Bradford White Corp Water Heater D 38T 155 User Manual

COMMERCIAL 24 VOLT FLUE DAMPER  
SERIES WATER HEATER WITH HONEYWELL  
INTEGRATED CONTROL SYSTEM  
Gas Water Heaters  
SERVICE  
MANUAL  
Troubleshooting Guide  
and Instructions for Service  
(To be performed ONLY by  
qualified service providers)  
Models Covered  
by This Manual:  
For The Bradford White  
“D” Series Models:  
D38T155  
D75T(125,160,300)  
D65T(370,399)  
D80T(180,199,250)  
D80T(425,505)  
D100T(199,250)  
D80L(399,450,505)  
D100L(199,250,270,300)  
D100S(199,250)  
Manual 47985A  
Save this manual for future reference  
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FEATURES OF HONEYWELL INTEGRATED CONTROLS SYSTEM  
Attractive digital water heater display on control panel for setting and displaying  
the temperature setpoint. Pressing temperature up and down buttons changes  
the temperature setpoint. Temperature format may be displayed in degrees F or  
degrees C.  
Single control board with plug in wiring controls temperature, ignition, and flue  
damper operation.  
Reduced number of parts for servicing and wiring.  
Plug in wiring reduces chance of miswiring.  
Water heater display will show diagnostic codes in the event the water heater  
needs servicing. Aids in diagnosing and servicing the water heater.  
Water heater display can show up to 10 previous error codes in the service mode  
to further aid in servicing the water heater.  
3
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Introduction  
It is intended for this manual to be used by qualified service personnel for the primary purpose of  
troubleshooting analysis and repair of the Bradford White 24 Volt Flue Damper Series Water  
Heater. Understanding the sequence of operation section of this manual will contribute greatly to  
troubleshooting this product.  
Troubleshooting begins by noting the error code, if any, on the water heater control display and  
finding the section in this service manual for diagnosing the problem for this error code. This step  
by step procedure beginning on page 5 will direct the service provider to a series of test  
procedures to determine root cause of failure.  
Contact Technical support immediately if diagnosis is not determined using the methods described  
in this service manual.  
Tools Required for Service  
Manometer:  
Multi-Meter:  
Two types available, a liquid “U” tube type or a digital (magna-helic)  
type. This device is used to measure gas and/or air pressures and  
vacuum.  
A digital type is strongly recommended. This device is used to measure  
electrical values. The meter you select must have the capability to  
measure volts AC, volts DC, Amps, micro-amps and ohms.  
Thermometer:  
Used to measure water temperature. An accurate thermometer is  
recommended.  
Water Pressure Gage:  
Used to measure water supply pressure. Also used to determine tank  
pressure by adapting to the drain valve of the heater.  
Jumper Leads:  
A length of wire (12" min.) with alligator clip at both ends.  
Various Hand Tools:  
Pipe wrench, channel locks, open end wrench set, 12" crescent wrench,  
Allen wrench set, torx bit set, screw drivers (common & phillips), long  
reach (12") magnetic tip phillips head screw driver #2 tip, ¼" nut driver,  
pliers (common & needle nose), socket set including a 1-1/16 deep well  
socket, wire cutters, wire strippers, wire crimpers, torpedo level, small  
shop vac, step ladder, and flashlight.  
4
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Specifications  
Power Supply  
Dedicated 120 VAC, 60 Hz., 15 A  
Less than 5 Amps.  
Current Draw  
Gas Supply Connection  
1" NPT connection to gas valve for 370,000 Btu/hr. and over for natural gas,  
¾" NPT for rest. Schedule 40 black iron pipe recommended.  
Approved Gas Type  
Natural or Propane. Gas supply must match the gas type listed on the water  
heater rating label.  
Gas Pressure (Nat. & L.P.)  
Manifold Pressure: 4.5" w.c. natural gas, 10.0" w.c. L.P. Gas Supply  
Pressure: At least 1" above manifold pressure with water heater operating,  
14" w.c. maximum.  
Venting System  
Atmospherically Vented, Type B venting system or approved chimney. Follow  
current National Fuel Gas Code requirements or in Canada, the Natural Gas  
and Propane Installation Code.  
Minimum Clearance for Servicing  
Maximum Water Supply Pressure  
24" Front Clearance, 20" Top, 6" Sides.  
150 PSI.  
Thermostat Sensor(s)  
Redundant thermister with 11,900 + or - 0.5% ohms resistance at 70 deg. F.  
Sensor inside well for lower sensor. Some models use an additional upper  
sensor (w/o well) with same resistance values.  
Control Board  
Honeywell Integrated Control Board for Temperature Control, Flue Damper,  
and Ignition Control Functions. Operates on 24 volts AC current from  
transformer. Some models use single sensor boards, others use two  
sensors.  
Control Display  
Honeywell LCD Control Display with Temperature Setpoint, Format, and Error  
Code Display in User Mode, Diagnostic Functions in Service Mode.  
Communicates with Control Board.  
Transformer  
Pilot  
120 VAC Primary, 24 VAC Secondary, 40 VA.  
Intermittent Pilot with Spark Electrode and Flame Sensor monitored by Control  
Board.  
Flue Damper  
24 VAC, 60 Hz., 80 Ma.  
5
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Sequence of Operation  
Thermostat calls for heat.  
The control board sends 24 volts from damper terminal #2 on the control plug  
to the flue damper.  
1
Flue damper begins to rotate open. Once the flue damper is fully open, the damper end switch closes and 24 volts  
is allowed to continue through damper to damper pin terminal #5.  
2
3
Trial for ignition (three 90 second ignition trials, with 65 second pauses  
between trials).  
Control Board simultaneously sends:  
1. 24 volts from control pin terminal #8, to “MV/PV”  
terminal of gas valve (common terminal).  
2. 24 volts from control pin terminal #2, to “PV”  
terminal of gas valve to establish  
gas flow at pilot.  
3. Low current high voltage from “spark”  
terminal, to generate spark at the pilot and  
ignite pilot gas flow.  
4. Pilot flame proving signal (measured in  
micro-amps). from the “sense” terminal, to  
prove pilot flame.  
4
5
Once pilot flame is proven, sparking will stop.  
Once sparking stops, 24 volts is sent from control pin  
terminal #5 on control board, to “MV” terminal on gas valve  
to establish main burner gas flow. Main burners ignite from  
the pilot flame.  
The control board constantly monitors pilot flame through  
the flame sensor rod. If pilot flame is lost, pilot and main  
burners are shut down. After a 65 second inter-purge  
period, the control will attempt to re-light the pilot beginning  
at sequence 3 above.  
Main burner fires until the thermostat is satisfied. The control  
board interrupts 24 volts through the damper and the gas valve  
circuit. Pilot and main burners are turned off.  
