Service manual | Atwood Mobile Products 94605 Water Heater User Manual

September 2003
INTRODUCTION
The 2004 edition of the Atwood Water Heater Service Manual is a resource created to
help service technicians identify Atwood product by serial number, diagnose service
problems and efficiently and effectively process warranty claims.
In 2003, Atwood relocated the Switch, Thermostat and ECO that was installed on the
back of combination 6 and 10 gallon Gas/Electric Water Heaters. A double switch is
now located inside the RV for convenience and a joint ECO and T-Stat is located on
the gas side of the water heater. This leaves only the relay and heating element on the
backside of the water heater.
Each of the manuals within this series offers a general overview of the product as well
as more specific product information. For each product within the manual, you will
find model identification, recommended tools and equipment, a sequence of
operation, warnings, annual maintenance procedures, parts and troubleshooting
guides, warranty procedures, flat rate schedules, and replacement part reference
charts.
Due to the rapidly changing personal computer revolution we have placed
troubleshooting information in a variety of places to make sure that the most accurate
information is available. The best place to find the current information about Atwood
products is our website: www.atwoodmobile.com. At our website brochures may be
downloaded, trouble shooting guides reviewed and the latest information bulletins can
be read. In addition all Atwood Authorized Service Centers are listed on our site,
accessible via an easy-to-use search system.
Service for all Atwood products is handled out of our Rockford location. Should you
have any questions regarding our products or the information contained in this
manual simply dial 1-800-825-4328. Be sure to have the Model and Serial Number when
you call.
Atwood Service Department
Disclaimer: The data presented in this publication is obtained from the most reliable sources, and is believed to be accurate as of the
date of publication. Responsibility for typographical errors or omission of data cannot be assumed by the publishers.
1
NOTES
THIS PAGE INTENTIONALLY LEFT BLANK
2
TABLE OF CONTENTS
Atwood Water Heaters
Atwood Letter
1
Aftermarket Model Identification
4
Pilot Models
Questions
5
Model Number Explanation / Features
6
Recommended Tools & Equipment
7
Gas Thermostat Controls & Pilot Assemblies
8
Pilot Sequence of Operation
9
Pilot & Main Burner
10
Trouble Shooting Guide
11
Engine Heat Exchange System / Aftermarket Heating Elements
12
Bolt-In Heating Element, Thermostat & ECO / 110 VAC Trouble Shooting Wiring Schematic
13
Screw-In Heating Element, Thermostat & ECO / 110 VAC Trouble Shooting Wiring Schematic
14
Electronic Ignition Models
Questions
15
Model Number Explanation / Features
16
Recommended Tools & Equipment
17
DSI Sequence of Operation
18
Trouble Shooting Guide - Electronic Ignition
19-20
Information Guide - Intermittent Ignition
21-22
Potted Channel Circuit Boards / Thermal Cut Off Device / Thermostat
23
Wiring Schematics
24
General Water Heater Information
Questions
25
Pressure Temperature Relief Valve / Water Heater Tank Corrosion / Atwood Clad Tank
26
Flushing Tank / Winterizing Instructions
27
Water Heater Terminology
28
Warranty
29
Warranty Procedures
29
30
Return Goods Policy (RETURN ADDRESS)
Flat Rate Schedule
31
Pilot Water Heater Parts Breakdown
32-34
Replacement Part Reference
G10B, G10C / G610-3B, GH610-3 / G4SM / G6A-2, G6A-3, G6A-6, G6A-6P, G6A-7, G6A-7P / GC6A, GC6A-3,
GC6A-6, GC6A-7 / GH6-3, GH6-6, GH6-7 / GC6AA-7, GC6AA-7P / GC6AA-8, GC6AA-8P / G610-3,
GC10-1, GC10-2, GC10-2P / GC10A-2 / GC10A-2P / G10-1, G10-1P, G10-2, G10-2P
Electronic Ignition Water Heater Parts Breakdown
Replacement Part Reference
35-37
G610-3E, GH610-3E / GCH6-4E, GCH6-6E, / GC6A-7E / GC6AA-7E / GC6AA-8E / GC6AA-9E, GC6AA-10E
G6A-2E, G6A-3E, G6A-4E, G6A-6E, G6A-7E, G6A-8E / G6A-3E, GH6-3E / GH6-4E, GH6-6E, GH6-7E,
GH6-8E / GCH6A-7E, GCH6A-8E, GCH6A-9E / GCH6A-10E /
GCH10A-2E, GCH10A-3E / GCH10-4E / G10-1E / GH10-2E, GH10-3E / GC10-1E, GC10-2E / GC10A-2E /
GC10A-3E / GC10A-4E
Service Tank Kit Part Numbers
Marine Water Heater Parts Breakdown
Atwood Training Tapes and Manuals
38
39
ORDER BLANK
3
Aftermarket Gas Water Heaters
Includes Doors & Switches (when appropriate)
G6A-7 ----------------------------------6 gal.
GC6AA-8 ------------------------------6 gal.
GC6AA-10E ----------------------------6 gal.
GCH6A-10E ----------------------------6 gal.
G6A-8E --------------------------------6 gal.
GH6-7 ----------------------------------6 gal.
GH6-8E --------------------------------6 gal.
G10-2 ----------------------------------10 gal.
GC10A-2 ------------------------------10 gal.
G10-3E --------------------------------10 gal.
GC10A-4E ----------------------------10 gal.
GCH10A-4E --------------------------10 gal.
w/pilot
combo w/pilot
electronic gas combo
electronic gas combo w/heat exchange
electronic
w/pilot, heat exchange
electronic w/heat exchange
w/pilot
combo
electronic
electronic combo
electronic combo w/heat exchange
Marine Water Heaters
EHM6-4WFHX ------------------------4 gal.
EHM6-SMFHX ------------------------6 gal.
H6-FHX --------------------------------6 gal.
EHM6-ATC ----------------------------6 gal.
EHM6-SMSS --------------------------6 gal.
EHM11-SSDHXT --------------------6 gal.
EHM11-SMFHX --------------------11 gal.
EHM11-SST --------------------------11 gal.
H11-FHX ------------------------------11 gal.
EHPM10 ------------------------------11 gal.
EH-20 ----------------------------------20 gal.
E20 ------------------------------------20 gal.
marine, front heat exchange & special hook-up
electric marine w/heat exchange
marine special
marine, heat exchange & temp. control
marine, rear heat exchange & special hook-up
marine, stainless steel dual heat exchange tube
electric marine w/heat exchange
electric, heat exchange stainless steel tank
marine special
electric marine w/special tube
electric marine w/heat exchange
electric marine
Marine International Water Heaters
EHM6-220-FHX ----------------------6 gal.
EHM6-220SST ------------------------6 gal.
EHM6-220-FHX ----------------------6 gal.
EHM11-220 --------------------------11 gal.
EHM11-220SST --------------------11 gal.
EHM11-220SS-4WFHX ----------11 gal.
EHM11-220SS-IMFHX ------------11 gal.
EH20-220 ----------------------------20 gal.
E20-220 ------------------------------20 gal.
marine, heat exchange, 220 volts
marine, heat exchange, 220 volts, stainless steel housing
marine, heat exchange, 220 volt, 1000 watt element
marine, heat exchange, 220 volts
marine, heat exchange, 220 volts, stainless steel housing
marine, heat exchange, w/special hook-up
marine, heat exchange, 220 volt, 1000 watt element
marine, heat exchange, 220 volts
marine, 220 volts
European Water Heaters
EURI6A-6E ----------------------------6 gal. International Electronic 3-bar valve
EURIH6-6E ----------------------------6 gal. International Electronic w/heat exchange
EURICH6-6E --------------------------6 gal. International Electronic Combo w/heat exchange
4
PILOT MODELS
QUESTIONS
The following questions should be answered during this portion of the manual:
· Are the Robertshaw and White Rodgers thermostat gas control valves inter-changeable?
· What is the minimum gas pressure required for proper water heater operation?
· Where on the water heater gas control can gas pressure be tested?
· Can the pilot flame be adjusted?
· What is minimum millivolt output of the thermocouple required for proper gas control operation?
· How can you test a thermocouple?
· How tight should the thermocouple connection be at the gas control?
· What is an E.C.O., where is it located and what is its function?
· What is a proper main burner air shutter adjustment?
· What is the proper control and main burner alignment?
· How can you easily check the calibration of a control?
5
Atwood 6 and 10 gallon Pilot Water Heaters
Atwood water heaters are designed and approved for use only in recreation vehicles (travel trailers, 5th wheels,
motor homes, etc.). They are offered in two sizes: 6 and 10 gallon capacities.
TYPE OF GAS IGNITION This unit is ignited outside of the trailer by a match, piezo ignitor or other ignition device. The water
temperature is adjustable at the thermostat control.
EXPLANATION OF MODEL NUMBER:
Pilot Models
G C
H
6 AA -
7
P
Pilot Relight
Version
Type of heating element
(GC_ A - _ = bolt on, GC_ A A-_ = screw in)
Gallon capacity (6 or 10)
Engine Heat Exchange
Combination gas and 110 VAC electric
Propane Gas
NOTE: When replacing the element on a combination gas/110 VAC unit, always check the back
of the heater for the type of element it has. It will either be a bolt-on or screw-in
element. They are no interchangeable.
FEATURES
• All units operate on propane gas.
•
A heat exchange option is available for motor homes. The water heater tank must have factory equipped
heat exchange tubes welded on it already. They cannot be added later. A new water heater tank with this
option is the only way to obtain this feature.
•
Skin mounting allows the water heater to be hooked up with plumbing and electrical before the sidewall is
erected.
•
The tank has a clad aluminum lining that protects against corrosion and does not need to be replaced on
a yearly or more frequent basis like anode rods do. A more detailed explanation of cladding is found in the
back of this manual.
•
95% of all servicing can be done on the outside of the water heater. 110 VAC heating components are the
exception since they are located on the back of the water heater inside the trailer.
•
A flush flange is available for all models. This makes the access door flush with the trailer sidewall.
•
There are multiple protection features in the form of a pressure-temperature relief valve, a limit switch in
the gas thermostat and an externally sealed combustion chamber.
•
On combination water heaters, the gas mode and the 110 VAC heating mode can be operated at the same
time since each mode has its own thermostat.
•
Both the six and ten gallon units have the lightest weight in the industry.
•
On all trailers purchased after June 1, 1997 Atwood Limited Warranty is for a period of two years. This
includes all reasonable labor charges.
•
We have 650+ Service Centers throughout the United States.
6
Recommended Tools and Equipment
U-Tube Manometer - This is the most accurate device for measuring gas pressure. If you use a dial-type
manometer, it should be calibrated periodically with this type of manometer.
Thermostat Wrench - This tool allows for easier and safer removal of the gas thermostat control. An
adjustable version for different size controls is available through most RV distributors or you may fabricate one
from angle iron. We do not recommend using a pipe wrench because it may damage the control causing it to
go out of calibration.
