gas is used multiply capacity by 0 63 Internal Diameter Inches Nominal Iron Pipe Size Inches tion of the anode is recommended to determine if replacement is necessary The anode s supplied in this water heater is slowly consumed thereby eliminating or minimizing corrosion and pro tecting the glass lined tank The anode s should be replaced when more than 6 inches 15 cm of core wire is exposed at ei ther end SEASONAL
34. n A WARNING Read and Review this entire Manual with special emphasis on the Draft Hood and Venting Sections Page 5 and Operation Section Pages 8 11 prior to any installation work LOCAL INSTALLATION REGULATIONS This water heater must be installed in accordance with these in structions local codes utility company requirements and or in the absence of local codes the latest edition of the National Fuel Gas Code ANSI Z223 1 in the United States or CGA CAN B149 Instal lation Codes in Canada LOCATION A The water heater should be installed in a clean dry location as close as practical to the gas vent or chimney Long hot water lines should be insulated to conserve water and energy The water heater and water lines should be protected from exposure to freez ing temperatures B A gas fired water heater should not be installed in a space where liquids which give off flammable vapors are to be used or stored Such liquids include gasoline LP gas butane and propane paint or adhesives and their thinners solvents or removers Because of natural air movement in a room or other enclosed space flammable vapors can be carried some distance from where their liquids are being used or stored The open flame of the water heater s inter mittent pilot or main burner can ignite these vapors causing an explosion or fire which may result in severe burns or death to those in range as well as property damage For these reasons
35. n on page 4 FOR INSTALLATIONS IN THE UNITED STATES If the water heater is to be installed in a confined space defined as one having a volume of less that 50 cubic feet 1 4 cu meters per 1000 Btu h of the total input of all appliances within that space an air supply must be provided The air must be supplied through two permanent openings of equal area one of which is to be located approximately 12 inches 30cm above the floor and the other of which is to be located approximately 12 inches 30cm below the ceiling The minimum net free area of each opening must be not less than one square inch per 1000 Btu h of the total input of all the appliances in the enclosure or structure if each of the openings communicates with other unconfined areas inside the structure If the required air is to be supplied directly from outdoors or a freely ventilated attic or crawl space or through vertical ducts there must be two openings located as specified above and each must have a minimum net free area of not less than one square inch 6 5 sq cm per 4 000 Btu h of the total input rating of all ap pliances in the en closure If horizontal ducts are used to communicate with the outdoors each opening must have a minimum net free area of not less than one square inch 6 5 sq cm per 2000 Btu h of the total input rat ing of all appliances in the en closure NOTE If the openings are to be covered with a protective screen or grill the net free
36. nd must be replaced Ignition Control Module is inoperative and must E be replaced Check Continuity of Blue and White wires between Ignition Control Module and Gas Is the Pilot Flame burning Control Valve Repair or replace as required to restore power to gas valve A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation VERIFY PROP ER OPERATION AFTER SERVICING 20 Replacement Parts The following Gaskets are required for Normal Maintenance for all Models SP5886 Tank Handhole Sealplate Gasket All other Parts can be ordered by providing the following information 1 Description of Part s such as Main Gas Valve Pilot Burner Main Burner Thermostat Damper Draft Hood Assembly Anode Rod Or other parts as required Complete models number and name of the water heater 2 Quantity of each part required 3 4 Serial Number of water heater 5 Specify Type of Gas 6 Address Parts Orders to your distributor or dealer How to Obtain Service Assistance 1 Should you have any questions about your new water heater or if it requires adjustment repair or routine maintenance it is sug gested that you first contact your installer plumbing contractor or previously agreed upon service agency In the event that the firm has moved or is unavailable refer to the telephone direc tory commercial list
