American Water Heater Heavy Duty Commercial Gas BCG3 User Manual

							31
FIGURE 25.
If  the  Temperature-Pressure  Relief  Valve  on  water  heater  weeps 
or discharges periodically, this may be due to thermal expansion.
NOTE: Excessive water pressure is the most common cause 
of  Temperature-Pressure  Relief  Valve  leakage.  Excessive 
water  system  pressure  is  most  often  caused  by  "thermal 
expansion" in a "closed system." See Closed Water Systems 
and  Thermal  Expansion  on  page  12.  The  Temperature-
Pressure  Relief  Valve  is  not  intended  for  the  constant  relief 
of thermal expansion.
Temperature-Pressure Relief Valve leakage due to pressure build 
up  in  a  closed  system  that  does  not  have  a  thermal  expansion 
tank installed is not covered under the limited warranty. Thermal 
expansion tanks must be installed on all closed water systems.
DO  NOT  PLUG  THE  TEMPERATURE-PRESSURE  RELIEF 
VALVE  OPENING.  THIS  CAN  CAUSE  PROPERTY  DAMAGE, 
SERIOUS INJURY OR DEATH.
Explosion Hazar d
Temperature-Pressure Relief  Valve
must comply with  ANSI Z21.22-
CSA  4.4 and  ASME code.
Properly sized temperature-
pressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
ANODE ROD INSPECTION
Property Damage Hazard
Avoid water heater damage.
Inspection and replacement of anode rod required.
CAUTION
The  anode  rod  is  used  to  protect  the  tank  from  corrosion.  Most 
hot water tanks are equipped with an anode rod. The submerged 
rod  sacrifices  itself  to  protect  the  tank.  Instead  of  corroding  tank, 
VENTING SYSTEM
Examine  the  venting  system  every  six  months  for  obstructions 
and/or deterioration of the vent piping.
Remove  all  soot  or  other  obstructions  from  chimney  which  will 
retard free draft.
REMOTE STORAGE TANK TEMPERATURE CONTROL
The  water  temperature  in  the  remote  storage  tank  (if  used)  is 
controlled by the storage tank temperature control.  The sensing 
element  is  mounted  in  the  hot  water  storage  tank,  see  Water 
Piping Diagram section.
A  change  in  water  temperature  in  the  storage  tank  lower  than 
the  tank  temperature  control  setting  will  cause  the  sensor  to 
activate  the  circulating  pump.  The  pump  then  circulates  the 
water through the heater where the thermostat senses the drop 
in water temperature and activates main burner operation of the 
water heater.
If the storage tank temperature control is out of calibration, replace 
with new control.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL 
TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE 
TO THE  WATER HEATER. 
TEMPERATURE-PRESSURE RELIEF VALVE TEST
Burn hazard.
Hot water discharge. Keep clear of  Temperature-
Pressure Relief V alve
discharge outlet.
It  is  recommended  that  the  Temperature-Pressure  Relief  Valve 
should be checked to ensure that it is in operating condition every 
6 months.
When checking the Temperature-Pressure Relief Valve operation, 
make sure that (1) no one is in front of or around the outlet of the 
Temperature-Pressure  Relief  Valve  discharge  line,  and  (2)  that 
the water discharge will not cause any property damage, as the 
water may be extremely hot. Use care when operating valve as 
the valve may be hot.
To check the pressure relief valve , lift the lever at the end of the 
valve several times, see Figure 25. The valve should seat properly 
and operate freely.
If after manually operating the valve, it fails to completely reset and 
continues to release water, immediately close the cold water inlet 
to the water heater and drain the water heater, see Draining And 
Flushing on page 32. Replace the Temperature-Pressure Relief 
Valve  with  a  properly  rated/sized  new  one,  see  Temperature-
Pressure  Relief  Valve  on  pages  12-13  for  instructions  on 
replacement.
MAINTENANCE 
						