U-TUBE MANOMETER
with 1/8” pipe nipple
THERMOSTAT WRENCH
Fill here
Correct
water
level
7
6
5
4
3
2
1
0
1
2
3
4
5
6
7
Manometer
connection
Multi-meter - This is the most versatile meter and will test AC voltage and continuity. A continuity test can be
used to test for a blown E.C.O. on a gas control.
Magnet Assembly Thermocouple Tester - This assembly can be obtained at an electronics or hardware store.
This same assembly can also be removed from a Robertshaw control. It will verify if a thermocouple is good.
For testing, screw a thermocouple into the tester, heat the thermocouple for 25 seconds and then press the
plunger down. If the plunger pops up in less that 25 seconds, the thermocouple is faulty.
MAGNET ASSEMBLY TO TEST
THERMOCOUPLE
MULTI-METER TO TEST
AC VOLTAGE AND CONTINUITY
Common Hand Tools - 1/8˝ and 1/4˝ nut drivers, open end wrenches, flat blade and Phillips screw drivers.
Leak Test Solution - A solution that bubbles when applied to gas fittings or connections showing when a gas
leak is present.
7
Gas Thermostat Controls and Pilot Assemblies
Only two makes of gas controls have been used on our pilot model water heaters. They are the Robertshaw
“Unitrol” and White Rodger (formerly Jade or ITT).
The Robertshaw control came in two different sizes of gas inlets: 3/8˝ inverted flare and 3/8˝ N.P.T. The
inverted inlet control is no longer available. Therefore, the water heater gas line connection will have to be
modified to 3/8˝ N.P.T. in order to use the current Robertshaw control.
The White Rodger control is the valve we are using on all production today. Formerly it had a 3/8˝ N.P.T.
inlet. Now it is only available with a 1/4˝ inlet. This improvement eliminates the adapter fitting into the control
allowing the use of only a single 45 degree elbow (3/8˝ flare x 1/4˝ N.P.T.). If you are replacing a current 1/4˝
inlet model control with a earlier model 3/8˝ inlet control you may have in stock, the adapter fitting that
mates the control and elbow fitting is still available.
Although the controls appear quite different in size, the White Rodger and Robertshaw control are
interchangeable. Their manifolds will both line up with the burner tube properly.
Both controls have a port to test gas pressure through the valve. This can be accomplished by removing the
cover screw and inserting a 1/8” pipe nipple. After attaching your manometer hose to this fitting, the
manometer should register 10” W.C. through the valve while it is operating.
ROBERTSHAW “UNITROL”
WHITE RODGERS (JADE, ITT)
• 3/8˝ Inverted inlet
• 3/8˝ N.P.T. outlet
3/8˝ N.P.T. outlet
(no longer available)
(no longer available)
• 1/4˝ N.P.T. inlet
• 3/8˝ N.P.T. inlet
3/8˝ N.P.T. outlet
(replaces all Robertshaw
and Jade controls)
3/8˝ N.P.T. outlet
There are two main pilot assemblies that you will encounter in the field.
The first is an earlier model Robertshaw pilot assembly with a 1/4˝ pilot gas line that mounted on the left
side of the main burner.
The current pilot is the Jade assembly with a 1/8˝ pilot gas line and it mounts on the right side of the main
burner.
The Robertshaw pilot is no longer available and the Jade pilot must be substituted. When installing a Jade
assembly in place of a Robertshaw assembly, if there is not a location on the right side of the main burner to
mount the Jade pilot, a new burner that has the proper mounting holes will have to be purchased.
Note: The size of the gas line does not have
any affect on the size of the pilot flame. Only
the gas pressure and pilot orifice regulate the
height of the pilot flame.
JADE
ROBERTSHAW
(obsolete, replace with Jade)
8
Pilot Sequence of Operation
ONE SHOT
E.C.O. 190°
Temperature Lever
Gas Inlet
11" W.C.
Pressure
ON/OFF Pilot Knob
Pilot Flame
Pilot Orifice (inside)
Thermocouple
Air Shutter
JADE CONTROL SYSTEM
PILOT OPERATION
• Gas Pressure
11˝ W.C. to control is necessary. Set with two gas appliances running.
• Gas Control
supplies gas to pilot orifice when control ON/OFF pilot knob is held at pilot position.
• Pilot Orifice
meters gas to heat thermocouple. Flame should be high enough to engulf the
thermocouple.
• Thermocouple
generates millivoltage to the gas control’s magnet assembly.
• Magnet
when it receives 12 millivolts or more it allows gas to flow freely to pilot without
holding pilot knob.
• E.C.O.
passes millivolts through the gas control and back to thermocouple. Trips
permanently open if water temperature exceeds 190°F.
MAIN BURNER OPERATION
• Gas Control
supplies gas to main burner when control knob is set to “ON” position and the
temperature lever is set to desired temperature after pilot is lit.
• Main Burner Orifice
meters gas through burner tube.
• Main Burner
pilot ignites gas when it reaches end of this tube. Flame height adjusted by sliding air
shutter. Ideal setting is 1/4 way open (.20˝). Flame should be primarily blue with
a trace of yellow.
• Temperature Knob
setting of knob determines burner cycle and water temperature. Temperature range is
70°F - 140°F.
9
Pilot and Main Burner
Pilot Adjustment
Only the gas pressure, gas valve and the pilot orifice regulate the height of the pilot flame. Early model gas
controls have a pilot adjustment screw, but this screw has very little effect on the pilot. The pilot
adjustment has been removed from the current White Rodger control. The flame should be high enough to
engulf the thermocouple at all times. A pilot flame any larger could blow the E.C.O. in the gas control. This
is typically the result of enlarging the pilot orifice hole with a pin or similar item. For further corrective
measures, refer to the trouble-shooting guide.
Temperature Lever
On/Off Pilot Knob
Pilot Flame
Flame Spreader
Air Shutter
Burner Tube
Thermocouple
Main Burner Adjustment
The gas pressure, air shutter cleanliness of the burner tube and orifice regulate the main burner flame. The
main burner flame should be mainly blue with a trace of yellow and fairly quiet. If it is not, adjust the gas
pressure to 11˝ W.C., ensure that the main burner air shutter is 1/4 way open and verify that the main
burner flame spreader is square to the end of the main burner. For further corrective measures, refer to the
trouble-shooting guide.
Gas Valve
ner Tube
r
de
Orifice Hol
Main Bur
(orientation found in water heater)
Main Burner Alignment
The manifold and main burner should be as perfectly aligned as possible. In other words, the gas valve
should be rotated at the same angle as the main burner tube. If it is not, rotate the gas control and/or the
orifice holder so that the orifice disperses gas straight down the center of the burner tube. If the valve must
be backed off any, check for water leaks at the coupling the control screws into before you operate the
water heater.
10
Pilot Water Heater
TROUBLE SHOOTING GUIDE
Effective: 5/26/98
Guides are only intended for use on Atwood® products by service technicians who have successfully completed
Atwood® training. This guide should be used in conjunction with the appropriate Instruction Manual provided with the
product and any applicable Industry standards. This is not intended to be a complete list. Please direct questions
concerning service of Atwood® products to 800-825-4328 before proceeding.
CAUSE
SOLUTION
PILOT OUTAGE
Gas pressure incorrect --------------------------Set pressure to a minimum of 11˝ W.C. with two or more appliances running
Blocked “U” tube --------------------------------Remove obstruction
Improper main burner alignment --------------Re-align main burner and main burner orifice holder and gas valve
Improper air adjustment ------------------------Adjust main burner air shutter approximately 1/4 open
Weak thermocouple------------------------------Replace thermocouple
Poor pilot flame ----------------------------------Clean or replace pilot orifice
Weak gas control magnet ----------------------Replace gas control
Defective E.C.O. in control ----------------------Replace gas control and check the pilot flame. It should be high enough to engulf
the thermocouple at all times.
PILOT OUTAGE WHEN BUTTON OR KNOB IS RELEASED
Thermocouple not hot --------------------------Hold button or knob for 30 seconds before releasing
Thermocouple loose ----------------------------Tighten connection at gas control
Weak thermocouple------------------------------Replace thermocouple
Weak gas control magnet ----------------------Replace gas control
Defective E.C.O. in control ----------------------Replace gas control
MAIN BURNER WILL NOT IGNITE
Blocked main burner orifice --------------------Clean or replace orifice
Main burner flame spreader mis-alignment --Square flame spreader to end of main burner
Blocked main burner ----------------------------Remove blockage
Improper air adjustment ------------------------Adjust main burner air shutter approximately 1/4 open
Blocked “U” tube --------------------------------Remove blockage
Gas control out of calibration ------------------Replace gas control
ERRATIC MAIN BURNER FLAME
Improper gas pressure --------------------------Set inlet pressure to a minimum of 11˝ W.C. with two or more appliances running
Improper air adjustment ------------------------Adjust main burner air shutter approximately 1/4 open
Partial blockage of main burner ----------------Remove blockage
Partial blockage of main burner orifice --------Clean or replace orifice
Flame spreader misaligned----------------------Re-align spreader or replace main burner
Blockage in “U” tube ----------------------------Remove blockage
Poor gas supply ----------------------------------Replace gas supply
Exhaust grille blocked --------------------------Remove blockage
Improper main burner alignment --------------Re-align main burner, main burner orifice holder and gas valve
SMOKING AND SOOTING
Gas pressure incorrect --------------------------Set pressure to a minimum of 11˝ W.C. with two or more appliances running
Poor gas supply ----------------------------------Replace gas supply
Improper pilot flame ----------------------------Clean or replace pilot orifice
Improper air adjustment ------------------------Adjust main burner air shutter approximately 1/4 open
Flame spreader mis-aligned --------------------Re-align or replace main burner
Blocked main burner ----------------------------Remove blockage
Improper main burner alignment --------------Re-align main burner, main burner orifice holder and gas valve
Blocked “U” tube --------------------------------Remove blockage
INSUFFICIENT WATER TEMPERATURE
Temperature selector out of place--------------Re-set to desired position
Bypass levers improperly positioned ----------Reposition levers
Improper air adjustment ------------------------Adjust main burner air shutter approximately 1/4 way open
Partial main burner blockage ------------------Remove blockage
Improper main burner adjustment ------------Re-align main burner and main burner orifice holder
Flame spreader mis-aligned --------------------Re-align or replace main burner
Blocked “U” tube --------------------------------Remove blockage
11
Engine Heat Exchange System
Heat Exchanger Tubes
Customer supplied SAE 053 A type
"E" hose clamp
or evuivalent
Annualar Grove
Heat Exchanger
Tubes
Coolant System Hose
(5/8" dia. SAE 20R3
or equivalent)
Customer
supplied tee
The engine heat exchange system allows a motor home to heat the water while traveling. This convenient
option allows you to arrive at your destination with hot water. Operating a pilot or electronic water heater on
gas while in transit is a dangerous practice.
This system consists of a U-shaped aluminum tube that is attached to the outside of the tank with welds. SAE
hoses are attached to both ends of this tube and are spliced into the engine coolant system.