7
8
Flue damper rotates to the closed position.  
LOCKOUT CONDITION  
Control board will go into “Soft Lockout” if the pilot cannot be lit  
after 3 ignition trials. The water heater display indicates a lockout  
condition by showing an error code number (62 or 63) with  
“Service Needed” in the display window. Refer to error codes in  
the diagnostic section of this Service Manual. In a “Soft Lockout”  
condition, the control will wait for 60 minutes and then make 3  
more attempts to light the pilot and establish the main burners.  
Soft lockout reset is accomplished by depressing the lower right  
button under “Reset” for 3 seconds.  
WIRING DIAGRAM  
If the water heater should reach 200 degrees F, then the high limit  
control will shut off the burners and the water heater will go into a  
“Hard Lockout”. Error code 65 will be shown in the water heater  
display. The control can only be reset in the “service mode”,  
which is detailed in the next section of this Service Manual.  
6
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Troubleshooting  
CAUTION  
Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals  
Water Heater Fault: Water heater does not operate  
Display Error Code: Water heater display does not operate - blank display  
Check main power supply to water  
heater - fuse, circuit breaker, plug  
receptacle, line cord or wiring to  
water heater.  
1
2
Check to make sure switch on top of  
control panel is in the ON position  
Checking line voltage to board.  
Pins to black and white wires.  
Checking primary voltage to  
transformer from board. Pins to  
black and white wires.  
Voltage at primary pins 1&3 (white and  
black wires) should be 110-120. If not,  
check Line In pins 1&4. Check line cord  
with ohmeter. Replace line cord if  
defective.  
Verify Primary and Secondary  
voltage at the control board.  
4
3
If there is not 24 volts at Secondary  
pins on the control board, check  
transformer. Replace transformer  
or wire harness.  
Checking secondary voltage from  
transformer. Pins to blue and yellow  
wires.  
Checking transformer voltage, front  
terminals are 24 volts, rear terminals  
are 120 volts.  
Does water heater display operate?  
Does damper begin to open?  
Increase thermostat setting if tank is  
warm and make sure the control  
display status reads “Heating”.  
With the control cover tilted down,  
measure the voltage between red and  
black wire pin connections to display.  
Voltage should be 24 volts AC  
measured at the back of the Control  
Display.  
N
Check wire connections of  
board to display. See  
illustration.  
Y
5
If no voltage at Display, check wire  
harnesses and voltage at E-com  
screw terminals (see photo 5).  
See next page  
Replace display if voltage is present at  
display pin terminals. Replace control  
board if no voltage is present at E-  
com terminals (1&3, white-black wires  
and 1&2, white-red wires) to display.  
7
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Troubleshooting  
CAUTION  
Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals  
From previous page  
Error code #55 on display.  
Remove damper from heater and  
jump black & yellow wires of  
heater harness. Refer to photo on  
this page.  
N
N
Does damper blade move to the full  
open position?  
Does water heater begin to  
operate?  
Y
Y
Check for debris limiting damper  
rotation. If no debris, replace  
damper.  
Error code #62 on display. See  
“Pilot Will Not Light”.  
Is there pilot flame?  
Y
N
N
Error code #62 on display. See  
“Pilot Lights, No Flame Signal”  
Does Main Burner operate?  
Y
Damper vane show in open position. If damper  
is closed, disconnect from harness and  
REMOVE damper from water heater.  
Does burner continue until  
thermostat set point is reached?  
See setting display in Service Mode  
and displaying temperature  
sensors.  
Error code #63 on display. See  
“Main Burner Short Cycles”.  
Y
Error code #56 on display.  
Check for debris limiting damper  
rotation. If no debris, replace  
damper  
N
Does the flue damper rotate to the  
fully closed position?  
6
Y
Harness shown disconnected from  
damper with BLACK and YELLOW  
wires jumped.  
System okay  
Error Code Shown  
in Water Heater Display  
Status Service Needed  
SELECT  
Lockout RESET  
Example of error code shown on control display.  
8
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Troubleshooting  
Using Control Display for Servicing the  
Water Heater  
ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY (FOR SERVICE PERSONNEL ONLY)  
The display has a “service mode” for changing the maximum setpoint and accessing information in aiding servicing of the  
water heater. This procedure is for service and installation personnel only. To enter the Service Mode, follow the steps  
illustrated below:  
Step 1: Press “Select” and “Temperature Up” buttons together and hold for 3 seconds until “Max Setpoint” is shown in the  
"Max Setpoint”  
next to Temperature  
Setpoint value.  
display.  
Max  
Setpoint  
idle  
Operational  
Statu  
s
SELECT  
SET  
Step 2: Pressing “Select” button to next mode  
Water  
Temp  
°F  
idle  
Status  
Operational  
SELECT  
SET  
The following is the sequence of modes available in “Service Mode” by pressing the “Select” button:  
Error Code Number (Display/Reset). This is only shown if there is an operating error in the “User Mode”.  
Error Code Shown  
in Water Heater Display  
Status Service Needed  
SELECT  
Lockout RESET  
9
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Troubleshooting  
1. Max Setpoint (Display/Change)  
Max Setpoint value in  
Water Heater Display  
Max  
°F  
Setpoint  
idle  
Operational  
Status  
SELECT  
SET  
&
2a. Water Temperature Average (Displays average if there are two sensors - sensor temperature displayed if single  
sensor is used).  
Water Temp  
°F  
idle  
Status  
Operational  
SELECT  
SET  
2b. Water Temperature - Upper Sensor (Displays if there is an upper sensor - some models)  
°F  
idle  
Status  
Operational  
Upper Sensor  
SELECT  
SET  
2c. Water Temperature - Lower Sensor (Displays if there are two sensors)  
°F  
idle  
Operational  
Status  
Lower Sensor  
SELECT  
SET  
10  
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Troubleshooting  
3.  
Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle)  
ȝA  
Heating  
Operational  
Flame Current  
Status  
SELECT  
SET  
4. Setpoint (Display/Change)  
setpoint  
°F  
idle  
Operational  
Status  
SELECT  
SET  
5.  
°F/°C (Display/Change)  
setpoint  
°F °F/C°  
idle  
Operational  
Status  
SELECT  
SET  
6.  
Differential (Display only - shows the differential of the thermostat)  
Differential  
°F  
idle  
Status  
Operational  
SELECT  
SET  
11  
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Troubleshooting  
7. Software Version (Display only)  
Soft  
idle  
Operational  
Status  
SELECT  
SET  
8. Error Code History (Displays if there are present error codes or up to 10 previous error codes). Water Heater Display  
will show a “--“ if there are no error codes.  
