A.O. Smith PCG250T403NOV 100 manual Service Handbook, Tools Required for servicing gas models

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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 in this handbook is designed to answer commonly faced situations encoun- tered in the operation of the standard Residential Gas product line and is not meant to be all-inclusive. If you are experiencing a problem not covered in this handbook, please contact the Technical Informa- tion Center listed on the back of this handbook for further assistance. Additional information is also available on the web site listed on the back of this handbook. This handbook is intended for use by licensed plumbing professionals and reference should be made to the Installation Instructions and Use

&Care Guide accompanying the product. This handbook contains supplemental information to the Installation Instructions and Use & Care Guide.

When servicing residential water heaters, it is essential that you return the unit to a safe condition before you leave the site. All original components must be re-installed and all safety measures must be implemented. In addition, the recommended water temperature setting is 120° F.

IMPORTANT: It is recommend that on every service call an inspection & cleaning of the air intake chamber screen and combustion chamber and air diverter assembly be performed. See page 24.

Tools Required (for servicing gas models):

• phillips head screw driver

• 3/8, 7/16, & 3/4 inch open end wrenches

• 3/16 inch Allen wrench

1-1/16 inch – 6 point – socket – for anode removal

• 5/16” nut driver

• pliers

• electrical multimeter (with alligator leads)

• digital or analog manometer

• gas pressure gauge

• Teflon® tape

• hose – to drain tank

Digital manometer shown.

Teflon® is a registered trademark of E.I. Du Pont De Numours and Company.

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Contents Models ALL Technical and Warranty Questions Tools Required for servicing gas models Service HandbookBreathing Hazard Carbon Monoxide Gas Fire or Explosion HarzardTable of Contents Installation of Residential GAS Water Heater Basic Installation & OperationCarbon Monoxide Warning Combustion AIR and Vent System RequirementsReference Vent Connectors Connector must be firmly attached Know the Water HEATER’S Component Parts Electronic Control Display Upper ControlGas Control Valve/Thermostat Lower Control Burner/Manifold Door Assembly Pressure SwitchAir Intake Chamber Fan HOW the Water HEATER’S Component Parts are Connected Power Anode RodSequence of Operation Water Heater OperationFILLING, Draining and Flushing the Water Heater Tank Lighting Instructions For Your Safety Read Before OperatingHotter Cooler Adjusting the Temperature on Electronic Control DisplayUsing the Electronic Control Display Fault Code DiagnosticsFault Code Retrieval FV-Sense Reset Sequence Reviewing Fault CodesElectronic Control Display Electronic Control Display TroubleshootingControl Display Status Problem Solution Control Display TroubleshootingLDO-SW, OPEN, and Clean Screen YES Troubleshooting FlowchartExternal Inspection and Cleaning Cleaning the Air Intake Chamber ScreenCleaning the Combustion Chamber and Air Diverter Assembly Electronic Control Display Removal / Replacement Installing the Electronic Control DisplayRemoving the Electronic Control Display Removing the Powered Anode Rod Powered Anode ROD Removal / ReplacementInstalling the Powered Anode Rod Pressure Switch Removal / Replacement Removing the Pressure SwitchInstalling the Pressure Switch Removing the Transformer Transformer Removal / ReplacementInstalling the New Transformer Removing the Air Intake Chamber Box AIR Intake Chamber BOX Removal / ReplacementInstalling the Air Intake Chamber Box Installing the Fan in the Air Intake Chamber Box Pressure Wiring Harness Removal / ReplacementInstalling the New Wiring Harness Replacing the Wiring HarnessUndue Pressure or Sudden Force Removing the Fan from the Air Intake Chamber AIR Intake Chamber FAN Removal / ReplacementInstalling the Fan in the Air Intake Chamber Box Pressure Tubing Removal / Replacement Installing the Air Intake Chamber Box GAS Control Inner DOOR/MANIFOLD/BURNER Assembly Removal / ReplacementTAB Installation Caution Must Be TakenReplacing the Flame Sense/Hot Surface Igniter Assembly Flame SENSE/HOT Surface Igniter Removal / ReplacementBurner Removal / Replacement Removing Old Burner Installing New BurnerPressure Burner Orifice Removal / Replacement Removing Old Burner Orifice Installing New Burner OrificeReinstalling The Inner Door/Manifold/Burner Assembly Removing the Gas Control Valve/Thermostat GAS Control VALVE/THERMOSTAT Removal / ReplacementInstalling the Gas Control Valve/Thermostat Checking the Gas Supply Pressure Checking the GAS Supply PressureLeakage Checkpoints GAS Water Heater Sizing GuideFormulas and Conversions General InformationMM millimeters =Inches X