Page 2 - SERVICE MANUAL; TABLE OF CONTENTS
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT SERVICE MANUAL Technical Literature Department ©2008 TABLE OF CONTENTS INTRODUCTION ............................................................ 2 Qualifications ............................................................ 2 Service Warning ...........
Page 3 - INTRODUCTION; QUALIFICATIONS - QUALIFIED SERVICE AGENT
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 2 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent INTRODUCTION This Service Manual is designed to be an aid in servicing and troubleshooting the 96% therm...
Page 4 - INSTRUCTION MANUAL; is not; TOOLS REQUIRED
Technical Literature Department 3 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL INSTRUCTION MANUAL Have a copy of the Instruction Manual that came with the water heater on hand for the...
Page 5 - INSTALLATION CONSIDERATIONS; Installation information given in this Service Manual; a complete installation; CLOSED WATER SYSTEMS; This type of failure is not covered under the limited; The temperature-pressure relief
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 4 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent INSTALLATION CONSIDERATIONS INSTRUCTION MANUAL Installation information given in this Service Manual is ...
Page 6 - AIR REQUIREMENTS
Technical Literature Department 5 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL AIR REQUIREMENTS Carefully review the requirements for combustion and ventilation air in the Instruction...
Page 7 - VENTING; Maximum Equivalent Length Requirements; = 5 linear feet of pipe
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 6 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent VENTING The venting information presented in this Service Manual is not a complete venting installation ...
Page 9 - ELECTRICAL REQUIREMENTS
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 8 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ELECTRICAL REQUIREMENTS The water heater covered by this Service Manual must be grounded in accordance w...
Page 10 - HOW IT WORKS; EXTERNAL VIEW
Technical Literature Department 9 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL OPERATION & SERVICE HOW IT WORKS This section of the Service Manual will cover operation, common ser...
Page 11 - BLOWER; VFD
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 10 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent BLOWER The blower is an assembly consisting of the blower housing, motor and an integrated VFD (variabl...
Page 12 - BURNER; Ignition Failure
Technical Literature Department 11 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL BURNER The images below show a complete blower/burner assembly removed along with a top view of the wat...
Page 13 - Burner & Blower Removal; BLOWER/BURNER REMOVAL PROCEDURE
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 12 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent BURNER (CONT) Burner & Blower Removal The burner should be removed and inspected whenever service i...
Page 14 - Blower Adapter; /4” Hex Machine Screws
Technical Literature Department 13 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL BURNER (CONT) Burner/Blower Removal (cont) Service Notes - Blower Flange & Blower Adapter Gaskets. ...
Page 15 - VENTURI; GA; Venturi Inlet; Supply Gas; Blower; Burner
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 14 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent VENTURI A Venturi is connected to the inlet of the blower. All combustion air flows through the Venturi...
Page 16 - GAS VALVE; Gas Valve Removal; GAS VALVE REMOVAL PROCEDURE; Venturi
Technical Literature Department 15 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL GAS VALVE The outlet of the gas valve is connected by flange directly to the side of the Venturi (page ...
Page 17 - GAS PRESSURE TESTING; Service Notes - Checking Gas Pressures
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 16 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent GAS PRESSURE TESTING The water heater covered in this Service Manual is rated at 100,000 Btu/hr input. ...
Page 19 - AIR PRESSURE SWITCHES; Normal State; Construction
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 18 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent AIR PRESSURE SWITCHES Air pressure switch technical bulletins TB-A023-06 and TB-S023-06 explain air pre...
Page 20 - TOP VIEW; Blocked Intake Switch
Technical Literature Department 19 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL AIR PRESSURE SWITCHES (CONT) The water heater covered in this Service Manual is factory equipped with t...
Page 21 - AIR PRESSURE SWITCH OPERATION; Before each call for heat begins,; before the blower starts; , the control system performs a; “Blower Prover Open.”; or; “Blocked Exhaust Vent”
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 20 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent AIR PRESSURE SWITCH OPERATION The control system monitors the “state” of the air pressure switches indi...
Page 22 - AIR PRESSURE SWITCH TESTING; Air pressure switch testing involves three procedures:; Normal State Test
Technical Literature Department 21 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL AIR PRESSURE SWITCH TESTING Air pressure switch testing involves three procedures: • Normal State Test ...
Page 25 - FLAME SENSING TEST; Flame sensing current typically runs much higher than minimum; “Ignition Failure”; lock out is a contaminated or corroded flame; Measuring Flame Sensing Current
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 24 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent FLAME SENSING TEST To prove burner flame during ignition the control system monitors flame sensing curr...
