Page 2 - TABLE OF CONTENTS; . This handbook contains supplemental
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 1 TABLE OF CONTENTS Page Introduction Terms......................................................... 1 Tools ........................................................
Page 3 - “R” Value
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 2 Tools Required: • Phillips head screw driver • 3/8, 7/16, ¾ inch open end wrenches • 3/16 inch Allen wrench • 11/16 inch – 6 point – socket – for anode removal ...
Page 4 - Water Hammer
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 3 Water Hammer – is a concussion of moving water against the sides of a containing pipe or vessel on a sudden stoppage of flow. EX: 1/2 “copper pipe, 5GPM flow (7...
Page 5 - is constructed of steel.
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 4 Centimeters = Inches X 2.54 MM (millimeters) = Inches X 25.4 Meters = Inches X .0254 Doubling the diameter of a pipe will increase its flow capacity (approximat...
Page 6 - INSTALLATION OF RESIDENTIAL GAS WATER HEATER
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 5 INSTALLATION OF RESIDENTIAL GAS WATER HEATER Exhaust Vent to Outside of Building Union See Manual and Labels For Installation Clearances Temperature And Pressur...
Page 7 - RESIDENTAL GAS WATER HEATER SERVICE; There is
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 6 RESIDENTAL GAS WATER HEATER SERVICE This portion of this manual applies to the Operations and Servicing of Residential Gas, Tank Type, Water Heaters, which are ...
Page 8 - Residential Gas – continued; AFTER HAVING CONFIRMED THAT THE WATER HEATER HAS BEEN INSTALLED
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 7 Residential Gas – continued Burner: The burner assembly consists of the main burner, main burner orifice, main burner gas supply tube, pilot burner, pilot burne...
Page 9 - Two metal probes mounted
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 8 Residential Gas – continued Temperature: Two metal probes mounted onto the back of the control are immersed inside the tank water. One probe (the shorter) acts ...
Page 10 - Residential Gas - continued; Time To Produce 2; Degree Burns on Adult Skin
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 9 Residential Gas - continued Water Flow: When a hot water faucet is opened, water pressure from the well tank or street main forces cold water into the water hea...
Page 11 - Pilot
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 10 Residential Gas - continued Service: Air: A gas burning appliance requires the oxygen contained in 12.5 cubic feet of air (at sea level) for every 1000 BTU of ...
Page 12 - Supply gas pressure; Testing with
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 11 • Possible carbon monoxide • Smell of burnt gas in the room Residential Gas – continued The instruction manual gives guidelines under “Air Requirements” and “U...
Page 15 - If ...
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 14 Residential Gas – continued Condensation is a mild acid – it will corrode steel Condensation is usually noted when: • water dripping is heard (only) while the ...
Page 16 - Exhaust Venting Notes
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 15 Residential Gas – continued Exhaust Venting Notes Follow current National Fuel Gas Code requirements for proper installation. “D” – Typically, same or larger d...
Page 17 - Possible Service issues associated with a blocked screen:
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 16 IMPLEMENTATION CATEGORY ANTICIPATED INTRODUCTION CLASS OF PRODUCTS INCLUDED IN THIS CATEGORY Phase I July 1, 2003 (July 1, 2004* Can.) 30, 40, and 50 gallon at...
Page 18 - FLAME ARRESTOR
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 17 FLAME ARRESTOR Made from Corderite, a fireproof ceramic material, the flame arrestor is built into the base of the water heater. Combustion air is drawn in thr...
Page 19 - Possible service issues associated with the flame arrestor.; COMBUSTION CHAMBER TEMPERATURE SENSOR; The TCO performs two primary functions:
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 18 If there has been a flammable vapor ignition, a qualified service agent needs to inspect the arrestor for cracks. The arrestor is not a replaceable part – the ...
Page 20 - ONE PIECE PILOT BURNER ASSEMBLY; Piezo igniter cable
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 19 SERVICE: There is no routine service associated with the TCO. The standard thermocouple millivolt output checks described in this service handbook still apply....