When the engine is running, the hot coolant flows past the tank through this tube and by means of heat
transfer through the welds, heating the water. The design of this system will not allow the water to reach a
boiling point. It will typically heat the water to about 130° F. in about 2-3 hours of driving.
Aftermarket Heating Elements
 WARNING
EXPLOSION / BURN INJURY
• Aftermarket heating elements can lack critical safety controls.
• Use of these devices can lead to an out of control heating of water tank and a
catastrophic wet side explosion.
YOU DO NOT NEED AN AFTERMARKET HEATING ELEMENT ON AN ATWOOD WATER HEATER. THE USE OF AFTERMARKET HEATING
ELEMENT DEVICES MAY ALSO RESULT IN DAMAGE TO COMPONENTS OR WATER HEATER.
Atwood’s written warranty states
- “failure or damage resulting from any alteration to our water heater is the owner’s responsibility”. ANY
ALTERATION, LIKE THE ADDITION OF AN AFTERMARKET HEATING ELEMENT DEVICE, WILL VOID THE WARRANTY.
• When Aftermarket heating elements are inserted
into the drain plug, customers are more prone not
to flush their tanks. Not flushing the tank
accelerates tank corrosion on both our pilot and
electronic ignition water heaters creating a situation
where the tank may have to be replaced. THIS WILL
BE A NON-WARRANTABLE SITUATION.
• Temperatures produced by these heating elements
can exceed the 190˚F. limit of the ECO on pilot model
gas control valves. This gas control valve contains a
one-shot ECO. When this ECO blows, the control is
completely non-functional and must be replaced.
THIS WILL BE A NON-WARRANTABLE SITUATION.
12
BOLT-IN
Heating Element, Thermostat & ECO
110VAC Trouble-Shooting
Wiring Schematic
UP
Temperature
Adjustment Dial
ECO
Re-Set
Button
Hot Lead
( 1 )-BLACK
Ground Lead
( 3 )-GREEN
Common Lead
( 2 )-WHITE
Switch
BLACK
Ground
BLACK
Manual Reset
High Temperature
Limit Switch
Fixed Thermostat
Element
Early model water heaters with 110 VAC heating
capacity used a bolt-on heating element and a one
piece thermostat/E.C.O..
In the case where the 110VAC portion of the water
heater is not heating water, the following diagnostic
steps and repairs should be investigated:
This 110 VAC system has an adjustable rectangular
thermostat that is surface mounted to the inner tank
and retained by a steel clip. The temperature settings
are HI, MEDIUM, and LOW. If the thermostat is
making unobstructed contact with the aluminum tank
and it is set to the HI position, it should heat the water
to 130° F. It will take longer to heat a tank of water on
electric than gas.
Turn POWER OFF to the appliance before
removing junction box cover.
The heating element was changed in 1996 from
1500W to 1400W bringing the amperage draw down
to 12.7 amps and allowing more cushion for the
15 amp circuit breaker that is normally placed in line.
This change adds a few minutes to the heating time.
There are 110 VAC aftermarket conversion kits being
offered by distributors in which the heating element is
screwed into the tank where the drain plug is located.
We do not offer such a kit. Our kit includes the tank
with the 110 VAC components already installed in it.
Perform the following steps with POWER ON to
water heater.
1. Verify switch-A is in ON position.
2. Insure there is 110VAC to the unit (measure
voltage across the black and white lead to the
appliance with POWER ON). If none, trace wiring
back and make appropriate wire repair.
Perform the following steps with POWER OFF to
water heater.
3. ECO Re-set Button-D should be depressed.
4. Check for continuity between screw-B and screwC of thermostat. If none, replace thermostat.
5. If water is insufficiently hot, check ECO /
Thermostat-E is on high.
6. Verify a good wire connection between thermostat
screw-C and heating element screw-G. Correct if
necessary.
7. There should be continuity between heating
element screw-G and screw-F. If none, element is
bad and should be replaced. Do not over-tighten
self-tapping screws when installing new element.
8. Check for continuity between element screw-G
and flange of element. If there is, element has
shorted. Element should be replaced.
9. Verify ground connection.
NOTE: Heating element can be operated on an empty
tank for a limited period of time before it self destructs.
13
SCREW-IN
Heating Element, Thermostat & ECO
110VAC Trouble-Shooting
Wiring Schematic
UP
G
F
B D
C
A
Hot Lead
( 1 )-BLACK
Ground Lead
( 3 )-GREEN
Common Lead
( 2 )-WHITE
Switch
BLACK
Ground
Element
BLACK
Fixed Thermostat
Manual Reset
High Temperature
Limit Switch
Current production water heaters with the 110 VAC
heating option use a screw-in heating element, a
separate pre-set thermostat and a separate ECO.
When the 110VAC portion of the water heater is not
heating water, the following diagnostic steps and
repairs should be investigated:
The screw-in heating element is rated at 1400 watts
just like the bolt-on element. It is an incalloy element
and can be run for a limited amount of time in a dry
tank without shorting out.
Turn POWER OFF to the appliance before removing
junction box cover.
Perform the following steps with POWER ON to
water heater.
1. Verify switch is in ON position.
2. Insure there is 110VAC to the unit (measure
voltage across the black and white lead to the
appliance with POWER ON). If none, trace wiring
back and make appropriate wire repair.
CAUTION: If the heating element is allowed to run
with a dry tank, allow the tank to cool down for 2-3
hours before adding water. Adding water before
the tank cools sufficiently could collapse the tank.
The thermostat and ECO are pre-set surface-mounted
discs. The thermostat is set at 140° F and is the same
thermostat used on the gas side of the electronic
ignition water heaters. The ECO is a backup
thermostat and will trip if the thermostat fails and the
water temperature exceeds 170° F.
Perform the following steps with POWER OFF to
water heater.
3. Manual reset ECO high limit switch-A should be
depressed. Check for continuity between
TERMINAL B and TERMINAL C of ECO.
4. Check for continuity between TERMINAL D and
TERMINAL E of thermostat. If there is none, replace
thermostat.
5. If water is insufficiently hot, insure thermostat is
flush with tank.
6. Verify a good wire connection between ECO
TERMINAL-C and heating element TERMINAL-F.
Correct if necessary.
7. Check for continuity between heating element
TERMINAL-F and TERMINAL-G. If none, element is bad
and should be replaced. Do not over-tighten selftapping screws when installing new element.
8. There should NOT BE CONTINUITY between element
screw-G and flange of element. If there is, element
has shorted. Element should be replaced.
9. Verify ground connection.
NOTE: Heating element can be operated on an empty
tank for a limited period of time before it self destructs.
14
E
ELECTRONIC IGNITION MODELS
QUESTIONS
The following questions should be answered during this portion of the manual:
· What is minimum gas pressure for proper water heater operation?
· Where on the gas solenoid valve can gas pressure be tested?
· What is the minimum voltage needed for operation?
· What is the proper wiring hook-up for the water heater circuitry?
· Can the Circuit Board Tester be used on both Fenwal and Channel circuit boards?
· How can the Circuit Board Tester be used to check a "flying lead" circuit board?
· What conditions can cause tracks on the back of the circuit board to blow?
· What is a proper main burner air shutter adjustment?
· What is the function of the thermal cut-off?
15
Atwood 6 and 10 gallon Electronic Ignition Water Heaters
Atwood water heaters are designed and approved for use only in recreation vehicles (travel trailers, 5th wheels,
motor homes, etc.). They are offered in two sizes: 6 and 10 gallon capacities.
TYPE OF GAS IGNITION This unit is ignited inside of the trailer by a remote
ON/OFF
switch. The water temperature is preset at 140° F.
EXPLANATION OF MODEL NUMBER:
Electronic Models
G C H 6 A
-
9
E
Electronic Ignition
Version
Type of heating element
(GC_ A - _ _ = bolt on, GC_ A A-_ _ = screw in)
Gallon capacity (6 or 10)
Engine heat exchange
Combination gas and 110VAC electric
Propane Gas
NOTE: When replacing the element on a combination gas/110 VAC unit, always check the back
of the heater for the type of element it has. It will either be a bolt-on or screw-in
element. They are not interchangeable.
FEATURES
• All units operate on propane gas.
•
A pre-set thermostat set for 140° F. An aftermarket retro-fit adjustable thermostat is available and
adjustable from 110° to 150° F.
•
A heat exchange option is available. The water heater tank must have factory equipped heat exchange
tubes welded on it already. They cannot be added later. A new water heater tank with this feature must be
installed to use the heat exchanger.
•
Skin mounting allows the water heater to be hooked up with plumbing and electrical before the sidewall is
erected.
•
This heater has a comparable, if not superior, anode type protection for the tank. The tank is manufactured
with a clad aluminum lining that protects against corrosion but does not need to be replaced yearly as an
anode rod. A more detailed explanation of cladding is found in the back of this manual.
•
95% of all servicing is done on the outside of the water heater. 110 VAC heating components are the
exception. Since they are located on the back of the water heater inside the trailer.
•
A flush flange is available for all models. This makes the access door flush with the sidewall.
•
There are multiple protection features in the form of a pressure-temperature relief valve, a limit switch in
the gas thermostat and an externally sealed combustion chamber.
•
Both the six and ten gallon units have the lightest weight in the industry.
•
On all trailers purchased after June 1, 1997 the Atwood Limited Warranty is for a period of two years. This
includes all reasonable labor charges.
•
We have 700+ Service Centers throughout the United States.
16
Recommended Tools and Equipment
U-Tube Manometer - This is the most accurate device for measuring gas pressure. If you use a dial-type
manometer, it should be calibrated periodically with this type of manometer.
Multi-meter - This is the most versatile meter and will test continuity and 12VDC. These tests will allow one to
verify voltage problems or faulty components. The entire electronic system can be tested with this meter.
U-TUBE MANOMETER
MULTI-METER TO TEST
CONTINUITY & VOLTAGE
with 1/8” pipe nipple
Fill here
Correct
water
level
7
6
5
4
3
2
1
0
1
2
3
4
5
6
7
Manometer
connection
Circuit Board Tester - The tester is capable of testing any of the circuit boards (Fenwal and Channel models)
that we have used on our water heaters. It is a simple table top device that will diagnose the following items on
a circuit board: power circuit, sense circuit, spark generation and the lock-out mode. For use on circuit boards
with a flying lead connection, splice a wire into the black wire of the tester harness with a 1/4˝ male terminal on
the free end.
CIRCUIT BOARD TESTER
MPD 32779
Common Hand Tools - 1/8˝ and 1/4˝ nut drivers, open end wrenches, flat blade and Phillips screw drivers.
Leak Test Solution - A solution that bubbles when applied to gas fittings or connections showing where a gas
leak is present.
17
DSI Sequence of Operation
• Gas Supply
11˝ W.C to solenoid valve is necessary
• 12VDC Battery
or filtered side
of Convertor
Voltage source to water heater
• ON/OFF Switch
It supplies 12VDC to water heater
• Thermal Cut-Off
A one shot heat sensing fuse that’s normally closed and sends power to the thermostat.