Page 26 - IGNITER CURRENT TEST; “Low Igniter Current”; with age and
Technical Literature Department 25 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL IGNITER CURRENT TEST The water heater covered by this Service Manual uses a hot surface igniter (HSI). ...
Page 27 - CONTROL SYSTEM; Plain english text based diagnostic information (fault messages)
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 26 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent CONTROL SYSTEM INTRODUCTION This portion of the service manual will cover the control system. The contr...
Page 28 - UIM; Service Notes - Button Pad Ribbon Cable; UIM Circuit Board Back
Technical Literature Department 27 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL UIM The UIM (User Interface Module) is the display on the front of the water heater. The UIM’s major co...
Page 29 - Commercial & Residential Product Differences; UIM - User Interface Module Display
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 28 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent UIM (CONT) User input buttons on the UIM include an Up, a Down, and three Operational buttons. The Up a...
Page 30 - data will only be visible on commercial models.
Technical Literature Department 29 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL UIM (CONT) Desktop Screen The Desktop screen is the default screen. If there are no active fault messag...
Page 31 - Table 4 - Status Icons
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 30 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent UIM (CONT) Table 4 - Status Icons STATUS ICON DESCRIPTION The temperature of the water in the tank has ...
Page 33 - OPERATING SET POINT ADJUSTMENT
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 32 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent OPERATING SET POINT ADJUSTMENT When the temperature sensed by the control system at the Temperature Pro...
Page 34 - CONTROL SYSTEM MENUS
Technical Literature Department 33 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL CONTROL SYSTEM MENUS Desktop: This is the default screen for the control system. If there are no active...
Page 35 - condition. It will contain the current fault message/condition.; Restore Factory Defaults:; This menu allows the end user to restore all settings to their
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 34 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent CONTROL SYSTEM MENUS (CONT) Heater Information: This menu contains historic operational and configurati...
Page 36 - CCB; Service Notes - CCB Replacement; Transformer
Technical Literature Department 35 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL CCB The CCB circuit board is the main control. All instructions for ignition and temperature control or...
Page 37 - Socket Identification
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 36 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent CCB (CONT) Socket Identification All wiring connections and sockets will be identified in the following...
Page 39 - Retries; Vent; ON
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 38 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent CCB (CONT) J7 Socket - Temperature Probe/ECO (immersion probe - top of the water heater) J9 Port - Comm...
Page 40 - WIRING DIAGRAM; This water heater is; polarity and ground sensitive; . The control system will lock out and
Technical Literature Department 39 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL WIRING DIAGRAM Service Notes - Polarity & Ground This water heater is polarity and ground sensitive...
Page 41 - SEQUENCE OF OPERATION
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 40 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent SEQUENCE OF OPERATION Call for heat initiated Air Pressure Switch Test Is Performed Blower Prover Switc...
Page 42 - TROUBLESHOOTING; Heater Status Menu; electrical requirements on page 8.; Resetting the control system
Technical Literature Department 41 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL TROUBLESHOOTING The control system performs exhaustive self diagnostics and displays detected fault con...
Page 43 - CONTROL SYSTEM UNRESPONSIVE; UIM Display Is Blank; UIM is Inoperable
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 42 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent CONTROL SYSTEM UNRESPONSIVE DISPLAYED MESSAGE CONDITION/INDICATES CHECK/REPAIR UIM Display Is Blank On/...
Page 44 - FAULT MESSAGES; “AC Reversed”
Technical Literature Department 43 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL FAULT MESSAGES DISPLAYED MESSAGE CONDITION/INDICATES CHECK/REPAIR “AC Reversed” The control system has ...
Page 45 - “Upper Probe Short”
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 44 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHECK/REPAIR “Upper Probe Short” The contro...
Page 46 - “Flame Detect Error”
Technical Literature Department 45 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHECK/REPAIR “Flame Detect Error” The contr...
Page 47 - “Blocked Inlet”
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 46 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHECK/REPAIR “Blocked Inlet” The control sy...
Page 49 - “Blower Prover Open”
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 48 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHECK/REPAIR “Blower Prover Open” (Blower N...
Page 53 - “Gas Valve Failure”
ULTRA HIGH EFFICIENCY POWER VENT/POWER DIRECT VENT - SERVICE MANUAL Technical Literature Department 52 of 52 Ashland City, TN © 2008 Servicing should only be performed by a Qualified Service Agent FAULT MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHECK/REPAIR “Gas Valve Failure” The contro...
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