WARNING  
Setting the water temperature  
to the maximum set point can  
result in scalding hot water  
delivered to the faucets. It is  
highly recommended that the  
idle  
Status  
Operational  
maximum setpoint be adjusted  
to the lowest temperature  
possible for the needs of the  
installation. Make sure the  
water heater control display is  
not in a public area that can  
result in the temperature  
settings being improperly  
adjusted.  
SELECT  
SET  
To change the Maximum Setpoint Limit (Max Setpoint) for the temperature setpoint:  
Step 1: In service mode press the “Select” button until “Max Setpoint” is displayed.  
Max  
°F  
Setpoint  
idle  
Status  
Operational  
SELECT  
SET  
12  
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Troubleshooting  
Step 2: Press “Set” button to enter setting mode. “Max Setpoint” will flash to indicate setting mode.  
Max  
°F  
Setpoint  
idle  
Operational  
Status  
SELECT  
SET  
Step 3: Press the “UP” or “DOWN” buttons to change the maximum setpoint value. This will limit the maximum setpoint  
the user can select. Note: The maximum setpoint is approximately 180°F.  
"Max Setpoint" continues to flash  
while making adjustments  
Max  
°F  
Setpoint  
idle  
Operational  
Status  
SELECT  
SET  
%
Step 4: Press “Set” button to confirm new “Max Setpoint” value and stop setting mode.  
"Max Setpoint" stops flashing  
Max  
°F  
Setpoint  
idle  
Status  
Operational  
SELECT  
SET  
%
13  
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Troubleshooting  
Step 5: 30 Seconds after the last button press, the Water Heater Display will go back to “User Mode”. It will read “Max  
Setpoint” without showing a temperature value if the temperature setpoint is at the maximum setting. The Water  
Heater Display can be set back to the “User Mode” immediately by pressing both the “Temperature Up” and “Select”  
buttons together for 3 seconds.  
Max  
Setpoint  
idle  
Status  
Operational  
SELECT  
SET  
%
&
Exiting Service Mode  
Display of Water Temperature:  
Step 1: In Service Mode, Press the “Select” button until “Water Temp” is displayed in the upper right section of the  
water heater display. For water heaters using two temperature sensors in the tank, this will be the average reading  
between the two sensors. For water heaters using a single sensor, this is the reading for the sensor.  
Water  
Temp  
°F  
idle  
Operational  
Status  
SELECT  
SET  
&
Step 2: For water heaters using two temperature sensors, pressing the “Select” button again displays the Upper  
Sensor temperature reading. “Upper Sensor” will be displayed in the lower right side of the status window of the  
water heater display.  
°F  
idle  
Status  
Operational  
Upper Sensor  
SELECT  
SET  
14  
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Troubleshooting  
Step 3: For water heaters using two temperature sensors, pressing the “Select” button again displays the Lower Sensor  
temperature reading. “Lower Sensor” will be displayed in the lower left side of the status window of the water heater  
display.  
°F  
idle  
Status  
Operational  
Lower Sensor  
SELECT  
SET  
To Display Flame Sense Current of the Pilot Flame Sensor:  
The pilot flame sense current is available only when the burners are in operation. Step 1: Make sure the status displays  
“Heating” or draw enough hot water to start the burners. Step 2: Enter the “Service Mode” described previously. Step 3:  
Press the “Select” button until a number value is displayed with “Flame Current” to the right of the number. The value  
displayed is in microamps (ȝA).  
Flame  
Current  
ȝA  
Heating  
Operational  
Status  
SELECT  
SET  
To Display and Change Temperature Setpoint:  
Step 1: In “Service Mode” press the “Select” button until “Setpoint” is shown in the water heater display  
setpoint  
°F  
idle  
Status  
Operational  
SELECT  
SET  
15  
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Troubleshooting  
Step 2: Press the “Set” button to enter the setting mode. “Setpoint” will flash in the water heater display.  
setpoint  
°F  
idle  
Operational  
Status  
SELECT  
SET  
Step 3: To raise the temperature setpoint, press the “Temperature Up” button until the desired temperature is shown on  
the water heater display.  
NOTICE  
The maximum temperature that can be set in the Water Heater Display is limited to the “Max Setpoint” described  
previously. To change the “Max Setpoint”, refer to the procedure “To Change the Maximum Setpoint Limit…"  
described previously under “Accessing the Service Mode on the Water Heater Display”.  
WARNING  
Setting the water temperature  
to the maximum set point can  
result in scalding hot water  
delivered to the faucets. It is  
highly recommended that the  
setpoint  
°F  
maximum setpoint be adjusted  
to the lowest temperature  
possible for the needs of the  
installation. Make sure the  
water heater control display is  
not in a public area that can  
result in the temperature  
settings being improperly  
adjusted.  
idle  
Status  
Operational  
SELECT  
SET  
%
Step 4: To lower the temperature setpoint, press the “Temperature Down” button until the desired temperature is shown  
on the water heater display.  
"Setpoint" Flashes  
setpoint  
°F  
idle  
Status  
Operational  
SELECT  
SET  
16  
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Troubleshooting  
Step 5: When the desired setpoint is reached on the water heater display, press the “Set” button to confirm the new  
setpoint. “Setpoint” stops flashing in the water heater display.  
setpoint  
°F  
idle  
Status  
Operational  
SELECT  
SET  
To Display and Change Temperature Format (°F/°C):  
To Change Temperature Format in Display from °F to °C or °C to °F:  
Step 1: While in “Service Mode”, press “Select” button until “°F/°C” is shown in the upper right portion of the water heater  
display.  
°F °F/C°  
idle  
Operational  
Status  
SELECT  
SET  
Step 2: Press “Set” button to change temperature format. “°F/°C” symbol will flash in the water heater display.  
°F °F/C°  
idle  
Operational  
Status  
SELECT  
SET  
17  
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Troubleshooting  
Step 3a: Press “Temperature Up” button to change temperature format to °C  
°C °F/C°  
idle  
Status  
Operational  
SELECT  
SET  
%
Step 3b: Press “Temperature Down” button to change temperature format to °F  
°F °F/C°  
idle  
Operational  
Status  
SELECT  
SET  
Step 4: Press “Set” button to confirm °F or °C format. °F/°C will stop flashing  
°F °F/C°  
idle  
Operational  
Status  
SELECT  
SET  
18  
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Troubleshooting  
Step 5: Pressing “Select” button will return display to setpoint in format selected (°F or °C) immediately  
°F  
idle  
Operational  
Status  
Lower Sensor  
SELECT  
SET  
Error Codes and Error History Display:  
If there is an operating problem with the water heater, an error code number will appear on the water heater display with  
“Service Needed” to the right of the “Status” indicator. The error code label is located under the water heater display.  
The following section in this Service Manual explains the error codes with corrective actions to repair the water heater.  