When tripped by excessive heat (190°F), (i.e. blocked burner or flue tube) it cuts power to
the circuit board and shuts down ignition.
• Thermostat
A normally closed non-adjustable temperature switch that sends current to the circuit
board. It opens when the water temperature reaches approximately 140°F.
• Circuit Board
The next step is the direct spark ignition system. For a period of 6-8 seconds the circuit
board will send voltage to both the gas solenoid valve and the electrodes. If ignition does
not occur, the board goes into a lock-out condition and the non-ignition light illuminated at
the ON/OFF switch.
• E.C.O.
A normally closed safety temperature switch that
sends voltage to solenoid valve. The switch opens if
the water temperature exceeds 180°F.
• Electrodes
Creates a spark to ignite gas. If the electrodes do not
sense a flame in 6-8 seconds, a signal is sent to the
board to shut the gas valve down and the system goes
into safety lock-out.
• Gas Valve
The dual solenoid valve that opens and sends gas to
electrodes when a minimum of 10.5 VDC is applied to it.
18
NOTE: If this situation exists, the ON/OFF switch must be
turned off and back on again.
Electronic Ignition Water Heater
TROUBLE SHOOTING GUIDE
Effective: 5/26/98
Guides are only intended for use on Atwood® products by service technicians who have successfully completed
Atwood® training. This guide should be used in conjunction with the appropriate Instruction Manual provided with the
product and any applicable Industry standards. This is not intended to be a complete list. Please direct questions
concerning service of Atwood® products to 800-825-4328 before proceeding.
CAUSE
SOLUTION
WATER HEATER LOCK OUT - SPARK PRESENT BUT NO GAS
Gas pressure incorrect ------------------------------------------Set inlet pressure at a minimum 11˝ W.C. with two or more gas
appliances running
Low voltage--------------------------------------------------------Correct power supply - 10.5 VDC minimum
Blocked main burner tube --------------------------------------Clean burner tube
Blocked main burner orifice ------------------------------------Clean or replace orifice
Loose wires on E.C.O. --------------------------------------------Secure wire connections
Loose wire connections on solenoid valve --------------------Secure wire connections
Loose valve wire on wiring harness ----------------------------Repair wire on edge connector or replace wiring circuit board harness
Defective E.C.O. --------------------------------------------------Replace E.C.O.
Defective circuit board--------------------------------------------Replace circuit board
Defective solenoid valve------------------------------------------Replace coils or solenoid valve
No gas to solenoid valve ----------------------------------------Correct gas supply
Dirty connector on circuit board --------------------------------Clean edge connector
WATER HEATER LOCK OUT - GAS PRESENT BUT NO SPARK
High tension lead wire loose ------------------------------------Secure wire connection on circuit board
Electrodes loosely attached to main burner ------------------Secure electrodes to main burner
Improper electrode gapping ------------------------------------Re-position spark gap to 1/8˝ and into path of flame
Dirty electrodes --------------------------------------------------Clean electrodes
Wires loose in electrode porcelain ------------------------------Replace electrodes
Cracked porcelain on electrode----------------------------------Replace electrodes
Defective circuit board--------------------------------------------Replace circuit board
WATER HEATER LOCK OUT - GAS AND SPARK PRESENT
Gas pressure incorrect ------------------------------------------Set inlet pressure at a minimum 11˝ W.C. with two or more gas
appliances running
Low voltage--------------------------------------------------------Correct power supply - 10.5 VDC minimum
Poor electrical ground--------------------------------------------Secure electrical ground
Electrodes out of flame pattern --------------------------------Re-adjust electrodes
Electrodes sparking to screw fastening burner to flue tube Adjust electrodes away from screw
Dirty electrodes --------------------------------------------------Clean electrodes
Partial obstruction in main burner ------------------------------Clean main burner
Partially obstructed main burner orifice------------------------Clean main burner orifice or replace
Improper air adjustment ----------------------------------------Adjust main burner air shutter approximately 1/4 open
Flame spreader on main burner out of adjustment ----------Adjust flame spreader so that it is square to the end burner tube out
of alignment of the main burner
Manifold not aligned with main burner ------------------------Re-align solenoid valve with main burner
Partially opening solenoid valve --------------------------------Replace solenoid valve
Defective circuit board--------------------------------------------Replace circuit board
continued
19
Electronic Ignition Water Heater (continued)
Effective: 5/26/98
CAUSE
SOLUTION
EXCESSIVE OR INSUFFICIENT WATER TEMPERATURES
By-pass kit valves not set properly ----------------------------Place valves in proper position
Thermostat not seated against tank ----------------------------Reseat thermostat
Defective thermostat----------------------------------------------Replace thermostat
ERRATIC BURNER FLAME OR SOOTING
Low gas pressure ------------------------------------------------Set inlet pressure at a minimum 11˝ W.C. with two or more gas
appliances running
Poor gas supply --------------------------------------------------Replace gas supply
Improper air adjustment ----------------------------------------Adjust main burner air shutter approximately 1/4 way open. Flame
should be mainly blue and quiet.
Poor main burner alignment ------------------------------------Adjust valve and main burner alignment
Misaligned burner flame spreader ------------------------------Align flame spreader so it is square with end of burner tube.
Blocked burner orifice --------------------------------------------Clean orifice. DO NOT enlarge orifice
Obstructed main burner------------------------------------------Clean main burner
Obstructed “U” tube ----------------------------------------------Clean “U” tube
Obstructed exhaust grille ----------------------------------------Remove obstruction
NO SPARK AND NO GAS
No voltage --------------------------------------------------------Correct power supply - minimum 10.5 VDC
Dirty edge connector on circuit board--------------------------Clean edge connector
Defective thermal cut-off ----------------------------------------Replace thermal cut-off
Defective ON/OFF switch ----------------------------------------Replace switch
Defective circuit board--------------------------------------------Replace circuit board
Defective thermostat----------------------------------------------Replace thermostat
20
INTERMITTENT IGNITION
Electronic Ignition Water Heater
INFORMATION GUIDE
Effective: 8/21/00
Guides are only intended for use on Atwood products by service technicians who have
successfully completed Atwood® training. This guide should be used in conjunction with
the appropriate Instruction Manual provided with the product and any applicable Industry
Standards. This is not intended to be a complete list. Please direct questions concerning
service of Atwood® products to 800-825-4328 before proceeding.
®
1.
CHECK ALL OF THE WIRE CONNECTIONS.
Poor or corroded wire connections cause most of the intermittent problems in water heaters. You
should go through and pull all of the wires off any spade connections. Then reconnect them and
ensure the connections are tight and corrosion free.
We want to point out two connections often overlooked.
First, check the (green) ground wire of the circuit board. This wire screws down under
the circuit board mounting screw. If that screw for the board is loose, you may not have a
secure ground.
Second, check the four wire edge connector going into the circuit board. Remove the
circuit board. Take a pencil eraser and clean the marks off the connection of the circuit
board. Reconnect the four wire edge connector onto the circuit board and then immediately
remove it. Look at the edge connection of the board. You need to see four good scratches
in the connection. If you do not see four scratches, then you will need to repair the edge
connector or replace the wire harness.
2.
CHECK THE INTEGRITY AND POSITION OF THE SPARK PROBE ASSEMBLY.
The gap between the sparking probe and the ground probe should be
1/8 inch. The probes should be clean and free of cracks, flaking and
1/8" corrosion. Position the probes so that they are in the path of the gas
flow. Cracks in the ceramic insulator can also be the source of an
intermittent problem. To check for cracks insert a fiber washer or any
other type of insulation material in the 1/8” gap between the rods.
Remove the gas valve from the circuit and turn the unit on. If you see
a spark jumping from the ceramic to the ground rod or bracket,
replace the spark probe.
3.
4.
CHECK THE ALIGNMENT OF THE MAIN BURNER TO THE ORIFICE.
Position the main burner tube (A) so that the gas coming out
of the orifice (B) is going straight down the middle of the
burner tube. If the alignment is off, the gas will bounce down
the tube which will alter the gas flow once it reaches the
spark. Manually shift the valve (C) with your hands to achieve
this alignment.
C
B
A
CHECK THE ALIGNMENT OF THE FLAME SPREADER ON THE BURNER TUBE.
At the end of the burner tube there is a dime-shaped deflector
A disk. This disk spreads the flame out for proper heat distribution.
1/4 open
Align the flame spreader (A) so that it is parallel to the end of the
tube and positioned in the center of the end of the tube. If the
flame spreader is out of position, it could divert the gas away
from the spark and cause intermittent ignition.
continued
21
Intermittent Ignition Water Heater (continued)
Effective: 8/21/00
5.
CHECK THE AIR ADJUSTMENT.
The burner tube has an adjustable air shutter on it at the end where it goes over the orifice.
Position the air shutter so that it is 1/4 of the way open. We are looking for a blue flame with
small traces of yellow in the flame. If the flame is fairly quiet then it is adjusted correctly.
6.
CHECK THE CLEANLINESS OF THE ORIFICE.
The orifice is the hex head brass fitting that is screwed onto the brass manifold of the valve. You
will have access to this part once the burner has been removed. Remove the brass orifice and
clean with isopropyl alcohol. NEVER enlarge the size of the orifice.
7.
CHECK FOR OBSTRUCTIONS IN THE MAIN BURNER TUBE.
The cleanliness of this tube is very important. Spider webs, soot and other debris can
accumulate, causing problems with gas flow down the tube. We recommend cleaning the burner
tube with a brush and not compressed air. Compressed air may not fully remove the obstruction.
8.
CHECK THE CLEANLINESS OF THE FLUE TUBE.
The flue tube is the 2-1/2 inch diameter tube that starts at the bottom right corner of the water
heater (where the main burner flame enters) and comes out the top left. This tube can become
blocked by debris like insect nests or soot. To clean remove the metal flue box in the top left
corner of the water heater. To facilitate cleaning unfold a wire hanger, wrap a rag around the end
and use this to swab out the tube.
9.
CHECK THE VOLTAGE TO THE VALVE.
Make sure that the voltage to the gas solenoid valve is between 10.5 and 13.5 volts DC. Voltage
drops can occur at almost any component. Turn on another twelve volt appliances when you
check the voltage so that you can see how the converter is working with a load. The voltage
itself can be intermittent. With linear converters the 12 VDC varies depending on the 115 VAC.
If the 115 VAC is high then the 12 VDC will be high, and if the 115 VAC is low then the 12 VDC
will be low. If the power to the water heater is connected to the unfiltered side of the converter,
move it to the filtered side.
10. CHECK THE GAS PRESSURE OF THE RV.
Make sure the gas pressure of the RV is checked with preferably the furnace and the range on
to simulate a load. The pressure should be 11 inch water column under load. Besides gas
pressure being at the proper level there are other strange things that can happen inside gas lines
that cause intermittent problems. We have seen oil build up in a gas line that meant there was
good pressure to one appliance but not the correct pressure to another appliance. Moisture
could also build up in the gas line that would freeze and partially block the line. Intermittent
pressure from the regulator of the bottles is still another area that should be investigated.
