A.O. Smith GAHH 50 100, PCG6240T403NOV 100, PCG2J5040T3NOV 100, PCG250T403NOV 100 Table of Contents

Page 5

TABLE OF CONTENTS

 

INTRODUCTION:

 

Service Handbook Introduction

3

Warnings and Cautions

4

Table Of Contents

5

INSTALLATION / OPERATION:

 

Basic Installation & Operation

6

Combustion Air and Vent System Requirements

7-10

KNOW YOUR WATER HEATER:

 

Know the Water Heater’s Component Parts

11-13

Water Heater Operation

14

Filling and Draining the Water Heater

15

Lighting Instructions

16

ADJUSTING TEMPERATURE CONTROL:

 

Adjusting the Temperature on the Electronic Control Display

17

Using the Electronic Control Display

18-19

Electronic Control Display Troubleshooting

20-23

COMPONENTS REMOVAL / REPLACING:

 

External Inspection and Cleaning

24

Electronic Control Display Removal / Replacement

25

Powered Anode Removal / Replacement

26-27

Pressure Switch Removal / Replacement

28

Transformer Removal / Replacement

29-30

Air Intake Chamber Box Removal / Replacement

31-33

Wiring Harnesss Removal / Replacement

34-36

Air Intake Chamber Fan Removal / Replacement

37-38

Pressure Tubing Removal / Replacement

39-40

Inner Door/Manifold/Burner Assembly Removal / Replacement

41-42

Flame Sense/Hot Surface Igniter Removal / Replacement

43

Burner Removal / Replacement

44-46

Burner Orifice Removal / Replacement

47-49

Gas Control Valve/Thermostat Removal / Replacement

50-52

CHECKPOINTS / GENERAL INFORMATION:

 

Checking the Gas Supply Pressure

52

Gas Water Heater Sizing Guide -and- Leakage Checkpoints

53

General Information

54-55

5

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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 Gas Control Valve/Thermostat Lower Control Know the Water HEATER’S Component PartsElectronic Control Display Upper Control Air Intake Chamber Fan Burner/Manifold Door AssemblyPressure Switch 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 DisplayFault Code Retrieval Using the Electronic Control DisplayFault Code Diagnostics 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 FlowchartCleaning the Combustion Chamber and Air Diverter Assembly External Inspection and CleaningCleaning the Air Intake Chamber Screen Removing the Electronic Control Display Electronic Control Display Removal / ReplacementInstalling the Electronic Control Display Removing the Powered Anode Rod Powered Anode ROD Removal / ReplacementInstalling the Powered Anode Rod Installing the Pressure Switch Pressure Switch Removal / ReplacementRemoving 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