Example of Error Code in the Display  
idle  
Service Needed  
SELECT  
Lockout RESET  
Error Code History:  
In “Service Mode” pressing the “Select” button after the “Software Version” (item 8 in the previously described sequence  
of service modes) will show an error code history, if there have been any previous operating problems with the water  
heater. If the display shows --, there is not a current error code.  
The Water Heater Display will provide up to 10 previous error codes. The oldest error code will be stored in code index  
#1 and the most recent in code index #10.  
19  
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Troubleshooting  
To view previous error codes:  
Step 1:  
In “Service Mode press the “Select” button until the next display after the “Software Version”. If there are no current  
error codes, the display will show -- .  
°F  
idle  
Operational  
Status  
SELECT  
SET  
Step 2:  
Press the “Temperature Down” button to select the error code index, starting with the most recent error code “10”.  
idle  
Status  
Operational  
SELECT  
SET  
%
Step 3:  
Press the “Select” button to view the error code for “code 10”. If there is a number displayed, note what the number is.  
The label next to the water heater display will identify the code number. If no number is displayed with only a “--“ in the  
water heater display, then there has not been an error code for error code index 10.  
idle  
Operational  
Status  
SELECT  
SET  
20  
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Troubleshooting  
Step 4:  
Press the “Temperature Down” button to change to the previous code index, code #9.  
idle  
Status  
Operational  
SELECT  
SET  
%
Step 5:  
Press the “Select” button for code index #9 to view if there are any code numbers.  
idle  
Operational  
Status  
SELECT  
SET  
Step 6:  
Continue pressing the “Temperature Down” button to change to the next error code index and press “Select” to view the  
error code number, if any, for that index number. Continue on to index #1, the oldest error code index. The water  
heater display will store up to 10 error codes with the oldest code starting in code index #1 with the most recent code in  
code index #10.  
Step 7: 10 seconds after the last button press, the Water Heater Display will revert back to the current error code  
display. To exit Service Mode, either wait 30 seconds or press Temperature Up button and Select Button for 3 seconds.  
setpoint  
°F  
idle  
Operational  
Statu  
s
SELECT  
SET  
%
&
Exiting Service Mode  
21  
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Troubleshooting  
ERROR CODE DEFINITIONS  
If the water heater has an operating problem, there will be a number in the water heater display with  
“Service Needed” shown below the error code number. Note the error code and the definition in the  
chart below. This label appears on the control box under the water heater display. The following  
sections will provide instructions for servicing each error code.  
22  
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WARNING  
The following procedure is for service and installation personnel only. Resetting lockout  
conditions without correcting the malfunction can result in a hazardous condition.  
If an error code is displayed (except for #4, low flame sense current), the water heater will be in a “lockout condition”  
with the water heater display showing the error code number and “Service Needed” in the status section of the  
display window. Error codes 62 (maximum number of retries detected) and 63 (maximum number if ignition  
recycles detected) are “Soft Lockouts” in which the control can be reset in the “User Mode” by pressing the lower  
right button under “Lockout Reset” shown in the lower right portion of the display. The control will also go through 3  
attempts to relight the burners every hour in the soft lockout condition.  
Error Code Shown in  
Water Heater Display  
Status Service needed  
SELECT  
Lockout RESET  
Press for 2 seconds  
%
All other error codes will put the water heater into a “Hard Lockout” condition, in which the water heater will not  
operate and cannot be reset in the “User Mode”. To reset a hard lockout, first enter the “Service Mode” described  
earlier by pressing both the “Temperature Up” and “Select Buttons” at the same time for 3 seconds. Then press the  
lower right button under “Lockout Reset” in the water heater display and hold for 3 seconds.  
Resetting Error Codes in Hard Lockout Condition  
Error Code Shown in  
Water Heater Display  
Status Service Needed  
SELECT  
Status Service Needed  
SET  
SELECT  
Lockout RESET  
%
Step 2: Press for 3 seconds to  
reset control in service mode.  
Step 1: Press for 3 seconds  
&
to enter service mode.  
23  
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SERVICE PROCEDURE D24-I  
Thermostat Circuit Testing  
CAUTION  
DANGER  
Be Careful When Making Voltage  
Measurements or Jumping Terminals  
Not to Damage or Deform Connectors or  
Connector Pins.  
120 volt exposure. To avoid personal injury,  
use caution while performing this procedure.  
This procedure assumes the flue damper is in working order. Be sure damper opens under its own power when the  
thermostat circuit is by-passed. Damper must be open or removed during this test. Do not force damper open using your  
hands or tools.  
Measuring upper  
Condition: Water Heater Not Operating  
Display shows error code “31” (Upper Sensor  
Readings Faulty) or error code “32” (Lower Sensor  
Readings Faulty)  
7
sensor resistance  
through wire  
harness  
(disconnected at  
control board).  
Unplug or disconnect electrical power to the water heater  
Check continuity of wire harness to affected sensor. Measurement  
of ohmeter should be close to 0 ohms. Replace wire harness if high  
resistance is measured (over 0.5 ohms) Check wires for intermittent  
connections, shorts, frayed insulation. Replace if necessary  
(see photo 8)  
Checking  
8
continuity of  
upper sensor wire  
harness.  
If wire harness checks out O.K.check resistance of sensor. Refer to  
section on Sensor Resistance Testing. If sensor resistance is not  
near the values shown in the table, then replace upper or lower  
sensor as indicated by error code number.  
Turn power on to water heater.  
Run water heater through heating cycle and verify proper operation.  
Sensor temperature can be viewed when burner shuts off (see  
section on viewing the display in “Service Mode”.  
Removing lower  
sensor from well.  
Held in place by a  
clip fastened to  
well shoulder.  
9
Condition: Water Heater Not Operating  
Display shows error code “65”  
High Water Temperature (over 200 deg. F)  
WARNING!  
Do not reset the display from the hard lockout  
state without correcting the cause of the  
overheating condition.  
Turn power “OFF”.  
Draw water to cool tank below 120 deg. F  
If sensor clip is damaged  
replace clip. Replace lower  
sensor if damaged.  
N
Check lower sensor. Is the sensor fully inserted into the well?  
Sensor is held in place with a clip fastened to the well (see photo 9)  
Check lower sensor wire making sure it is not damaged or has  
breaks in the wire insulation. Check upper harness wires to upper  
sensor, if used (some models).  
See next page  
Check Sensor Resistance  
(see “Sensor Resistance  
Testing” section & photo 7)  
Y
24  
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SERVICE PROCEDURE D24-I  
Thermostat Circuit Testing  
WARNING!  
Do not operate water heater without verifying that the overheating condition has been corrected.  
Condition: Water Heater Not Operating  
Display shows error code “65”  
High Water Temperature (over 200 deg. F)  
Continued  
Once cause of overheating condition has been diagnosed  
and corrected, the control may be reset  
Reconnect and switch on power to the water heater.  
