RESIDENTIAL GAS WATER HEATERS - Tank & Tankless Water ...

1 Service Handbook1206 322153-000 Rev. 00 POWER VENTED GAS MODELS WITH HOT SURFACE IGNITIONNOT FOR USE IN MANUFACTURED (MOBILE) HOMESRESIDENTIAL GAS WATER HEATERSTABLE OF CONTENTSNote: References to the Manual refer to the Installation and Operating Manual .GENERAL INFORMATION 2 CHECKING THE GAS SUPPLY PRESSURE 3 LEAKAGE CHECKPOINTS 4 TEMPERATURE ADJUSTMENT 5 ANODE ROD REMOVAL/REPLACEMENT 6 DIP TUBE REMOVAL/REPLACEMENT 7 DOOR-BURNER ASSEMBLY REMOVAL/REPLACEMENT 8 FLAME SENSOR AND IGNITER REMOVAL/REPLACEMENT 10 BURNER AND ORIFICE REMOVAL/REPLACEMENT 12 DOOR GASKET REPLACEMENT 16

2 CONTROL MODULE REMOVAL/REPLACEMENT 18 VALVE MODULE REMOVAL/REPLACEMENT 20 TEMPERATURE SENSOR AND CABLE REMOVAL/REPLACEMENT 21 GAS VALVE REMOVAL/REPLACEMENT 22 BLOWER REMOVAL/REPLACEMENT 24 ROTATING THE BLOWER 25 PRESSURE SWITCH REMOVAL/REPLACEMENT 26FV SENSOR 27 CLEANING THE COMBUSTION CHAMBER 28 CLEANING THE BLOWER 29 TECHNICAL BULLETINS 30 TROUBLESHOTING CHART 362 Draw effi ciency is the quantity of hot WATER available to the consumer before the outlet WATER temperature decreases by 25F (14C ).

3 A 40 gallon WATER heater will typically provide 70% (28 gallons) of this usable hot WATER (60% is the minimum). The burner or elements are allowed to operate during this test. Incoming, cold WATER mixes the remaining stored WATER below this 25F (14C ) Factor is an indicator of the combined thermal effi ciency and standby effi ciency of a WATER heater. The higher the energy factor, the more effi cient the WATER heater will and gases will separate from WATER as temperature increases.

4 R Value is a measure of the resistance of a substance to heat fl rate is the amount of WATER that is heated to a set temperature, per effi ciency is the WATER heater s ability to contain heat in the tank. A minimum of tank WATER heat loss per hour is desired. temperature change/ R value = Btu/h loss/square foot of tank surfaceTemperature rise is the increase in the temperature from its coldest inlet WATER temperature to the desired hot (outlet) setting. Typically it is assumed that the entering WATER be 40 F (5 C), stored WATER desired to be 120 F (49 C) resulting in a temperature rise of 80F (44C ).

5 Thermal efficiency is approximately the amount of generated BTU (British Thermal Units), which enters the WATER . A percentage of the total BTU passes out through the vent cannot (for all practical purposes) be expands when it is and Conversions:BTU (British Thermal Unit) is the heat required to raise 1 pound of WATER 1F 1 BTU = 252 cal = kcal1 cal = JoulesBTU X = Kilo JoulesBTU divided by 3,413 = KilowattsTo convert from Fahrenheit to Centigrade: ( F 32) times 5/9, or .556, equals degrees gallon of (120 F, 49 C) WATER weighs approximately X.

6 45359 = KilogramGallons X = Liters% of Hot = (Mixed Temp. Cold) divided by (Hot Temp. Cold)% Thermal Effi ciency = (GPH X X Temp. Rise X ) divided by BTU/H InputBTU Output = GPH X X Temp. Rise X = (BTU/H Input X % Eff.) divided by (Temp. Rise X )One cubic foot of Natural Gas contains about 1000 BTU of therm is equal to 100,000 BTUOne cubic foot of Propane Gas contains about 2500 BTU of gallon of Propane gas contains about 91,250 BTU of pound of Propane gas contains about 21,600 BTU of pound of gas pressure is equal to inches WATER column pressureInches of WATER Column X.

7 036091 = PSII nches of WATER Column X .073483 = Inches of Mercury (Hg.)Centimeters = Inches X (millimeters) = Inches X = Inches X .0254 Doubling the diameter of a pipe will increase its fl ow capacity (approximately) : Tank is constructed of steel. The inside of the tank is constructed of a glass lining bonded to the steel. This prevents WATER to metal contact and rusting of the tank. An anode rod will be installed within the tank. The hex-head plug end of the anode is visible on the top of the WATER heater.

8 This metal rod offers secondary protection of the tank against corrosion where the application of glass is not possible (threaded tank openings). These areas will have small areas of WATER to metal WATER HEATERS will contain at least one thermostat (to operate the heater) and one high limit (to prevent WATER from overheating).GENERAL INFORMATION 3 Gas pressure checks are done with fl owing gas using a gas pressure manometer capable of reading pressure in inches of WATER gas pressure checks are measured before the gas control valve and as close to the WATER heater as possible.

9 Manifold (main burner) gas pressure is measured at the pressure tap on the bottom of the gas control valve (see Figure 1). Use an allen wrench to remove the plug, then attach the gas : Desired gas pressures will be noted on the gas valve label located on the gas control valve and rating gas pressure is under desired pressure requirementIncrease supply gas pressure regulator the gas utility company to readjust gas pressure on main supply. Technicians can not adjust main gas supply pressure.

10 Supply gas pressure is over desired pressureAdd gas pressure the gas utility company to readjust gas pressure on main supply. Technicians can not adjust main gas supply pressure. Manifold gas pressure is more than +/- .4 inch from values indicated on gas valve or rating plateEnsure there is adequate supply gas the main burner orifice is the correct size for the WATER heater model being the above tests have been performed and the results were correct replace the gas control valve.