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SERVICE HANDBOOK FOR
STANDARD RESIDENTIAL
HIGH EFFICIENCY ATMOSPHERIC VENT
(FVIR) GAS WATER HEATERS
MODELS:
GAHH 40 100, GAHH 50 100,
GP 6 40YPC T 100, GP 6 50YPC T 100,
PCG6240T403NOV 100, PCG250T403NOV 100,
PCG2J4040T3NOV 100, PCG2J5040T3NOV 100,
12 40GPC T 100, 12 50GPC T 100,
PCG2J4040T3NOV 100, PCG2J5040T3NOV 100
Printed in U.S.A. 10/10 318181-000
1
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ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, CONTACT A. O. SMITH WATER HEATERS RESIDENTIAL TECHNICAL ASSISTANCE AT 1-800-527-1953 OR WWW.HOTWATER.COM. 2
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SERVICE HANDBOOK Your safety and the safety of others is extremely important in the servicing of this water heater. Many safety-related messages and instructions have been provided in this handbook and on the water heater to warn you and others of a potential hazard. Read and obey all safety messages and instructions throughout this handbook. It is very important that the meaning of each safety message is understood by you and others who service this water heater. The information contained
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Breathing Hazard - Carbon Monoxide Gas Install vent system in accordance with Fire or Explosion Harzard codes. Do not operate water heater if flood Do not store or use gasoline or other flammable vapors and damaged liquids in the vicinity of this or any other appliance. Heater should not be installed for High Avoid all ignition sources if you smell Natural or LP gas. Altitude operation above 10,100 feet Do not expose water heater control to excessive gas (3,078 m). pressure. Do not o
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TABLE OF CONTENTS INTRODUCTION: Service Handbook Introduction ...........................................................................................................................3 Warnings and Cautions .......................................................................................................................................4 Table Of Contents ........................................................................................................................................
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BASIC INSTALLATION & OPERATION INSTALLATION OF RESIDENTIAL GAS WATER HEATER Water Supply- Cold* Water See Labels and Exhaust Vent to Shut-Off Installation Instructions Ouside of Building Valve and Use & Care Guide *Massachusett: Install for clearances. a vacuum relief in cold Union water line per section Use Draft Hood 19 MGL 142. supplied with unit Union Expansion Tank Pressurize to Equal Supply Water Pressure* (Relieve water pressure To Fixtures - Hot on the expansion tank before adjus
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COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS Combustion Air Requirements: Table 1: Minimum Square Typical Room BTUH Input Feet with WARNING with 8’ Ceiling 8’ Ceiling Carbon Monoxide Warning 30,000 188 9 x 21 45,000 281 14 x 20 Water heater must be vented to outdoors. 60,000 375 15 x 25 Vent must be installed by a qualified technician using 75,000 469 15 x 31 the local and state codes or, in the absence of local 90,000 563 20 x 28 and state codes, the National Fuel Gas Code, 105,000 657 2
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COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS All Air from Inside the Building: When Minimum Free Area of Permanent Openings for additional air is to be provided to the confi ned Ventilation and Combustion Air Supply - All Air from area from additional room(s) within the building, Outdoors Only. the total volume of the room(s) must be of Based on total BTUH input rating for all utilizing suffi cient size to properly provide the necessary equipment within the confi ned space. amount of fresh a
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COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS Vent Connectors: 1 SQ. INCH PER 1. Type B, Double wall, U.L. Listed Vent Pipe. 2000 BTUH 100 SQ. INCH 2. Single wall Vent Pipe. MINIMUM (EACH) Maintain the manufacturer’s specifi ed minimum CONFINED OUTLET clearance from combustible materials when using SPACE type B double wall vent pipe. Vent connectors made of type B, double wall OUTDOOR AIR DUCTS vent pipe material may pass through walls or partitions constructed of combustible material if the
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COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS The following fi gures are examples of vent pipe • The connector must be firmly attached and system installations and may or may not be typical sealed to prevent it from falling out. for your specifi c application. Consult the “National • To aid in removing the connector, a thimble or Fuel Gas Code”, NFPA 54, ANSI Z223.1-current slip joint may be used. edition and the guidelines set forth by prevailing • The connector must not extend beyond the lo