Enter service mode on the water heater display (see  
illustration)  
Press button under “Lockout Reset” and hold for 3  
seconds.  
Set thermostat to the desired setting.  
Water heater should start.  
Monitor temperatures for one complete heating cycle  
making sure the maximum tank temperature remains well  
below 200 deg. F  
25  
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SERVICE PROCEDURE D24-I  
Conditions: Upper or Lower Sensor Reading  
Faulty, High Water Temperature, or suspect  
thermostat is not accurate.  
Thermostat Circuit Testing  
Sensor Resistance Testing  
Upper Sensor  
1. Determine resistance value of upper sensor. Test across  
grey wires.  
Upper thermister location  
(applicable models)  
2. Draw quart of water off T&P valve. Using a thermometer,  
determine water temperature.  
10  
3. Use table below to verify correct resistance per water  
temperature measured.  
Lower Sensor:  
1. Determine resistance value of lower sensor. Test across  
center wire (common) to each outside wire. Resistance of both  
thermisters in the lower sensor should be close to each other.  
If the resistance values for both thermisters are not close to  
each other, replace the lower sensor. The dual thermisters are  
used to provide high limit protection in case the thermostat  
circuit fails to shut off the water heater.  
Checking resistance of  
upper sensor  
Lower thermister  
access located inside  
control box.  
11  
2. Draw quart of water off Drain Valve.  
Using a thermometer, determine water temperature.  
3. Use table below to verify correct resistance per water  
temperature measured.  
Are readings  
correct?  
Replace  
N
thermister  
Checking resistance of  
lower sensor (center and  
outside pins)  
Y
Check harness  
continuity.  
Continuity okay?  
Replace  
harness  
N
CAUTION  
Be Careful When Making Resistance  
Measurements Not to Damage or  
Y
Deform Connectors or Connector Pins.  
Replace  
control board  
Sensor Resistance at Various Temperatures  
Example: If water temperature is 84°F, then the resistance through the sensor would be 8449 (see shaded area).  
NOTE: Sensor resistance increases as the temperature falls.  
In Degrees F  
°F  
40  
50  
60  
70  
80  
90  
100  
110  
120  
130  
140  
150  
160  
170  
180  
190  
200  
0
1
2
3
4
5
6
7
8
9
26109  
19906  
15314  
11884  
9299  
7333  
5827  
4663  
3758  
3048  
2488  
2043  
1688  
1402  
1170  
982  
25400  
19383  
14925  
11592  
9078  
7165  
5697  
4562  
3679  
2986  
2439  
2004  
1656  
1376  
1150  
965  
24712  
18876  
14548  
11308  
8862  
7000  
5570  
4464  
3602  
2925  
2391  
1966  
1625  
1351  
1129  
949  
24045  
18383  
14180  
11032  
8653  
6839  
5446  
4368  
3527  
2866  
2344  
1928  
1595  
1327  
1110  
933  
23399  
17905  
13823  
10763  
8449  
6683  
5326  
4274  
3453  
2808  
2298  
1891  
1566  
1303  
1090  
917  
22771  
17440  
13477  
10502  
8250  
6531  
5208  
4183  
3382  
2752  
2253  
1856  
1537  
1280  
1071  
901  
22163  
16990  
13140  
10248  
8057  
6383  
5094  
4094  
3312  
2697  
2209  
1820  
1509  
1257  
1053  
886  
21573  
16553  
12812  
1000  
7869  
6238  
4982  
4006  
3244  
2643  
2166  
1786  
1481  
1235  
1035  
871  
21000  
16128  
12494  
9760  
7685  
6098  
4873  
3922  
3177  
2590  
2124  
1753  
1454  
1213  
1017  
857  
20445  
15715  
12185  
9526  
7507  
5961  
4767  
3839  
3112  
2538  
2083  
1720  
1427  
1191  
999  
842  
713  
828  
814  
801  
788  
775  
762  
749  
737  
725  
26  
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SERVICE PROCEDURE D24-II  
Pilot Operation Testing  
CAUTION  
DANGER  
Be Careful When Making Voltage  
Measurements or Jumping Terminals  
Not to Damage or Deform Connectors or  
Connector Pins.  
120 volt exposure. To avoid personal injury,  
use caution while performing this procedure.  
Condition:  
Pilot will not light or stay lit,  
Error codes 62, or 63 shown on Water  
Heater Display  
Check across “MV/PV” & “PV” Wire  
leads to gas valve  
12  
Reset control by pressing the lower  
right button under “reset” on the  
N
display for 3 seconds. Does control  
Replace control board  
board start ignition sequence and  
start sparking (sparking noise at pilot  
or at board)  
Y
Check for:  
N
N
Y
Loose or damaged ignition wire  
Grounded pilot electrode  
Damaged pilot.  
Is there spark at the pilot?  
Y
Is there 22-27 volts AC output across  
terminal pins 8 & 2 on “Control” plug  
of Control Board? Carefully insert  
meter probe in wire plug to check pin  
terminals. Make sure control is in the  
trial for ignition sequence (see  
Sequence of Operation).  
Replace control board.  
(see photo 13)  
Y
Loosen pilot tubing connection at  
the gas valve and soap test.  
Is there pilot gas flow out of the  
gas valve? See pilot illustration  
for pilot inspection. (Wires must  
be connected to gas valve during  
this test).  
Is there 22-27 volts AC input across  
wire leads  
Check for clogged or kinked pilot  
tube, clogged pilot orifice. Clean  
or replace as needed.  
Y
“MV/PV” & “PV” (yellow & red wires)  
at Gas Valve?  
(see “Pilot Burner Inspection”)  
(see photo 12)  
N
N
Check wire harness for damage or  
loose connections. Repair or replace  
as needed.  
Tighten pilot tube connection at  
the gas valve. Check incoming  
gas pressure to water heater. if  
okay, replace gas valve  
Turn on power to the water heater  
and verify proper operation  
13  
Checking for 24  
volts output to  
pilot valve  
(yellow and red  
wire pin  
terminals) on  
control board  
“control” plug.  
27  
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SERVICE PROCEDURE D24-II  
Pilot Inspection  
Condition:  
Error code 57: Flame Rod Shorted  
to Ground  
Disconnect power. Shut off gas  
supply to water heater. Slide out  
burner assembly (see section on  
“removing pilot and main burner  
assembly”).  
Check to see if pilot shield is touching  
pilot flame sensor or flame sensor  
touching pilot hood. Bend shield to  
prevent interference or replace pilot  
shield.  
Check pilot flame sense wire for  
broken insulation. Replace pilot if  
defective  
Make sure pilot shield  
clears flame sense rod  
Reinstall pilot and burner assembly.  
Reconnect gas line union, turn on  
gas.  