37. o avoid vapors ignit ing NOTE Flammable vapors may be drawn by air currents from surrounding areas to the water heater 2 TEMPERATURE SETTINGS The thermostat is adjusted to its lowest temperature position when shipped from the factory To meet commercial water use needs it is adjustable up to 180 F 82 C However water temperatures over 125 F 52 C can cause severe burns instantly or death from scalds This is the pre ferred starting point for setting the control for supplying general purpose hot water Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat The most ener gy efficient operation will result when the temperature setting is the lowest that satisfies the needs consistent with the applica tion A DANGER There is a hot water SCALD POTENTIAL if the thermostat is set too high To adjust the water temperature insert a small straight screwdriver into slotted screw in hole in front of thermostat and turn wheel to desired setting Thermostat is adjustable up to 180 F CAUTION Hotter water increases the risk of SCALDING Honeywell THERMOSTAT Honeywell White Rodgers Figure 6 Thermostat adjustment 10 E Do not allow combustible materials such as newspaper rags or mops to accumulate near water heater F If there is any difficulty in understanding or following the OPERA TION or MAINTENANCE instructions
38. plied to the Damper Assembly Guide and correct if necessary Is the THERMOSTAT LED now illuminated ture higher than the water tem setting Is Thermostat LED now perature in tank illuminated Ensure that power is being supplied to the Is 24 VAC power present at water heater Refer to Section 1 the Yellow Wire Terminal inside POWER LED in this Troubleshooting Thermostat Guide and correct if necessary Is the THERMOSTAT LED now illuminated Is 24 VAC power present at Blue Wire Terminal inside Ther mostat Thermostat is defective or out of calibration and must be replaced A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation VERIFY PROP ER OPERATION AFTER SERVICING 17 System Sentinel Troubleshooting Guide Section 3 the IGNITION LED Is the IGNITION LED Illuminated YES Did the Damper Assembly fully open Check Damper for obstruc tions remove if necessary Did Damper fully open ina The Thermostat has called for papi Mad elon 4 heat the Damper Assembly has fully opened and 24 VAC power is being supplied to the Ignition Con trol Module and the ignition sequence will begin The System Sentinel Panel is defective and must be replaced Is 24 VAC present between the Gray ground wire and the Red 24 V wire connected to the Ignition 5 Remo
39. r liquids or other combustible materials in the vicinity of this or any other appliance To do so may result in an explosion or fire Do not return to your building until authorized by the gas supplier or fire department WHAT TO DO IF YOU SMELL GAS f you cannot reach your gas supplier call the fire department Improper installation adjustment alteration service Do not try to light any appliance or maintenance can cause injury property damage or death Refer to this manual Installation and ser Do not touch any electrical switch do not use any vice must be performed by a qualified installer ser phone in your building vice agency or the gas supplier Printed in USA AP10386 16 09 02 A General Safety Precautions Be sure to read and understand the entire Use amp Care Manual before attempting to install or operate this water heater Pay particular attention to the following General Safety Precautions Failure to follow these warnings could result in a fire or explosion causing prop erty damage bodily injury or death Should you have any problems understanding the instructions in this manual STOP and get help from a qualified installer or service technician or the gas supplier A WARNING Gasoline as well as other flammable materials and liquids adhesives solvents etc and the vapors they produce are extremely dangerous DO NOT handle use or store gasoline or other flammable
40. ration VERIFY PROP ER OPERATION AFTER SERVICING it System Sentinel Troubleshooting Guide Section 5 the ECO LED Is the ECO LED Illuminated ECO is open Allow tank to cool The ECO Energy Cut Off device and reset If ECO again trips the is not tripped open and power is Thermostat High limit is defective being supplied to the PV termi Replace as required nal on the Gas Control Valve Is ECO LED now illuminated Is the Pilot Flame burning The System Sentinel Panel is defective and must be replaced Refer to Section 3 the IGNITION LED and Section 4 the PILOT VALVE LED of Trou bleshooting Guide Repair or replace compo nents as required Section 6 the MAIN VALVE LED Is the MAIN VALVE LED Illuminated The Ignition Control Module is providing 24 VAC between the MV and MV PV terminals on Gas Control Valve and Main Burn er should be operating Is 24 VAC present between Blue wire on Is the Spark Ignitor operating MV Terminal and White wire on MV PV The System Sentinel Panel is Can sparking be heard terminal on the Ignition Control Module defective and must be replaced Is the inlet gas pressure at or below the maximum as specified on the rating plate Is 24 VAC present between Blue YES wire on MV Terminal and White wire on MV PV terminal on gas 9 valve Main Gas Valve is inoperative a