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KNOW THE WATER HEATER’S COMPONENT PARTS Electronic Control Display (Upper Control) The Electronic Control Display panel used on this water heater provides an easy-to-read, eye level display for temperature adjustment, fault code diagnostics and recall, powered anode rod operation and setting the temperature scale for either Fahrenheit (°F) or Celsius (°C). Figure 11. Electronic Control Display (Upper Control) Gas Control Valve/Thermostat (Lower Control) The gas control valve/thermostat is wher
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KNOW THE WATER HEATER’S COMPONENT PARTS Burner/Manifold Door Assembly The burner/manifold door assembly consists of several components such as: main burner, burner orifice, manifold tube and flame sense / hot surface igniter. See figure below for the complete list of components (Figure 13). Figure 13. Main Burner Manifold Tube Manifold Door Scoop side to be placed View Flame Sense / Hot Surface on the same side as Port Igniter Assembly View Port. Burner Orifice* Flame Sense/ Hot Surface Ign
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KNOW THE WATER HEATER’S COMPONENT PARTS Figure 16. Flammable Vapor Cut Off Switch (FV Sensor) The water heater is equipped with a FV sensor, for detecting the presence of flammable vapors (e.g. spilled gasoline). When the sensor detects those vapors, the heater will shut down and not operate. If flammable vapors are detected or the sensor is inoperative, an icon will flash on the electronic control display and the heater will go into a lockout mode. The water heater will not function agai
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WATER HEATER OPERATION The figure below shows the water heater’s sequence of operation when a call for heat is initiated. The gas control valve/thermostat will attempt to light the burner three times. If the flame sense rod in the burner/ manifold assembly does not detect ignition, the control will enter lockout mode indicated by the electronic control display’s flashing of the appropriate status code. SEQUENCE OF OPERATION Call for heat indicated by flashing of display screen status codes.
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FILLING, DRAINING AND FLUSHING THE WATER HEATER TANK It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during operation. The water heater should be drained if being shut down during freezing temperatures. To drain the tank, perform the following steps: 1. Turn off the gas to the water heater at the manual gas shut-off valve and turn off the electrical power to the gas control/thermostat valve. 2. Open a nearby hot water faucet until
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LIGHTING INSTRUCTIONS Read and understand these directions thoroughly before attempting to operate the water heater. Make sure the view port is not missing or damaged. Make sure the tank is completely filled with water before operating the water heater. The gas control valve/thermostat has an “On/Off Switch” and needs to be turned on before the water heater is operational. Check the label on the front of the water heater near the gas control valve/thermostat for the correct gas. Do not start
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ADJUSTING THE TEMPERATURE ON THE ELECTRONIC CONTROL DISPLAY Adjusting the Temperature Set Point - The thermostat of this water heater has been factory set at its lowest position. It is adjustable and must be reset to the desired temperature setting to reduce the risk of scald injury. The electronic control display temperature should be set at approximately 120°F (49°C) and this is the preferred starting point, see Figure 21 Some states have a requirement for a lower setting. If you need hot
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USING THE ELECTRONIC CONTROL DISPLAY How to select or change the temperature scale from Fahrenheit (°F) to Celsius (°C). Gas Control Valve/Thermostat Settings Figure 22. HOTTER COOLER Electronic Control Display 1. The temperature scale defaults to Fahrenheit (°F). 2. To change to Celsius (°C), press the two temperature adjustment buttons at the same time for more than five (5) seconds but less than 10 seconds to enter the Temperature Scale Selection mode. In this mode the currently a
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USING THE ELECTRONIC CONTROL DISPLAY Reviewing Fault Codes: 1. Press the red up arrow button one time. 2. The display will show either E0 or E1. 3. If E0 is shown, there are no faults. By pressing the up arrow button again the display will exit the Field Service mode, or the control will exit automatically after no button is pressed for five (5) seconds. 4. If E1 is shown, the control will flash the icons of the most recent fault. 5. Pressing the red up arrow button again will shown ho
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ELECTRONIC CONTROL DISPLAY TROUBLESHOOTING ELECTRONIC CONTROL DISPLAY Please check guidelines below. For your safety, water heater service should be performed only by a qualified service person. Read the GENERAL SAFETY INFORMATION supplied by the water heater manufacturer. CONTROL DISPLAY STATUS PROBLEM SOLUTION 1. Check the 5-conductor data cable that 1. “POWER” Flashing Communication Error runs between the upper and lower controls. Check that the wiring is not The system has