Flame Sense Rod  
Check for Gas Leaks  
Spark Electrode  
Reconnect power and verify proper  
ignitions.  
28  
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SERVICE PROCEDURE D24-II  
Pilot Operation Testing  
CAUTION  
DANGER  
Be Careful When Making Voltage  
Measurements or Jumping Terminals  
Not to Damage or Deform Connectors or  
Connector Pins.  
120 volt exposure. To avoid personal injury,  
use caution while performing this procedure.  
Condition:  
Pilot lights, no or low flame signal. Control  
Display shows “4” or “62” for Error Codes  
(Service Needed). Control continues to spark  
until system “Lock Out”.  
Main burner will not light.  
Meter  
Probe  
Check for loose or damaged flame sense  
lead from pilot to Control Board. (see  
illustration to the right). Is flame sense lead  
okay?  
Repair wire lead  
N
N
N
Flame rod  
Multi-meter set  
to check  
or replace pilot.  
continuity.  
Y
Check for loose or damaged ground wire(s)  
from gas valve to control board. Check  
continuity of wires with ohmeter. Are ground  
wires okay?  
Repair ground  
wire(s) or replace  
as needed.  
Y
Meter  
Probe  
Correct improper  
venting condition.  
Refer to Installation  
Instructions  
Check venting conditions or negative  
pressure.  
Checking pilot flame sensor wire and flame  
rod for continuity.  
Is vent system okay?  
Y
Make sure pilot shield is in place  
and not bent or damaged (refer  
to section on main burner and  
pilot assembly) . Determine  
cause for condensing and  
correct.  
Is heater condensing causing pilot  
interruption?  
Y
ȝA  
(Possible under sized water  
heater or high demand periods.)  
N
Heating  
Status  
Flame Current  
Operational  
NOTE:  
SELECT  
SET  
The microamp output of the pilot may be  
checked by entering “Service Mode” on the  
water heater display and pressing “Select”  
until the flame current is shown. The control  
must be in the heating mode with the pilot lit  
to display a reading. See section on  
accessing service mode on the water heater  
display.  
Check continuity of sense lead  
to flame rod. If no continuity,  
clean pilot flame rod or replace  
pilot. Check pilot flame  
appearance - if weak check for  
clogged pilot orifice, bent pilot  
tubing, or low inlet gas  
Pilot flame sensor microamp output  
shown in display using service mode.  
Pilot must be lit to get reading.  
pressure.  
(see above illustration)  
Micro-amp readings  
0.000 Micro Amp =  
Replace control board or pilot if wire is  
damaged.  
Clean pilot flame rod or replace pilot.  
1.0 micro amp or less =  
29  
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SERVICE PROCEDURE D24-III  
Main Burner Operation Testing  
CAUTION  
DANGER  
Be Careful When Making Voltage  
Measurements or Jumping Terminals  
Not to Damage or Deform Connectors or  
Connector Pins.  
120 volt exposure. To avoid personal injury,  
use caution while performing this procedure.  
Checking MV &  
14  
MV/PV control plug  
pins to gas valve  
for 24 volts output  
during heating  
cycle (pilot must be  
lit with no  
Condition:  
Main burner will not light,  
Display shows “Heating” under temperature  
setpoint.  
Tank is cold.  
sparking).  
See “Pilot Will Not  
Light”  
N
Is Pilot lit?  
Y
Y
Does control board continue to spark with  
pilot lit?  
See “Pilot Lights, No Flame  
Signal”  
N
Insert meter probes into back of  
“Control” plug on control board to contact  
pins for measuring voltage.  
Is there 22-27 volts AC across  
pin terminals 5 & 8? (Refer to wiring  
diagram also see photo 14)  
Be sure control display is showing “Heating”,  
pilot is lit and control is not sparking.  
Recheck voltage across control board  
pin terminals 5 & 8 (MV & MV/PV)  
Is voltage present?  
N
N
Replace control board.  
Y
Y
Brown wire disconnected  
from “MV” terminal of gas  
valve  
Ground lug of  
gas valve  
15  
Check incoming gas pressure  
to gas valve and manifold  
pressure to burners (See next  
p a g e f o r p r o c e d u r e f o r  
checking manifold pressure). If  
inlet gas pressure is O.K.,  
replace gas valve. (See photo  
on next page for gas valve  
inlet pressure tap)  
Disconnect brown wire lead from  
“MV” terminal of gas valve.  
Is there 22-27 volts AC across  
brown wire lead & ground?  
(see photo 15)  
Y
N
Check wire harness for damage or loose  
connections. Repair or replace as needed.  
Checking main valve (MV) voltage to gas valve.  
30  
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SERVICE PROCEDURE D24-III  
Main Burner Operation Testing  
CAUTION  
DANGER  
Be Careful When Making Voltage  
Measurements or Jumping Terminals  
Not to Damage or Deform Connectors or  
Connector Pins.  
120 volt exposure. To avoid personal injury,  
use caution while performing this procedure.  
Condition:  
Main burner short cycles.  
Control Display may show error  
code “63, 57, or 4” and be in  
“Soft Lockout” state.  
Check gas inlet pressure to the water  
heater gas valve.  
Line pressure should be:  
Nat. = Min. 5.5" W.C.: Max. 14.0" W.C.  
LP = Min. 11.0" W.C.; Max. 14.0" W.C.  
Is gas pressure within proper  
Determine cause of incorrect gas  
pressure and correct. Contact  
your gas supplier.  
N
specification? (see photo below)  
Y
Check manifold pressure. See photo on lower right section of page for  
manifold pressure tap location. Refer to water heater rating label for  
specified manifold pressure. If the manifold pressure is not within 0.3"  
w.c. of the specified pressure, then remove the regulator cap from the  
gas valve and turn plastic screw clockwise to increase pressure and  
counterclockwise to decrease pressure. Be sure inlet gas pressure is at  
least 1" w.c. above the manifold pressure. Replace regulator screw and  
pressure tap cap when finished. Is manifold pressure O.K.?  
N
Replace Gas Valve.  
Y
Check venting conditions, clogged vent,  
Correct improper venting  
condition. Refer to  
Installation Instructions  
N
down drafts or negative building  
pressure  
Is vent system okay?  
Line gas  
pressure port  
Gas Valve pressure  
regulator cap (adjustment  
screw accessible by  
Y
removing cap screw)  
Is there sufficient combustion air being  
supplied to the water heater? Are there  
combustion air openings or supply pipes  
to the room? Open access door to the  
utility room to see if problem is  
corrected.  
Provide proper  
combustion air to water  
heater. Refer to  
N
16  
Installation Instructions  
Y
Check for unstable pilot flame or  
oxidation of the flame rod on pilot  
causing weak pilot signal. Make sure  
pilot shield is in place and does not  
touch pilot flame sensor.  