11. INTERMITTENT CIRCUIT BOARD.
If you have gone through all of the above checks and the intermittent problem is still occurring,
only then check the circuit board. Ensure the circuit board is clean and reasonably moisture free
before you change it.
There are two major points that should have stood out to you from this list.
First, the majority of intermittent ignition problems on Atwood electronic ignition water heaters
can be corrected by cleaning certain components or making simple adjustments.
Second, ignition problems can be found in other components than the circuit board. The circuit
board is not the end all solution to ignition problems. This mindset developed a number of years
ago with the introduction of the first circuit boards that were not very reliable. We’ve learned a lot
since then. Technology has progressed making today’s circuit boards very reliable. The circuit
board can only do what the other components of the water heater allow it to do.
22
**POTTED CHANNEL CIRCUIT BOARDS
Atwood **potted circuit boards can be tested using a
multi-meter. This test must be performed with the
circuit board removed, and the meter set to the ohms
scale. This will check the continuity of all tracks on
the harness connection of the board.
The following steps should be used to test each track.
A. Cross leads of meter to ensure it is registering
continuity.
B. TO TEST POWER TRACK:
Place negative lead of the multi-meter to ground (green
wire) track of edge connection and positive lead of the
multi-meter to top power (brown wire) track of edge
connection. If no continuity, board is defective. *Atwood
does not warranty this installation related failure.
C. TO TEST LAMP TRACK:
Place negative lead of the multi-meter to ground (green
wire) track of edge connection and positive lead of the
multi-meter to lamp (blue wire) track of edge
connection. If no continuity, this indicates blown lamp
track. Circuit board will still fire unit but lamp light will
not come on. This is caused by a short in the blue wire
between the unit and the switch. Wiring must be
corrected before the board is replaced. *Atwood does
not warranty this installation related failure.
D. TO TEST VALVE TRACK:
Place negative lead of the multi-meter to ground (green
wire) track of edge connection and positive lead of the
multi-meter to valve (red wire) track of edge connection.
If no continuity, this indicates a blown valve track.
• If the valve wire is shorting under the flue box –
Atwood will warranty the board.
• If the E.C.O. terminals are contacting the drawn pan
– Atwood will warranty the board only if the inner
tank of the water heater was installed flush on the
floor of the coach.
• If the inner tank of the water heater does not rest
flush against the floor of the coach –*Atwood does
not warranty this installation related failure.
* Installation related failures on circuit boards are the
responsibility of the coach manufacturer.
** Non potted circuit boards can be checked by turning the
board over and visually inspecting each track for a burn
mark or break in the track itself. A burn mark or broken
track indicates the board is blown. Depending on which
track is blown determines whether it is covered under
Atwood’s warranty as stated in section B, C and D.
THERMAL CUT-OFF DEVICE
Current Atwood direct ignition water heaters are equipped
with a thermal cut-off device. This device is located on the
incoming power wire and is connected to the thermostat. The
thermal cut-off is designed to permanently break circuit and
shut down the water heater before excessive heat can cause
damage due to obstructions in the main burner tube or flue
tube caused by spiders or mud wasps. These obstructions
can cause the main burner flame to burn outside the main
burner tube. When the flame or the heat from the flame
contacts the thermal cut-off, the circuit will open.
If there is no heat damage to the thermal cut-off, and if it is
determined defective, Atwood will cover the replacement of
this device under warranty. We will allow .25 hour at your
Atwood approved warranty rate. If there is heat damage the
device performed its safety feature and no warranty labor will
be allowed. Any obstructions should be removed, alignment
checked and gas pressure taken before a new thermal cut-off
is installed.
Note: When replacing a thermal cut-off, also examine the grill
in the access door while the door is in the closed
position. The wide aluminum band of the grill should
be at the bottom. If it is at the top, this condition may
trap exhaust heat and possibly also cause thermal cutoff to trip. To correct, remove the grill from the door
and snap back in place with the wide aluminum band at
the bottom.
THERMOSTAT
The thermostat on this water heater is pre-set at 140° F. The
water heater will cycle off when the water temperature
reaches 140° F. and will generally take 20-25 minutes to
reach this temperature. It will cycle back on when the water
temperature cools down to approximately 115° F. In the latter
part of the heating cycle though, it is very common for the
pressure-temperature relief valve to weep. Refer to the page
covering weeping relief valves to remedy this situation.
If a customer is dissatisfied with the temperature of the
water, first check the water temperature with a cooking
thermometer and verifying that the initial cycle is within the
time noted above. If not, an adjustable thermostat may be
purchased allowing the water temperatures to be adjusted
from 110 - 150° F. It fits in place of the original thermostat.
23
Water Heater Wiring Schematics
Junction Box on Back of Unit
Wiring Schematic
G6A-2E, G6A-3E, GH6-4E,
GH6-3E Water Heaters
(Rear Mount ECO and
Thermostat Models).
Battery
White
Ground
Blue
Brown
White
Red
Non-ignition
Light
Circuit
Board
Orange
Green
REMOTE
SWITCH
White
Valve
Sparker
Wiring Schematic G6A-3E,
G6A-4E, GH6-3E, GH6-4E,
GCH6-4E, G6A-6E, GCH6-6E,
GH6-6E Water Heaters
(Front Mount ECO and
Thermostat Models).
Wire Connection
Battery
Brown
Blue
Green
Red
Brown
Circuit
Board
Red
4
5
6
ECO TSTAT
Red
1
2
3
Red
White
Valve
Sparker
Wiring Schematic G6A-7E, GH6-7E,
GC6A-7E, GCH6-7E, GC6AA-7E,
G6A-8E, GH6-8E, GC6AA-8E,
GCH6AA-8E, GCH6A-9E
Gas Solenoid
Valves
RED
BL
U
BR GRE E
OW EN
N
Non-Ignition
Light
ECO
Switch
BLUE
(6)
(4)
Thermal Cut-Off
BROWN
RED
Wire Connection
BROWN
BROWN
Remote
Switch
(6
(4 )
(3 )
)
(2
)
12 volt DC
(3) (2)
GREEN
Fixed Temperature
Control Thermostat
REMOTE
SWITCH
GREEN
BATTERY
GREEN
Spark & Sense
CAUTION
When servicing controls, label all wires prior to disconnection.
Wiring errors can cause personal injury or property damage.
Verify proper operation after servicing.
Dotted lines are wired by customer
24
GENERAL INFORMATION
QUESTIONS
The following questions should be answered during this portion of the manual:
· What causes the pressure-temperature relief valve to weep when unit is in heating cycle?
· How can weeping pressure-temperature relief valves be reduced or eliminated?
· What are the proper draining procedures to help reduce lime deposits and extend tank life?
· Will a tank split for any other reason besides freezing?
· What functions do the retaining rings serve when replacing an inner tank?
· What are the most common ways to winterize a tank?
25
PRESSURE-TEMPERATURE RELIEF VALVE
Weeping or dripping of a pressure-temperature relief valve while the water heater is running DOES NOT mean it is
defective. This is normal expansion of water as it is heated in the closed water system of a recreation vehicle. The
Atwood water heater tank is designed with an internal air gap at the top of the tank to reduce the possibility of weeping
and dripping. In time, the expanding water will absorb this air. To replace the air follow these steps:
Step 1: Turn off water heater
Step 2: Turn off incoming water supply
Step 3: Open the closest hot water faucet in the coach
Step 4: Pull handle of pressure-temperature relief valve straight out and allow water to flow until it stops.
Step 5: Allow pressure-temperature relief valve to snap shut, turn on water supply and close faucet.
Air Expansion Pocket
Hot Water Outlet
Relief Valve
125/150 psi
210°
1/2" N.P.T.
Drain Plug
Cold Water Inlet
WATER HEATER TANK CORROSION
Pinhole leaks from galvanic corrosion may cause the water heater tank to fail.
Microscopic particles of metals (like iron and copper) suspended in water, set up a reaction inside the water heater that
is not unlike the principle on which an automotive battery operates. The aluminum tank is the anode and the metals in
the water serve as the cathode. Consequently, the aluminum gradually sacrifices itself and aluminum particles are carried
away with the water flow.
A white scaly material (aluminum oxide) often is formed around the points where the heaviest action is taking place and
heat accelerates the process. Severity of the problem varies considerably in different locales depending on the metal and
mineral content of the water. White deposits inside the water heater tank are usually from water impurities that have
settled out.
Periodic flushing of the water heater tank under pressure is recommended to slow down this process. For flushing
instructions see your owners manual or contact Atwood for a copy of our recommended procedure.
ATWOOD CLAD TANK
The Atwood water heater tank is constructed of a core of high strength aluminum. The interior of the tank consists of a
15% thickness of type 7072 aluminum (pure aluminum and zinc) that is fused to the core during the rolling process.
This material protects the tank from the affects of heavy metals and salts found in waters throughout the country. It is
anodic to these heavy metals and acts much like an anode in a steel glass lined tank except it will last much longer.
There is also no need to replace an anode on a yearly basis.
Flushing the tank on a regular basis has been found to be helpful in insuring the best performance of your water hater
and adding to the useful life of the tank. For flushing instructions see your owners manual or contact Atwood for a copy
of our recommended procedures.
26
FLUSHING YOUR WATER HEATER TO REMOVE
THE ROTTEN EGG ODOR
1. Turn off your main water supply. Drain you water
heater tank. Reinstall drain plug. Remove the
pressure-temperature relief valve. With a funnel
use 4 parts white vinegar to two parts water. (In a
6 gallon tank that would be 4 gallons vinegar to 2
gallons water).
WINTERIZING INSTRUCTIONS
1. Turn off your main water supply, that is, your pump or
your water hook up source.
2. Drain your water heater inner tank. Upon doing so, you
will note that, due to the location of the drain plug,
approximately two quarts of water will remain in the
bottom of the tank. This water contains most of the
harmful corrosive particles. If while draining the unit, you
note that it is flowing sporadically or trickling, instead of
flowing steadily, we recommend one of two things. You
should first open your relief valve to allow air into the
tank and secondly, take a small gauge wire or coat
hanger device and prod through the drain opening to
eliminate any obstructions.
2. Cycle the water heater, letting it run under normal
operation 4-5 times. At no time do you remove the
vinegar from the tank Once this has been
completed, remove the drain plug and drain the
water heater.
3. After thoroughly draining the tank, to remove the
sediment, flush the water heater.
If you elect to use air pressure, it may be applied
either through the inlet or outlet on the rear of the
tank or applied through the pressure-temperature
relief valve. Remove the pressure-temperature
relief valve and insert your air pressure through
the pressure-temperature relief valve coupling. In
either case, with the drain valve open, the air
pressure will force the remaining water out of the
unit.