41. regulations or cus toms A General Safety Precautions To meet commercial water use needs the thermostat on this water heater is adjustable up to 180 F However water temperatures over 125 F can cause severe burns instantly or death from scalds This is the preferred starting point for setting the control for supplying general purpose hot water Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat The most energy efficient operation will result when the temperature setting is the lowest that satisfies the needs consistent with the application A DANGER Water temperature over 125 F can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before setting temperature at water heater Feel water before bathing or showering Temperature limiting valves are available see manual Maximum water temperatures occur just after burner has shut off To find hot water temperature being delivered turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications Temperature Time to Produce Serious Burn 120 F More th
42. sure tube from tap on plenum top plate 3 Remove screws 11 in plenum back plate See Illustration 1 Remove back plate Remove screws 8 in plenum top Remove grommet in plenum top and insert igniter wire through hole Remove plenum top 4 Disconnect flexible gas line at gas inlet Remove two 2 nuts that hold manifold assembly Slide manifold out evenly and set aside 5 Remove four 4 screws from burner to be removed Slide burn er out slowly so that burner chamber refractory is not damaged 6 Reverse above steps to install new burner Make sure that all gas connections are tight and all screws are reassembled and tight ened do not over tighten screws To Remove Pilot Assembly 1 Refer to steps 1 through 4 above 2 Disconnect pilot tube from gas valve Remove grommet from side of plenum where pilot tube enters Carefully push pilot tube through hole in plenum wall holding the other end closest to the pilot firmly to avoid loosening from pilot Blower Protective Cage Plenum Top Plate Grommet hidden in this view DS aca 1B jd 9 CES UTX Plenum Back Plate Illustration 1 Burner Removal See Illustration 1a for a detailed view of the plenum area 3 Remove the two 2 screws from pilot assembly Rotate pilot down and clockwise then rock back assembly to remove from mounting plate 4 Reverse above steps to install new pilot assembly Make sure that all gas connec
43. t flame at least every three months Refer to Figures 7 8 9 or 10 for normal flame pattern Fallen scale can usually be dislodged from the tops of the burners with a thin rod then vacuumed or brushed from the bottom of the burner box If a more thorough cleaning is deemed necessary to restore a normal flame pattern the burner tray assembly should be removed and the burners cleaned individually See page 12 for Xtreme models A CAUTION CAUTION For your safety removal and cleaning of burner tray and individual burners should be performed ONLY by a qualified service techni cian as it involves disconnection of gas piping and leak testing Figure 7 Pilot Flame Pattern Standard Burner Figure 8 Pilot amp Main Burner Flame Pattern Standard Burner Figure 9 Pilot Flame Pattern Power Assist Burner amp Xtreme Units es Figure 10 Pilot amp Main Burner Flame Pattern Power Assist Burner amp Xtreme Units Maintenance Burner and pilot assembly removal instructions specific to Xtreme models ONLY For instructions on burner removal for standard and power assist models refer to page 13 To Remove Burner s 1 Turn off gas and electric to unit Remove the two 2 screws that hold the blower protective cage over blower Remove blower pro tective cage and set aside to be reassembled later 2 Disconnect power cable to blower Disconnect igniter wire to igni tion module and pres