Page 21 - To replace a pilot assembly:
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 20 To replace a pilot assembly: 1. Turn off the gas supply 2. Disconnect the piezo cable from the piezo button (connection near gas control valve). 3. Disconnect ...
Page 22 - Five point inner door seal inspection:
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 21 The three seals on the inner door should be checked every time any service is performed. The sight glass should be checked to insure it is not damaged or missi...
Page 23 - PIEZO IGNITER; – The parts on these models may change due to improvements/changes
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 22 PIEZO IGNITER C3 TECHNOLOGY models will feature a Piezo igniter to light the pilot burner. The push button switch will be located on the top of the gas control...
Page 24 - WHY WATER HEATER TANKS LEAK; Condensation) Products of combustion contain
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 23 WHY WATER HEATER TANKS LEAK WHAT WHY PREVENTION Water Pressure Water expands when it is heated (Thermal Expansion). Water cannot be compressed. Excessive Press...
Page 25 - Continued; WATER CONDITIONS; WHAT; C) and increase only as
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 24 WHY WATER HEATER TANKS LEAK - Continued WATER CONDITIONS WHAT WHY PREVENTION “Hard” Water “Hard” water contains minerals. As water is heated the minerals separ...
Page 26 - TECHNICAL BULLETIN - 11; WATER HAMMER
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 25 TECHNICAL BULLETIN - 11 WATER HAMMER GENERAL Water hammer is the destructive forces, pounding noises and vibration in a piping system when water flowing throug...
Page 27 - TECHNICAL BULLETIN - 13
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 26 TECHNICAL BULLETIN - 13 MINERAL BUILD-UP SYMPTOMS • Rumbling • Crackling • Popping CAUSE With the advent of high input and larger storage tanks in both commerc...
Page 28 - TECHNICAL BULLETIN - 14; ALUMINUM HYDROXIDE; If tank is new with no lime build-up to any degree:
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 27 TECHNICAL BULLETIN - 14 ALUMINUM HYDROXIDE SYMPTOMS “Crackling”, “gurgling”, or “popping” noises from new water heaters (installed less than six months). CAUSE...
Page 29 - TECHNICAL BULLETIN - 21; DISCOLORED WATER; TREATMENT
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 28 TECHNICAL BULLETIN - 21 DISCOLORED WATER SYMPTOMS Rusty, brown, black, or yellow water appearing in the hot water. CAUSE Complaints of discolored water are com...
Page 30 - TECHNICAL BULLETIN - 22; SMELLY WATER
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 29 TECHNICAL BULLETIN - 22 SMELLY WATER CAUSE The most common cause of “smelly water” is a non-toxic sulfate reducing bacteria, scientifically termed Divibrio Sul...
Page 31 - TECHNICAL BULLETIN - 23; CHLORINATION PROCEDURE; All hot water lines must receive treatment.
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 30 TECHNICAL BULLETIN - 23 CHLORINATION PROCEDURE CAUSE The chlorination procedure is used to eliminate various bacteria that accumulate and grow in water heaters...
Page 32 - TECHNICAL BULLETIN - 35; NOT ENOUGH HOT WATER - GAS
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 31 TECHNICAL BULLETIN - 35 NOT ENOUGH HOT WATER - GAS CAUSE Not enough hot water complaints are becoming more frequent in the water heater industry. This increase...
Page 33 - TECHNICAL BULLETIN - 45; THERMAL EXPANSION
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 32 TECHNICAL BULLETIN - 45 THERMAL EXPANSION SYMPTOMS • Effects are only noticeable after hot water use followed by periods of no water use. • Relief valve drips ...
Page 35 - TECHNICAL BULLETIN - 52; LEAKING TEMPERATURE AND PRESSURE RELIEF VALVE
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK State Water Heater Technical Training Department © 2004 Ashland city, TN 34 TECHNICAL BULLETIN - 52 LEAKING TEMPERATURE AND PRESSURE RELIEF VALVE SYMPTOMS • Water seeping around the relief valve tank connection • Leakage at the threade...