Connect hose barb to manifold  
pressure port shown above, then  
connect monometer to measure  
gas manifold pressure.  
(See Pilot Inspection section)  
Manifold Pressure Port with hose  
barb inserted for measuring  
pressure  
Check burner tubes for scale or debris  
build-up. Clean burner as necessary.  
(see Main Burner and Pilot Removal and  
Inspection)  
Check tank flues for blockage or debris  
build-up causing restriction.  
(see Flue Baffle Removal, Inspection)  
31  
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SERVICE PROCEDURE D24-IV  
Main Burner & Pilot  
Removal and Inspection  
WARNING  
Heater components may be HOT when performing the following steps in this procedure.  
Take necessary precaution to prevent personal injury.  
Gas Valve  
Wire Leads  
Main Burner Removal  
Burner Rack  
Mounting  
Screw  
Gas Valve  
Control Knob  
Step 1.  
Disconnect (un-plug) water heater from  
electrical supply.  
Gas Supply  
Line  
Step 2.  
Step 3.  
Turn “OFF” gas supply to water heater.  
Rotate gas valve control knob to the “OFF” position  
(see photo 17).  
17  
Step 4.  
Step 5.  
Step 6.  
Disconnect Gas supply line from the gas valve  
(see photo 17).  
18  
Pilot Flame Sense  
Wire (White)  
Disconnect wire leads from gas valve  
(see photo 17).  
Disconnect white flame sense wire & orange ignition  
wire from Control Board (see photo 18).  
Pilot spark wire  
(Orange)  
Step 7.  
Step 8.  
Remove the two burner rack mounting screws (see photo 17).  
Slide complete burner rack out from heater  
(see photo 19).  
Step 9.  
To install burner, reverse above procedure.  
Step 10. Check for gas leaks and verify proper operation.  
19  
Main Burner Inspection  
Step 1.  
Burner tubes should be free of any flue  
scale or other debris. Clean  
burner tubes using a stiff brush and/or  
shop vac. Burner ports should have uniform  
openings. Replacement is recommended for  
burners where port area is deteriorated or  
other unintended openings are present.  
Pilot  
Shield  
Step 2.  
Step 3.  
Insure pilot shield is in place (see photo 20).  
20  
Inspect pilot position to insure smooth burner  
ignition from pilot flame. Pilot should be  
mounted using the two mounting screws through  
the burner support bracket resulting in a level  
pilot position.  
32  
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SERVICE PROCEDURE D24-IV  
Main Burner & Pilot  
Removal and Inspection  
Pilot Shield  
Pilot Burner Removal  
21  
Step 1.  
With burner rack removed from heater, disconnect  
pilot tube connection from gas valve  
Step 2.  
Remove the two pilot burner mounting screws  
securing the pilot and pilot shield in place.  
Step 3.  
Step 4.  
Remove pilot shield and pilot from burner rack.  
To install pilot burner and pilot shield, reverse above  
procedure. Be sure to reconnect green ground wire.  
Ground Wire  
Location  
Pilot & Pilot Shield  
Mounting Screws  
Pilot Burner Inspection  
Step 1. Inspect pilot for the following:  
a) Broken or cracked ceramic insulators. If found,  
pilot must be replaced.  
Flame  
Rod  
b) Damaged electrode or flame sense wire. If found,  
pilot must be replaced.  
22  
Ceramic  
c) Oxidation build-up on flame rod. Clean flame rod  
or replace pilot as necessary.  
Insulators  
Pilot  
Orifice  
Step 2.  
Inspect pilot orifice:  
Ignition  
Wire  
a) Remove 7/16" ferrule nut from bottom of pilot.  
b) Remove pilot tube and orifice from pilot.  
7//16"  
ferrule  
Nut  
Flame Sense  
Wire  
c) Inspect pilot tube for blockage. Clean or replace  
as necessary.  
Aluminum  
Pilot Tubing  
d) Inspect pilot orifice for blockage. Clean or replace  
as necessary.  
33  
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SERVICE PROCEDURE D24-IV  
Control Board Replacement  
DANGER  
120 volt exposure. To avoid personal injury,  
unplug while performing this procedure.  
Control board replacement  
Step 2: Unplug wire connections from board.  
24  
Step 1: Disconnect Power  
23  
Depress  
plastic  
tabs  
Wire connections  
Step 3: To remove board, tilt control panel to the right  
and slide control hook tabs from slots in control panel.  
25  
To remove lower sensor  
Remove clip, pull sensor out.  
Slots in  
control panel  
26  
Unhook tabs  
from control  
panel slots  
Remove clip  
Pull out sensor  
IMPORTANT  
When replacing lower sensor, make sure  
sensor is fully inserted into the well and  
securely held by the clip on the well groove.  
(see photo 25)  
34  
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SERVICE PROCEDURE D24-V  
Flue Baffle Removal, Inspection  
WARNING  
Heater components may be HOT when performing the following steps in this procedure.  
Take necessary precaution to prevent personal injury.  
27  
Step 1.  
Step 2.  
Disconnect (unplug) water heater from electrical supply.  
Disconnect venting from draft diverter and remove draft  
diverter from top of water heater.  
Step 3.  
Step 4.  
Step 5.  
Disconnect flue damper from wire harness and remove  
flue damper from top of water heater (see photo 27).  
If required, turn “OFF” water supply & disconnect top plumbing  
connection from top of water heater.  
28  
Remove screws holding jacket head to top of water heater  
and remove jacket head from top of water heater. Note, it may  
be necessary to use a screw driver to pry underneath  
jacket head (see photo 28).  
Step 6.  
Step 7.  
Remove insulation from top of water heater to expose  
collector cover.  
Remove screws from side (or top) of collector cover. Note, it may be  
necessary to chisel away some foam to access screws (see photo 29).  
29  
Step 8.  
Step 9.  
Remove collector cover from water heater by using  
pipe wrench as illustrated in photo 30.  
Remove flue baffles from water heater. Note, it may be necessary  
to use pliers to loosen and remove baffles from flue tubes (see photo 31).  
30  
Step 10. Visually inspect flue baffles. Flue baffles may show signs  
of oxidation; this is normal. If the oxidation has deteriorated  
any portion of the flue baffle, replacement is recommended.  
If any restrictors are missing, replacement is recommended.  
Step 11. Upon completion of inspection or subsequent replacement,  
reinstall flue baffles into heater.  
31  
Step 12. Reinstall collector cover and insulation over collector cover.  
Flue Baffle  
Step 13. Reinstall jacket head, flue damper and draft diverter. Reconnect venting.  
Step 14. Reconnect plumbing connection to top of water heater  
& turn on water supply if required.  
Step 15. Check for leaks and verify proper operation.  