44. tions are tight and all screws are reassembled and tightened do not over tighten screws Ignition Wire Illustration 1a Detailed veiw of plenum area 12 Maintenance TO REMOVE BURNER TRAY 1 Turn off manual gas shut off valve 2 Disconnect gas pipe union and wiring to gas valve pilot amp blower If so equipped 3 Remove retaining screw or bracket from burner tray rail on side opposite gas valve 4 Slide burner tray assembly out When reinstalling the burner tray assembly make certain it is pushed in all the way against the stop attached to the bottom pan Then reinstall the re taining screw or bracket 5 Reconnect gas pipe union and wiring to gas valve pilot and blower If so equipped turn on manual gas shut off valve and test for gas leak VENTING SYSTEM Inspect venting system at least yearly to make certain the passageways are free and unobstructed and that the vent connectors from the water heater s draft hood to the chimney are properly positioned and securely attached Remove any obstructions in vent connector or chimney and replace any corroded through vent connectors CONTROLS The manifold pressure and controls should be checked at least yearly by a qualified service technician BLOWER Clean the blower periodically to remove any buildup of lint or dirt Remove the inlet plate and blow out any lint or dirt on the wheel and on the screen of the inlet plate
45. to repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified ser vice technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP READ THE SAFETY INFORMATION 5 TURN THE GAS COCK KNOB CLOCKWISE ABOVE ON THIS LABEL USING A SLOTTED SCREW DRIVER INSERT INTO TEMPERATURE ADJUSTMENT OPEN ING TURN SCREW CLOCKWISE y TO THE LOWEST SETTING THERMOSTAT GAS COCK KNOB GAS VALVE TEMPERATURE ADJUSTMENT SCREW TURN OFF ALL ELECTRIC POWER TO THE APPLIANCE THIS APPLIANCE IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE PILOT DO NOT TRY TO LIGHT THE PILOT BY HAND TO OFF WAIT FIVE 5 MINUTES TO CLEAR OUT ANY GAS IF YOU THEN SMELL GAS STOP FOLLOW B IN THE SAFETY INFORMATION ABOVE ON THIS LABEL IF YOU DON T SMELL GAS GO TO NEXT STEP TURN GAS COCK KNOB COUNTER CLOCKWISE Y TO ON TURN ON ALL ELECTRIC POWER TO THE APPLIANCE SET THERMOSTAT TO DESIRED SETTING IF THE APPLIANCE WILL NOT OPERATE FOLLOW THE INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE AND CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLIER TOTURN OFF GAS TOAPPLIANCE SET THE THERMOSTAT TO LOWEST SETTING 3 TURN THE GAS COCK KNOB CLOCKWISE Y TURN OFF ALL ELECTRIC POWER TO THE APPLIANCE IF SERVICE IS TO BE PERFORMED TO OFF
46. ts ignition and manifold pressure occur immediately The rated operating manifold pressure is listed on the water heater rating plate For purposes of input adjustment the minimum inlet gas pressure with main burner on is also shown on the rating plate A 1 8 NPT tapping is provided on the outlet side of the gas valve for connecting a manometer to check this pressure If nec essary adjust the pressure to the proper value by turning regulator adjustment screw clockwise to increase pressure or counter clockwise to decrease pressure 4 CHECK INPUT Consult the local Gas Company to determine the heating value of the gas supplied Check input by clocking gas meter with all other gas appliances turned off Use the following formula 3 600 x Heating Value x Number of Cubic Feet Timed INPUT ptum J Seconds Clocked A WARNING DO NOT exceed Input shown on the water heater s rating plate Operation To insure accuracy for rating clock enough cubic feet of gas so that the clocked time is at least 60 seconds Small adjustments can be made by varying the manifold pressure from the designated settings mentioned above 5 INTERMITTENT PILOT FLAME ADJUSTMENT No adjustment is required with normal inlet gas pressures The pilot flame ad justment valve is pre set and does not normally require re ad justment 6 HIGH ALTITUDE Ratings of gas appliances are based on in stallation and operation at sea level of elev
47. ual AP10386 16 The instructions in the Use amp Care Manual supplied with the water heater should be followed in addition to the following Instructions for the GX90 High Altitude models 1 HIGH ALTITUDE INSTALLATION The following water heater models are Installations above 8 000 feet are not permitted Failure to comply will result certified for installations at elevations between 2 000 and 8 000 feet with no in improper and inefficient operation of the appliance producing carbon change in construction i e no change in orifice size monoxide gas in excess of safe limits which could result in serious personal H injury or death AP13504 02 04