3. After thoroughly draining the tank, you should then flush
it with air pressure or fresh water. If you elect to use air
pressure, it may be applied either through the inlet or
outlet on the rear of the tank. It may also be applied
through the relief valve part. In this case, it will be
necessary to first remove the relief valve support flange.
In either case, with the drain valve open, the air pressure
will force the remaining water, along with the corrosive
particles, out of the unit. However, if air pressure is
unavailable, your unit can be flushed with fresh water.
Fresh water should be pumped into the tank either with
the assistance of the on-board pump or with the
assistance of external water either through the inlet or
outlet found on the rear or the relief valve coupling
located on the front of the unit. Continue this flushing
process for approximately five minutes allowing ample
time for the fresh water to agitate the stagnant water on
the bottom of the tank and thus forcing the deposits
through the drain opening.
If air pressure is unavailable, your unit can be
flushed with fresh water. Fresh water should be
pumped into the tank either with the onboard
pump or external water pressure. External
pressure may be hosed into the unit either
through the inlet or outlet found on the rear of the
tank or the pressure-temperature relief valve
coupling located on the front of the unit.
Continue this flushing process for approximately
five minutes allowing ample time for the fresh
water to agitate the stagnant water on the
bottom of the tank and forcing the deposits
through the drain opening.
4. Upon completion of the steps above, replace the drain
plug and the pressure-temperature relief valve.
4. Upon completion of the steps above, replace the
drain plug and the pressure-temperature relief
valve.
5. After this procedure, there will be approximately two
quarts of water left at the bottom of the inner tank.
Should this water freeze it will not cause any splitting of
the tank.
5. Refill tank with fresh water that contains no
sulphur.
The Atwood water heater is designed for use in a
Recreation Vehicle. If you use your vehicle frequently
or for long periods of time, flushing the water heater
several times a year will prolong the life of the storage
tank.
27
WATER HEATER TERMINOLOGY
Terminology
Terminology
Definition
Definition
AGA
American Gas Association
Main Burner
Access Door
hinged cover on outside of water
heater
Main Burner Air Shutter the slotted sleeve on tube that
allows for gas and air adjustment
By Pass Kit
a combination of hoses and valves
that can aid in the winterization of
the water heater
Main Burner Orifice
CGA
Canadian Gas Association
N.P.T. (Nat'l Pipe Thread) a plumbing measurement standard
Calibration
the condition determining whether
the thermostat is registering
temperatures properly
Cam-Loc Fastener
a door securing device
Circuit Board
an electronic panel that controls the
spark, solenoid valve and senses
the main burner flame
Drawn Pan
metal pan attached to the water
heater tank and fastened to coach
sidewall to isolate combustion to
outside of coach
a gas and air mixing tube
a precision drilled fitting that
regulates the BTU's of
combustion
Pilot Assembly
A gas tube, orifice & thermocouple
Pilot Orifice
a precision drilled thimble shaped
component that meters gas flow
to pilot
Pilot Relight Ignition Module 12 volt electronic panel that
provides spark ignition and flame
sense to maintain pilot flame
Pressure-Temperature
Relief Valve
a pressure and temperature safety
device used on water heating
vessels.
Ring and Gasket
retaining fiber & metal rings that
secure combustion pan to tank
E.C.O. (energy cut off) high temperature re-set shut off
device
Sight Glass
burner flame viewing port on
access door
Electrolysis
electro chemical corrosive process
that can cause pinholes in tanks
Spark Probe Assembly
a spark electrode & flame sensing
Fenwal Tester
a diagnostic circuit board analyzer
Thermal Cut-Off
Flame Spreader
a round deflective piece found at
the combustion end of main burner.
Flue Box
a chamber that separates air intake
and exhaust
heat sensing diode that cuts
power to circuit board if a flame
backs out of the burner tube or
flue tube normally caused by an
obstruction in these areas
Thermostat (gas)
a temperature sensitive device for
turning on and off the flow of gas
(T-stat)
DSI
direct spark ignition a.k.a.
electronic ignition
Flue Tube
combustion and water heating
surface area on inside of tank
Flying Lead
flame sensing wire that is
sometimes found hard wired to
circuit board
Thermostat (120 volt AC) a surface mount temperature
sensitive device that turns on/off
heating element
Front of Water Heater
access door side of water heater
Gas Solenoid Valve
a 12 volt DC device that turns on or
off the flow of gas
Thermostat (12 Volt DC) a surface mount temperature
sensitive device that turns on/off
the voltage to the circuit board
Immersion Element
an AC electrical heating coil that is
immersed directly into water
Inverted Flare
type of connection using double
flare fitting and tube nut
Inner Tank
®
Jade Knob Clip
patented, designed vessel for
heating water
Thermocouple
a device, when heated, generates
millivolts of electricity
UL
Underwriters Laboratories
"U" Tube
also referred to as a flue tube on
some water heater models
Winterization
process of preparing a water
heater for cold winter storage
a horse shoe retainer clip on main
shaft of Jade® Gas thermostat that
allows for proper moving of
ON/OFF knob and shaft
28
ATWOOD WATER HEATER
LIMITED WARRANTY
Warranty Procedures
Atwood water heater, furnace, range, hardware or detector
warranties can be submitted in one of two ways.
Atwood Mobile Products warrants to the original owner and subject
to the below mentioned conditions, that this product will be free of
defects in material or workmanship for a period of two years from
the original date of purchase. Atwood’s liability hereunder is limited
to the replacement of the product, repair of the product, or
replacement of the product with a reconditioned product at the
discretion of the manufacturer. This warranty is void if the product
has been damaged by accident, unreasonable use, neglect,
tampering or other causes not arising from defects in material
workmanship. This warranty extends to the original owner of the
product only and is subject to the following conditions:
If you are already set up with an owner care program with an
OEM, you should submit the faulty part and claim through
their system.
To submit a claim directly through Atwood the following
information is required:
1. Owner’s Name and Address.
2. Date of Purchase - obtain from copy of original bill of sale.
3. Model and Serial Number - The model and serial number,
which is located on every water heater, furnace and range
is required on all Atwood appliance claims.
4. Manufacturer, Model, Year and VIN # of RV.
5. Work Performed - Describe in detail findings of existing
problem and corrective measure taken.
6. Return Parts - A “MUST RETURN” parts list is attached.
Failure to return parts listed will result in denial of your
warranty claim.
7. Return Good Number - a Return Goods Number (RGN)
must accompany all returned parts. This number may be
obtained by calling the Atwood Mobile Products Service
Department at 1-800-825-4328. The RGN must be clearly
marked on the outside of each carton. Failure to do so will
result in your shipment being refused at our receiving
department.
8. Return Freight - Atwood does not accept C.O.D.
shipments. Freight to return parts to Atwood should be
indicated on your claim or repair order and you will be
reimbursed.
9. Travel Time - Because our warranty is based on the
customers ability to present the unit for service, and in an
attempt to maintain our low cost products, reimbursement
for mileage, service calls and travel time WILL NOT BE
ALLOWED.
10. Payment for Warranty Service - All parts are replaced at
no charge, freight prepaid upon our inspection. Labor, on
net 30 accounts is paid by credit memo within 30 days of
receipt of parts.
11. Flat Rate Schedule - A reasonable flat rate schedule for
warranty repairs has been set for each Atwood product
and/or parts. Should unusual circumstances take you
beyond the standard time allowance, you must have prior
approval by contacting the Atwood Mobile Products
Service Department at 1-800-825-4328, and press option
5 after the recording.
1. For a period of two years from the date of purchase, Atwood will
replace the complete water heater if the inner tank leaks due to
corrosion. This warranty includes reasonable labor charges
required to replace the complete water heater.
2. For two years from the date of purchase, Atwood will repair or
replace any part defective in material or workmanship. This
warranty includes reasonable labor charges, required to remove
and replace the part. Service calls to customer’s location are not
considered part of these charges and are, therefore, the
responsibility of the owner.
3. This warranty does not cover the following items classified as
normal maintenance:
a. adjustment of gas pressure
b. cleaning or replacement of burner orifice
c. cleaning or adjustment of burner tube
d. cleaning or adjustment of flue
e. cleaning or adjustment of pilot and thermocouple
f. adjustment of pressure-temperature relief valve
4. In the event of a warranty claim, the owner must contact, in
advance, either a certified Atwood Service Center or the
Atwood Service Department. Warranty claim service must be
performed at a certified Atwood Service Center (a list will be
provided at no charge) or as approved by the Consumer Service
Department, Atwood Mobile Products, 4750 Hiawatha Drive,
Rockford, IL 61103-1298 USA. Phone: (815-877-5700).
5. Return parts (or water heater) must be shipped to Atwood
“Prepaid”. Credit for shipping costs will be included with the
warranty claim. The defective parts (or water heater) become the
property of Atwood Mobile Products and must be returned to the
Consumer Service Department, Atwood Mobile Products, 4750
Hiawatha Drive, Rockford, IL 61103-1298 USA.
6. This warranty applies only if the unit is installed according to the
installation instructions provided and complies with local and state
codes.
7. The warranty period on replacement parts (or water heater) is the
unused portion of the original warranty period.
8. Damage or failure resulting from misuse (including failure to seek
proper repair service), misapplication, alterations, water damage,
or freezing are the owner’s responsibility.
9. Atwood does not assume responsibility for any loss of use of
vehicle, loss of time, inconvenience, expense for gasoline,
telephone, travel, lodging, loss or damage to personal property
or revenues. Some states do not allow the exclusion or limitation
of incidental or consequential damages, so the above limitations
or exclusions may not apply to you.
10. Any implied warranties are limited to two (2) years. Some states
do not allow limitations on how long an implied warranty lasts, so
the above limitation may not apply to you. This warranty gives
you specific legal rights and you may also have other rights which
vary from state to state.
11. Replacement parts (components or tanks) purchased outside of
the original water heater warranty carry a 90 day warranty. This
includes the part at no charge and reasonable labor charges to
replace it.
This Atwood heater is designed for use in recreational vehicles for the
purpose of heating water as stated in the “data plate” attached to the
water heater. Any other use, unless authorized in writing by the Atwood
Engineering Department, voids this warranty.
29
FOR EFFICIENT PROCESSING OF CLAIM
FURNACE/LP DETECTORS
Atwood Mobile Products
Salt Lake City Operations
1874 South Pioneer Road
Salt Lake City, UT 84104
1. Call for a RGN number.
2. Fill Warranty Service Report form out completely.
3. Using tape or a tag mark the returning part with the
RGN #.
4. Package part including the Warranty Service Report in
the box.
5. On the outside of the package clearly mark the RGN
number.
6. Return part to the correct Division of Atwood Mobile
Products.
CO DETECTOR
KIDDE Safety (1-800-880-6788)
1394 South Third Street
Mebane, NC 27302
RANGE/COOK TOPS/DROP-INS/SOL-A-VENTS
Atwood Mobile Products
Wedgewood Operations
6320 Kelly Willis Road
Greenbrier, TN 37073
Return Goods Policy
Effective August 7, 1995, all Atwood defective returns will no longer
be repaired at the warehouses and returned to customers. Defective
returns will be shipped back to the respective manufacturing facility
for problem cause analysis within 30 days of sales. Full credit will be
issued if the cause analysis determines Atwood is responsible. If the
cause analysis determines the customer is responsible, partial or no
credit will be issued.