35  
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SERVICE PROCEDURE D24-VI  
Anode Removal and Inspection  
WARNING  
Heater components may be HOT when performing the following steps in this procedure.  
Take necessary precaution to prevent personal injury.  
Step 1.  
Disconnect (unplug) water heater from electrical supply.  
32  
Step 2.  
Step 3.  
Step 4.  
Turn “OFF” water supply to water heater.  
Open a near by hot water faucet to relieve tank pressure.  
Connect hose to drain valve of water heater and route to an open drain. Open  
drain valve and drain a minimum of 5 gallons of water from the water heater.  
Close drain valve and disconnect drain hose from water heater.  
Step 5.  
Step 6.  
Step 7.  
Step 8.  
Disconnect venting from draft diverter and remove draft diverter from top of  
water heater.  
33  
Disconnect flue damper from wire harness and remove flue damper from top  
of water heater (see photo 32).  
If required, turn off water supply and disconnect top plumbing connection from  
top of water heater.  
Remove screws holding jacket head to top of water heater  
and remove jacket head from top of water heater. Note, it may  
be necessary to use a screw driver to pry underneath  
jacket head (see photo 33).  
34  
Step 9.  
Remove insulation from top of water heater to expose collector cover,  
remove if necessary. (see next page for approx. anode locations)  
Step 10. Remove screws from side (or top) of collector cover. Note, it may be  
necessary to chisel away some foam to access screws (see photo 34).  
Step 11. Locate and remove anode rods from top of water heater (1-1/16 hex socket).  
Note, anodes located outside of the collector (see photo 35) may require foam  
to be chiseled away to access anode rods. (see next page for approx. anode locations)  
35  
Step 12. Visually inspect anode rod. Anode rod may show signs of depletion;  
this is normal. If the anode shows signs of depletion  
(approximately 5/8", see photo 36), replacement is recommended. If any of  
the steel core of the anode is exposed, replacement is recommended.  
Step 13. Upon completion of inspection or subsequent replacement,  
reinstall anode rods into water heater.  
Anode  
Step 14. Check for leaks.  
Step 15. Reinstall collector cover & insulation over collector cover.  
Replace Anode  
36  
Step 16. Reinstall jacket head, flue damper and draft diverter. Reconnect venting.  
Step 17. Reconnect plumbing connection to top of water heater if required.  
Step 18. Restore water supply and power to water heater.  
Step 19. Verify proper operation.  
36  
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SERVICE PROCEDURE D24-VI  
Anode Removal and Inspection  
Approximate Anode Rod Locations  
37  
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Generic Parts List  
2
3
1
5
4
11  
10  
30  
8
9
7
6
28  
24  
29  
12  
13  
14  
27  
23  
19  
22  
25  
26  
21  
20  
15  
15A  
16/16A  
17/17A  
18  
1. Draft Diverter w/Leg Kit  
2. Draft Diverter  
3. Draft Diverter Leg  
4. Damper Outlet Reducer  
5. Flue Damper  
6. Hot Outlet Nipple  
7. Cold Water Inlet Dip  
Tube  
11. Flue Core  
20. Burner Assembly Complete  
21. Brass Drain Valve  
12. 1" x ¾" Reducer Bushing  
13. Nipple T&P Valve  
22. Cold Water Inlet Nipple (side)  
23. Thermostat Well  
14. T&P Valve  
15. Cleanout O-Ring  
15A. Cleanout Gasket (ASME)  
16. Cleanout Access Cover  
24. Damper Harness  
25. Lower Thermostat Sensor  
26. Control Box Assembly Complete  
27. Hot Water Outlet Nipple (side)  
28. Upper Thermostat  
16A. Cleanout Access Cover (ASME)  
17. Cleanout Cover Screw  
8. Hex Head Anode  
9. Flue Baffle  
10. Flue Reducer  
17A Cleanout Cover Screw (ASME)  
18. Cleanout Jacket Cover  
29. Utility Cover  
30. ASSE Approved Mixing Valve  
31. Pipe Plug ¾ NPT  
19. Thermostat Sensor Clip  
38  
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Generic Parts List  
13A  
1A  
2A  
4A  
3A  
14A  
16A  
7A  
8A  
5A  
9A  
6A  
17A  
18A  
10A  
11A  
12A  
15A  
19A  
20A  
1A. Draft Panel  
11A. Pilot Mounting Screw  
12A. Burner Tube Support  
13A. Manifold Bracket  
14A. C-Cane Manifold  
15A. Manifold Straight  
16A. Manifold Bracket  
17A. 90° Street Elbow Black  
18A. 1" Down Pipe Nipple Black  
19A. 1" 90° Elbow Black  
20A. Ground Wire  
2A. Burner Rack  
3A. Burner Tube  
4A. Gas Valve  
5A. Burner Manifold  
6A. Main Burner Orifice  
7A. Pilot Shield  
8A. Pilot Burner  
9A. Pilot Orifice  
10A. Pilot Tubing  
39  
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Generic Parts List  
19B  
20B  
7B  
17B  
18B  
8B  
6B  
5B  
4B  
3B  
9B  
16B  
2B  
12B  
10B  
11B  
13B  
1B  
14B  
15B  
1B. Temperature Display  
2B. Control Box Cover  
3B. Integrated Control Board  
4B. Screw 8-16 X ½ PHCR  
5B. Transformer  
11B. Power Cord Strain Relief  
12B. Pilot Wire Strain Relief  
13B. Secondary Transformer Wiring Harness  
14B. Primary Transformer Wiring Harness  
15B. Screw 8-18 x ¾ PHCR  
6B. Ground Lug  
16B. Gas Valve Control Wiring Harness  
17B. Damper Wiring Harness  
7B. On/Off Switch  
8B. Control Box Panel  
9B. Screw 8/32 X ¼ PHCR  
10B. 7/8" Snap Bushing  
18B. Power Cord  
19B. Display Control Wiring Harness  
20B. Display Cover Wiring Harness  
40  
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Glossary of Terms  
AC  
Alternating Current  
British Thermal Units per Hour  
Carbon Monoxide  
Carbon Dioxide  
BTU/H  
CO  
CO2  
DC  
ECO  
GFI  
GPM  
Hz  
Direct Current  
Energy Cut Off  
Ground fault interrupt  
Gallons per Minute  
Hertz  
LED  
NOx  
NPT  
PSI  
VA  
VAC  
W.C.  
°C  
°F  
ȝA  
Light Emitting Diode  
Oxides of Nitrogen  
National Pipe Thread  
Pounds per Square Inch  
Volt Amps  
Volts Alternating Current  
Inches of Water Column  
Degrees Centigrade  
Degrees Fahrenheit  
Micro Amp  
NOTES  
41  
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NOTES  
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NOTES  
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Email  
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