48. unctioning calling for heat and 24VAC power is being supplied to the Damper Assembly Refer to Section 2 of Troubleshooting Guide IGNITION When illuminated this red LED indicates that the Damper Assembly is opened For the standard burn er 24 VAC power is being supplied to the Ignition Con trol Module and the ignition sequence has begun For the Power Assist Burner 24 VAC power is supplied through the N C side of the pressure switch actuating the relay and supplying 120 VAC to the blower After sufficient pressure is reached in the plenum the N O side of the pressure switch closes and 24 VAC power is supplied to the Ignition Control Module beginning the ignition sequence Refer to Section 3 of Troubleshooting Guide PILOT VALVE When illuminated this red LED indicates that the Ig nition Control Module is supplying 24 VAC power to the ECO Energy Cut Off device or High Limit Refer to Section 4 of Troubleshooting Guide ECO When illuminated this red LED indicates that the ECO Energy Cut Off device or High Limit is closed and 24 VAC power is being supplied to the PV Pilot Valve terminal on the Gas Control Valve Refer to Section 5 of Troubleshooting Guide When illuminated this red LED indicates that the Ignition Con trol Module is supplying 24 VAC power to the MV Main Valve terminal on the Gas Control Valve Refer to Section 6 of Troubleshooting Guide System Sentinel Troubleshooting Gui
49. upplied with Damper Assembly into holes located around the base of Damper Assembly Refer to Figure 3 E Electrical connections to the drive motor are made with a plug that is polarized to insure correct insertion The drive motor re ceptacle is external to the casing for easy access Refer to Fig ure 3 3 VENTING The responsibility for providing a vent of adequate ca pacity and in good usable condition is that of the installing contrac tor There is a limit to the Btu h capacity of any given vent or chim ney style and height For installations in the United States capaci ty tables are printed in Appendix G of the National Fuel Gas Code ANSI 2223 1 For installations in Canada this information is con tained in Appendix B of CAN CGA B 149 Installation Codes As an alternate method for sizing a vent connected to more than one appliance the effective area of the vent shall be not less than the area of the largest vent connector plus 50 of the areas of addi tional draft hood outlets Any horizontal run of vent connector connecting the draft hood to the gas vent or chimney must have an upward slope of at least 1 4 per foot of length Single wall vent connectors must be at least 6 from adjacent unprotected combustible surfaces Joints of vent con nectors should be securely fastened by sheet metal screws or other approved method Provide support for vent or vent connectors to keep weight off draft hood 4 GAS SE
50. ve Damper Drive iin ls Pressure switch is Motor cover is the green defective and must CALL FOR HEAT LED be replaced Check continuity of Red illuminated Is there 24 VAC and Gray wires between Is 24 VAC power present present between Damper Assembly and Igni between the Blue and Gray the common pole tion Control Module Is con wires in the Polarized Plug at and the normally tinuity good Damper Assembly open pole of the pressure switch 1 Remove Ignition Cable and check for good continuity replace if necessary Refer to Troubleshooting 2 Check Ignitor Electrode gap for proper Guide Section 2 the THER spacing 1 8 to 5 32 Correct if necessary MOSTAT LED to determine if 3 Examine Ceramic Insulator on Pilot Assem Thermostat is operable Repair bly for cracks Replace if cracks are evident or replace if required If all of the above components check okay replace Ignition Control Module Is the green IGN GAS PWR LED illuminated s blower operating s there 120 VAC Y Ignition Control Module is defec across Brown wire tive and must be replaced Y Is 24 VAC present across coil of relay gt and Blue wire of blower Repair or replace the Wiring Har Blower is defective ness YES and must be replaced Relay is defective NO and must be replaced Damper Assembly is defective and must be replaced The water h
51. vice inside of No the Thermosiat Is the Spark Ignitor operating Can sparking be heard The System Sentinel Panel is defective and must be replaced Remove Ignition Cable and check for good conti nuity replace if necessary Check Ignitor Electrode gap for proper spacing 1 8 to 5 32 Correct if necessary Is 24 VAC present between the Brown wire on PV Examine Ceramic Insulator on Pilot Assembly for Terminal and White wire on PV MV Terminal on cracks Replace if cracks are evident the Gas Control Valve Is 24 VAC present between the Brown wire on PV Terminal and Gray Ground wire on Ignition Control Module Is the inlet gas pres sure at or below the maxi mum as specified on the rating plate Gas Control Valve is inoperable and must be no replaced Is the ECO LED illuminated C Check continuity of Brown wire between ECO Device inside of Ther Ignition Control Module is inoperable and must be Is the IGNITION LED illuminated mostat and PV Terminal on Gas Control Valve Repair or replace wire as needed to restore power to PV Termi nal on gas valve Refer to Section 3 the IGNITION LED in the Refer to Section 5 the ECO LED in the Troubleshooting Guide Troubleshooting Guide replaced A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous ope
Download Pdf Manuals
Related Search