Warranty Returns - the warranty policy, must return policy and
approved labor rates provide the framework for warranty returns by
product line.
Non-Defective Returns - A restocking fee of 20% will be charged
for handling of overstock returns or standard stock items ordered
incorrectly by the customer providing the product is received in
resalable condition. Product that has been specifically designed at
a customers request is non-returnable. Obsolete or out dated
product will not be accepted for credit.
Shipping Damage - Once the product has been accepted at its final
destination it is the customers responsibility to file a damage claim
with the carrier.
Follow Warranty Procedures for Atwood returns.
Return Parts
When returning parts, there are three divisions responsible for
specific product and their claims. Prior to returning parts, a Return
Goods Number (RGN) must be obtained by calling the Atwood
Mobile Product Service Department at 800-825-4328.
Shipping - Reasonable shipping charges are reimbursed on
defective and warranty parts if the analysis determines Atwood is
responsible for the disposition. All products not shipped via Atwood
trucks should be shipped prepaid via UPS ground unless negotiated
at the time the RGN is given. No collect shipments will be accepted.
Packaging - The RGN must be identified on each container & all
packing information. Product returned must be properly packaged
to prevent shipping damage. Full credit will not be issued on
product sent back on an open skid or improperly packaged.
Additional product boxes are available upon request.
Submit claims to the correct division. Failure to do so makes claim
processing a more difficult and lengthy process delaying payment of your
claims. Together we can maintain a speedy and efficient warranty program.
WATER HEATERS//HARDWARE (jacks, couplers, 5th wheel & braking systems)
Atwood Mobile Products
4750 Hiawatha Drive
Rockford, IL 60013
30
Must Return Parts List
Under Atwood’s Warranty Administration Program we require,
with the return of warranty claims, the specific parts noted below.
Failure to accompany your claims with these parts will result in
the non-shipment of a replacement part, or the non-processing
of the appropriate credit until such time as the part is received by
Atwood.
Before returning the part, a RGN (Return Goods Number) must be
obtained. This number can be acquired for all products except
seating, by calling the Atwood Mobile Products Service
Department at 1-800-825-4328. To obtain RGN’s for seating
components, please call 1-219-522-7891. Without this RGN
appearing on the outside of the shipping carton, the shipment
will be refused at our receiving department.
FURNACE
All parts
HARDWARE
Couplers
Jacks
Actuators
Master cylinders
Shock absorbers
Foundation brakes
Power jacks
Power jack motors
All 5th Wheel items
RANGE & OVENS
Regulators
Oven thermostats
Safety pilot valves
Burner valves
Manifolds
Top pilot valves
12v ignition module
Burners w/ignition
electrode
Complete ranges (BY
APPROVAL ONLY)
SEATING COMPONENTS
All parts
WATER HEATER
Complete water heaters
Inner tanks
Gas thermostat valves
Circuit boards
Gas solenoid valves
Electric thermostats
Heating elements
Pilot assemblies
Spark probe assemblies
E.C.O. & T-stat kits
Thermal cut-offs
Pressure-Temperature
Relief
Valves
Water Heaters
Flat Rate
Schedule
June 17, 2003
TIME ALLOWANCE SCHEDULE
in hours
Replacement of:
Standard Pilot
Electronic Ignition
Model
Model
Access Door.........................................................................................................30 ...........................................................................................30 ......................................................
Circuit Board....................................................................................................N/A ...........................................................................................50 ......................................................
Complete Water Heater ........................................................1.50 ......................................................................................1.75 * ..................................................
Drain Valve or Plug.................................................................................30 ...........................................................................................30 * ..................................................
Electric On-Off Switch ...................................................................50 ...........................................................................................50 * ..................................................
Heating Element ....................................................................................1.00 ......................................................................................1.00 * ..................................................
Inner Tank ............................................................................................................2.00 ......................................................................................2.30 ......................................................
Main Burner...........................................................................................................50 ...........................................................................................50 ....................................................
On-Off Light Wall Switch ......................................................N/A ...........................................................................................75 ......................................................
Pilot Assembly .............................................................................................50 ........................................................................................N/A ......................................................
Pilot Ignitor Module .............................................................................50 ........................................................................................N/A ......................................................
Pressure-Temp. Relief Valve .............................................50 ...........................................................................................50 * ..................................................
Relay ...........................................................................................................................................................................................................................................50 * ..................................................
Solenoid Valve..............................................................................................N/A ...........................................................................................50 ......................................................
Spark & Probe Assembly ......................................................N/A ...........................................................................................50 ......................................................
Thermal Cut Off ........................................................................................N/A ...........................................................................................30 ......................................................
Thermostat & E.C.O. ......................................................................N/A ...........................................................................................50 * ..................................................
Thermostat-electric ...............................................................................50 ...........................................................................................50 ......................................................
Thermostat-gas ......................................................................................1.00 ........................................................................................N/A ......................................................
* indicates time allowed for Electric/Marine units
Note: All flat rates include diagnostic time and when applicable,
gas leak test.
31
First number in matrix refers to
illustration number, the second
is the part number.
PILOT Water Heater
6 - 10 gallon
20
10
21
19
13
17
18
16
13
14
15
5
7
1
3
6
12
10
10
8
9
11
4
10
11
2
26
28
29
22
23
27
23
25
30
24
10 gallon bolt-on
heating element
6 gallon bolt-on
heating element
32
6 &10 gal. screw-in
heating element
G10B, G10C
GC10A-2
GC10A-2P
GC10-1, GC10-2, GC10-2P
G10-1, G10-1P, G10-2, G10-2P
G4SM
G610-3, G610-3E, GH610-3
GC6AA-8, GC6AA-8P
GC6AA-7, GC6AA-7P
GH6-3, GH6-6, GH6-7
G6A, G6A-2, G6A-3, G6A-6,
G6A-6P, G6A-7, G6A-7P
REPLACEMENT PART REFERENCE
September 2003
GC6A, GC6A-3, GC6A-6, GC6A-7
Pilot
Water Heaters
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
93212 Piezo Ignitor Kit - battery operated (not shown)
Retrofits on all pilot model water heaters
92616 Robertshaw Pilot - not shown
92973 Inverted Flare Adapter (not shown)
93923 E.C.O.
92610 Gas Line Grommet (not shown)
No Longer Available (use 91603)
✗
✗
✗
No Longer Available (Use 92942)
✗
✗
✗
✗
✗
✗
91285 Jade Orifice fits 91603 Pilot (not shown)
✗
No Longer Available
✗
✗
✗
✗
90960 Flue Box & Gasket
✗
✗
✗
✗
✗
✗
2
92640 Grille, New Style in Door
✗
✗
✗
✗
✗
✗
3
91602 Robertshaw Thermostat
(3/8" NPT inlet, 3/8" NPT outlet)
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
91601 White Rodger thermostat
(1/4" NPT inlet, 3/8" NPT outlet)
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
91346 Elbow Bushing - 1/4" inlet, 3/8" outlet
1
4
5
6
91044 45° Elbow 3/8" x 3/8" - OLD
91347 Elbow - 1/4" x 3/8" inlet - NEW
✗
✗
✗
✗
✗
92615 Main Burner 6 Gallon
✗
✗
✗
✗
✗
✗
✗
✗
93221 Main Burner 10 Gallon
7
92742 Main Burner Orifice (6 Gal.)
8
93914 Main Burner Orifice (10 Gal.)
91441 90° Elbow 3/8" x 3/8"
✗
✗
✗
✗
92741 Main Burner Orifice Elbow -outlet
✗
✗
✗
✗
✗
9
91603 Jade Pilot
✗
✗
✗
✗
✗
10
91858 Door Hardware Kit
✗
✗
✗
✗
✗
✗
11
91514 Access Door (6 Gallon) Colonial White
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
93993 Access Door (10 Gal.)
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
12
91928 Set of 4 Corner Brackets
✗
13
91857 Drain Plug 1/2"
14
92698 Petcock Drain Valve 1/8"
15
93804 Piezo Electrode - hard-wired
Measure drain coupling
Measure drain coupling
✗
16
93801 Piezo Ignitor Module - hard-wired
17
93803 Piezo Wiring Harness - hard-wired
18
96010 Ring & Gasket Kit for service tank
✗
✗
✗
✗
✗
✗
19
91796 Drawn Pan 6 Gallon Pilot
✗
✗
✗
✗
✗
✗
20
91604 Pressure Temperature Relief Valve
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
93935 Drawn Pan 10 Gallon Pilot
21
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
91240 Styrofoam tank cover - top
✗
No Longer Available (Use 91240 & 91241)
✗
✗
✗
✗
✗
91241 Styrofoam tank cover - bottom
✗
✗
93912 Fiberboard Jacket (10 Gal.)
No Longer Available (Use 91238 & 91239)
91174 Fiberboard Jacket (6 Gal.)
✗
✗
33
✗
✗
21
91238 Styrofoam tank cover - bottom
✗
✗
✗
✗
✗
✗
91239 Styrofoam tank cover - top
✗
✗
✗
✗
✗
✗
✗
22
91182 110VAC On/Off Switch & Jct Box (10 Gal.)
23
91580 110 VAC Element (Bolt-on)
24
92942 110VAC E.C.O. Switch
✗
✗
✗
25
92943 110VAC 140° Thermostat
✗
✗
✗
✗
✗
26
92857 110VAC On/Off Switch (6 Gal.)
92858 110VAC On/Off Switch (10 Gal.)
26
91092 110VAC On/Off Switch (6 Gal.)
✗
✗
No Longer Available (use 910921 or 91116)
No Longer Available (use 91089 or 91182)
✗
✗
✗
✗
91089 110VAC On/Off Switch (10 Gal.)
27
91853 110 VAC Thermostat (Rectangle)
28
91116 110VAC On/Off Switch & Jct Box (6 Gal.)
29
91160 110 VAC Element/Gasket (screw-in)
29
92249 110 VAC Element/Gasket (screw-in)
30
91873 Thermostat/E.C.O. 110 VAC
N/S
93297 Conversion to Pilot 6 gallon 110VAC
N/S
93299 Conversion to Pilot 10 gallon 110VAC
N/S
91591 Conversion to Pilot 6 gallon 110VAC
N/S
91596 Conversion to Pilot 10 gallon 110VAC
✗
✗
✗
No Longer Available (use 92249)
✗
✗
✗
✗
✗
✗
✗
✗
✗
No Longer Available (use 91591)
No Longer Available (use 91596)
✗
✗
34
✗
G4SM
G10-1, G10-1P, G10-2, G10-2P
GC10-1, GC10-2, GC10-2P
GC10A-2P
GC10A-2
G10B, G10C
G610-3, G610-3E, GH610-3
GC6AA-8, GC6AA-8P
GC6AA-7, GC6AA-7P
GH6-3, GH6-6, GH6-7
G6A, G6A-2, G6A-3, G6A-6,
G6A-6P, G6A-7, G6A-7P
REPLACEMENT PART REFERENCE
September 2003
GC6A, GC6A-3, GC6A-6, GC6A-7
Pilot
Water Heaters
ELECTRIC SIDE
ELECTRIC WATER HEATERS
6 gallon screw-in
heating element
10 gallon screw-in
heating element
23
24
19
24
25
25
6 gallon screw-in
heating element
10 gallon screw-in
heating element
16
19
17
18
18
22
21
10 gallon bolt-on
heating element
6 gallon bolt-on
heating element
35
ELECTRONIC Water Heater
6 - 10 gallon
15
12
28
Red
31
15-A
Red
Brown
Brown
14
1
4
6
30
33
29A
4A/B
13
29B
12
12
5
7
5A
8
9
10
11
11
3
2
8A
12
8B
Rear-mount
12VDC
electronic
thermostats
Front-mount
12VDC
electronic
thermostats
28
26
First number in matrix refers to illustration number, the second is the part number.
36
GCH10A-2E, GCH10A-3E, GC10A-2E, GC10A-3E
G10-1E, GH10-1E
G610-3E, GH610-3E
G10-2E G10-3E
GC10-1E, GC10-2E
GH10-2E, GH10-3E
G6A-2E, GH6-3E
✗
✗
✗
✗
✗
✗
93105 Adjustable Thermostat (retrofits
✗
front-mount thermostats) (not shown)
92610 Gas Line Grommet (not shown)
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
1
90960 Flue Box and Gasket
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
2
92640 Grille, New Style in Door
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
3
91514 Access Door (6 Gal.) Colonial White ✗
✗
✗
✗
✗
3
93993 Access Door (10 Gal.)
✗
✗
✗
✗
✗
✗
4
91420 Potted Circuit Board
(post electrode connection)
No Longer Available (Use 91504)
4A
93865 Potted Circuit Board
(Spade Electrode Connection
✗
✗
✗
✗
✗
✗
4B
93851 Potted Circuit Board - Combo
5
91606 Electrode (Remote Sense)
✗
✗
✗
✗
✗
GC10A-4E, GCH10A-4E
GC6AA-7E, GC6AA-8E, GC6AA-9E
✗
GCH6A-10E, GC6AA-10E
GCH6A-7E, GCH6A-8E, GCH6A-9E
✗
G6A-3E, GH6-3E. GH6-4E, G6A-4E
G6A-6E, G6A-7E, G6A-8E
✗
September 2003
GH6-6E, GH6-7E, GH6-8E
✗
REPLACEMENT PART REFERENCE
GCH6-4E, GCH6-6E, GCH6-7E, GC6A-7E
91470 130° Front Mount thermostat (not shown) ✗
Electronic
Water Heaters
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
6
93189 Wiring Harness
6
93191 Wiring Harness Combo
7
91044 45° Elbow 3/8"
8
93870 White Rodger Valve (6 & 10 Gal.)
✗
✗
✗
8A
93243 Gas Valve Bracket - (6 Gal.)
(Use with 93870)
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
10
93914 Main Burner Orifice 10 Gallon
11
91638 Main Burner 6 Gallon
11
92615 Main Burner 6 Gallon
11
96206 Main Burner 10 Gallon
12
91858 Door Hardware Kit
✗
✗
✗
13
91928 Set of 4 Corner Brackets
✗
✗
✗
14
96010 Ring & Gasket Kit for service tank ✗
✗
15
92220 Styrofoam tank cover - bottom
✗
92221 Styrofoam tank cover - top
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
92742 Main Burner Orifice 6 Gallon
✗
✗
✗
91563 Orifice Holder
✗
✗
✗
10
✗
✗
✗
9
✗
✗
✗
94787 Gas Valve Bracket - 1 piece
✗
✗
93862 Gas Valve Bracket - (10 Gal.)
(Use with 93870)
8B
✗
✗
✗
93919 Wiring Harness
✗
✗
No Longer Available (Use 93189)
✗
✗
✗
✗
✗
✗
✗
93868 Electrode (Local Sense)
6
✗
✗
✗
No Longer Available (Use 91504)
✗
✗
✗
✗
✗
✗
✗
5A
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
91238 Styrofoam tank cover - bottom
✗
✗
✗
✗
✗
✗
✗
✗
91239 Styrofoam tank cover - top
✗
✗
✗
✗
✗
✗
✗
✗
37
✗
15-A 93871 Drawn Pan (Electronic 10 Gal.)
GC10A-4E, GCH10A-4E
GCH6A-10E, GC6AA-10E
G6A-3E, GH6-3E. GH6-4E, G6A-4E
G6A-2E, GH6-3E
GH10-2E, GH10-3E
✗
GC10-1E, GC10-2E
✗
G10-2E G10-3E
✗
G610-3E, GH610-3E
✗
G10-1E, GH10-1E
GC6AA-7E, GC6AA-8E, GC6AA-9E
✗
GCH10A-2E, GCH10A-3E, GC10A-2E, GC10A-3E
GCH6A-7E, GCH6A-8E, GCH6A-9E
15-A 91802 Drawn Pan (Electronic 6 Gallon)
G6A-6E, G6A-7E, G6A-8E
September 2003
GH6-6E, GH6-7E, GH6-8E
REPLACEMENT PART REFERENCE
GCH6-4E, GCH6-6E, GCH6-7E, GC6A-7E
Electronic
Water Heaters
✗
✗
✗
✗
✗
✗
✗
No Longer Available (Use 91092 or 91116)
No Longer Available (Use 91089 or 91182)
✗
✗
✗
16
92857 110VAC ON/OFF Switch (6 Gal.)
16
92858 110VAC On/Off Switch (10 Gal.)
16
91092 110VAC ON/OFF Switch (6 Gal.)
16
91089 110VAC On/Off Switch (10 Gal.)
17
91853 110 VAC Thermostat (Rectangular) ✗
18
91580 110 VAC Element (Bolt-on)
19
91182 110VAC On/Off Switch & Jct Box
21
92942 110VAC E.C.O.
✗
22
92943 110VAC 140° Thermostat
✗
23
91116 110VAC On/Off Switch & Jct Box
24
92249 110VAC Elmnt/Gskt (screw-in) Kit
✗
25
91873 Thermostat/E.C.O. 110 VAC
✗
28
91447 Front Mount E.C.O./thermostat
✗
✗
29A
91857 Drain Plug Kit 1/2"
✗
✗
29B
92698 Petcock Drain Valve 1/2"
30
91604 Pressure Temperature Relief Valve ✗
✗
✗
✗
✗
✗
✗
31
91859 Switch 12 VDC-White
✗
✗
✗
✗
✗
✗
✗
31
91959 Switch 12 VDC-Black
✗
✗
✗
✗
✗
✗
✗
31
91230 Switch 12 VDC-White Combo
33
93866 Thermal Cut-off
✗
✗
✗
✗
✗
✗
✗
N/S
90145 Fuse, Mini 2AMP
✗
✗
✗
✗
✗
✗
N/S
N/S
N/S
91224 Junction Box 110V
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
✗
93849 Relay
✗
✗
91222 Junction Box 110V
✗
✗
✗
38
SERVICE TANK KIT
PART NUMBERS
GAS
G6A-2, G6A-3, G6A-6, G6A-7
G10-1, G10-2
GAS PILOT-RELIGHT
G6A-6P, G6A-7P
GC6AA-7P, GC6AA-8P
GAS/PILOT RELIGHT COMBINATION
GC10-2P
G10-1P, G10-2P
GC10A-2P, GC10A-3P
GAS & ELECTRONIC IGNITION
GH10-1E, GH10-2E, GH10-3E
G10-1E, G10-2E, G10-3E
G6A-4E, G6A-6E, G6A-7E, G6A-8E
GH6-4E, GH6-6E, GH6-7E, GH6-8E
GAS/ELECTRIC & ELECTRONIC IGNITION
GCH6-4E, GCH6-6E, GCH6-7E
GC6A-7E
GCH10A-4E
GCH10A-1E, GCH10A-2E, GCH10A-3E
GC10A-4E
GC10A-1E. GC10A-2E, GC10A-3E
GC10-1E, GC10-2E
GCH10-2E
GAS/ELECTRIC COMBINATION
GC6A-3, GC6A-6, GC6A-7, GC6AA-7, GC6AA-8
GCH6A-7E, GCH6A-8E, GCH6A-9E
GCH6A-10E
GC6AA-7E, GC6AA-8E, GC6AA-9E
GC6AA-10E
GC10-1, GC10-2
GC10A-2, GC10A-3
HEAT EXCHANGE
GH6-3, GH6-6, GH6-7
●
●
91028
91060
91053
91059
94205
93953
93952
93950
91642
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
INNER TANK INCLUDES THE FOLLOWING:
●
91641
91596
91593
91592
91591
MODELS
91412
September 2003
91411
REPLACEMENT PART REFERENCE
All tanks include the insulation jacket, rings and
gaskets.
On all combination gas/110VAC tanks, in addition to the
items mentioned above, they will also come equipped
with the 110VAC heating components attached (junction
box, thermostat, ECO and heating element).
39
EHM 4-SM
EHM 6-SM
EHM 11-SM
EHM 20
ELECTRIC WATER HEATER
ALL MARINE WATER HEATER CAPACITIES
1
3
2B
2A
r
4
t
a
Re
n
Fro
10
9
8
7
6
1
5
ITEM
PART
#
STATUS
1
91585
NLA
1
91586
NLA
1
93291
NLA
1
93873
NLA
NLA - MUST BUY NEW UNIT
ITEM
DESCRIPTION
EHM6 Service Tank
EHM6 FHX Tank
EHM11 Service Tank\
EHM11 FHX Tank
PART
#
DESCRIPTION
92248
91745
91740
90037
92942
92943
EHM4-SM Service Tank
Plate
ECO Switch (220V)
Thermostat, ECO, plate, wires (110V)
High Limit
Thermostat (140o)
2/3
90037
Thermostat/ECO Kit
4
5
6
7
91874
90045
92236
91479
91489
91580
91851
92679
91098
91604
92655
91459
91782
91781
Drain Valve 3/4˝
Access Cover (NEW STYLE)
Insulator
Front & Rear Hold Down Bracket (4 & 6 gal)
Front & Rear Hold Down Bracket (11& 20 gal)
Heating Element (110V) and gasket
Heating Element (220V) and gasket
Gasket Heating Element (110V)
Gasket Heating Element (220V)
Relief Valve (50 psi)
Relief Valve (75 psi)
Thermostat for Solenoid Valve (EHP10)
Solenoid Valve (EHP10)
Water Valves (EHP10)
2A
2B/3
2C
3
8
9
10
N/S
N/S
N/S
40
Download PDF