							32
5. Ensure  the  drain  hose  is  secured  before  and  during  the 
entire flushing procedure. Flushing is performed with system 
water pressure applied to the water heater.
6.  Open the water heater drain valve to flush the storage tank.
7.  Flush the water heater storage tank to remove sediment and 
allow the water to flow until it runs clean.
8.  Close the water heater drain valve when flushing is completed.
9.  Remove the drain hose.
10.  Fill the water heater - see Filling The Water Heater in this manual.
11.  Turn on the electrical supply to place the water heater back 
in operation.
12.  Allow the water heater to complete several heating cycles to 
ensure it is operating properly.
RECOMMENDED PROCEDURE FOR PERIODIC  
REMOVAL OF LIME DEPOSITS FROM TANK TYPE   
COMMERCIAL WATER HEATERS
The  amount  of  calcium  carbonate  (lime)  released  from  water  is 
in  direct  proportion  to  water  temperature  and  usage,  see  chart.  
The higher the water temperature or water usage, the more lime 
deposits  are  dropped  out  of  the  water.  This  is  the  lime  scale 
which forms in pipes, heaters and on cooking utensils.
Lime accumulation not only reduces the life of equipment but also 
reduces efficiency of the heater and increases fuel consumption.
The usage of water softening equipment greatly reduces the hardness 
of the water. However, this equipment does not always remove all of 
the hardness (lime). For this reason it is recommended that a regular 
schedule for deliming be maintained.
The  time  between  cleaning  will  vary  from  weeks  to  months 
depending upon water conditions and usage.
The depth of lime buildup should be measured periodically. Heaters 
equipped  with  cleanouts  will  have  about  2"  of  lime  buildup  when 
the level of lime has reached the bottom of the cleanout opening. A 
schedule for deliming should then be set up,based on the amount 
of time it would take for a 1" buildup of lime. It is recommended that 
the water heater initially be inspected after 6 months.
Example 1:
Initial inspection after 6 months shows 1/2" of lime accumulation. 
Therefore, the heater should be delimed once a year.
Example 2:
Initial  inspection  after  6  months  shows  2"  of  lime  accumulation. 
Therefore, the heater should be delimed every 3 months.
FIGURE 26.
water ions attack and eat away the anode rod. This does not affect 
water’s taste or color. The rod must be maintained to keep tank in 
operating condition.
Anode  rod  deterioration  depends  on  water  conductivity,  not 
necessarily  water  condition.  A  corroded  or  pitted  anode  rod 
indicates  high  water  conductivity  and  should  be  checked  and/or 
replaced more often than an anode rod that appears to be intact. 
Replacement of a depleted anode rod can extend the life of your 
water  heater.  Inspection  should  be  conducted  by  a  qualified 
technician,  and  at  a  minimum  should  be  checked  annually  after 
the warranty period.
Artificially  softened  water  is  exceedingly  corrosive  because  the 
process substitutes sodium ions for magnesium and calcium ions.
The  use  of  a  water  softener  may  decrease  the  life  of  the  water 
heater tank.
The  anode  rod  should  be  inspected  after  a  maximum  of  three 
years and annually thereafter until the condition of the anode rod 
dictates  its  replacement.    Anode  replacement  is  not  covered  by 
warranty. NOTE: artificially softened water requires the anode rod 
to be inspected annually.
DRAINING AND FLUSHING
Burn harzard.
Hot water discharge.
Keep  hands   clear  of  drain
valve  discharge.
It is recommended that the water heater storage tank be drained 
and  flushed  every  6  months  to  reduce  sediment  buildup.  The 
water heater should be drained if being shut down during freezing 
temperatures. See Features And Components in this manual for 
the location of the water heater components described below.
TO DRAIN THE WATER HEATER STORAGE TANK:
1.  Turn off the electrical supply to the water heater.
2.  Turn off the gas supply at the Main Gas Shutoff Valve if the 
water heater is going to be shut down for an extended period.
3.  Ensure the cold water inlet valve is open.
4.  Open  a  nearby  hot  water  faucet  and  let  the  water  run  until 
the water is no longer hot.
5.  Close the cold water inlet valve to the water heater.
6.  Connect a hose to the water heater drain valve and terminate 
it to an adequate drain.
7.  Open the water heater drain valve and allow all the water to 
drain from the storage tank.
8.  Close  the  water  heater  drain  valve  when  all  water  in  the 
storage tank has drained.
9.  Close the hot water faucet opened in Step 4.
10.  If the water heater is going to be shut down for an extended 
period, the drain valve should be left open.
TO FLUSH THE WATER HEATER STORAGE TANK:
1.  Turn off the electrical supply to the water heater.
2.  Ensure the cold water inlet valve is open.
3.  Open  a  nearby  hot  water  faucet  and  let  the  water  run  until 
the water is no longer hot. Then close the hot water faucet.
4.  Connect  a  hose  to  the  drain  valve  and  terminate  it  to  an 
adequate drain. 
						

							33
Do not smoke or have open flame or sparks in vicinity of heater. 
Do not mix UN•LIME with other chemicals. Do not allow contact 
with magnesium, aluminum or galvanized metals.
Chemical Hazard
• Product contains phosphoric acid.
• Keep out of reach of children.
• Use rubber or neoprene gloves.
Contains  phosphoric  acid.  In  case  of  external  contact,  
flush  with  cool  water.  If  irritation  persists,  get  medical 
attention. If swallowed, give 1 or 2 glasses of water or milk and   
call physician.
Get  immediate  medical  attention  for  eyes.  Keep  out  of  reach 
of children.
NOTE:  THE USE OF RUBBER OR NEOPRENE GLOVES IS 
RECOMMENDED, ESPECIALLY IF YOU HAVE ANY OPEN 
SORES OR CUTS TO AVOID UNNECESSARY IRRITATION 
OR DISCOMFORT.
1.  Turn  off  fuel  and/or  power  supply  to  heater.  Also,  turn 
off power to any electrical device or equipment, which is 
attached, or part of the system.
2.  Open hot water side of faucet closest to heater and allow 
water to run until it is cool enough to handle safely.
3.  Close cold water inlet valve to heater.
4.  Connect hose to drain valve at bottom of heater and start 
draining heater into suitable floor drain area.
5.  Remove  pressure  relief  valve    while  heater  is  draining. 
N OT E: D o not replac e pre s sure reli ef valve  unt il deliming 
is completed. Pressure relief valve  opening will also act 
as a vent in c ase of possible c ontact bet ween the delimer 
and  the  anode  rod(s),  which  may  produce  flammable 
hydrogen-air mixtures.
6.  If pressure relief valve  appears to be limed-up, place it in a 
clean glass or plastic container adequate in size so that you 
can pour enough UN•LIME® into container to cover the valve 
and allow space for foaming. When foaming stops, run fresh 
cool  water  into  the  container  and  rinse  the  pressure  relief 
valve  for a few minutes.
7.  If  heater  does  not  drain  completely  after  a  reasonable 
length of time, turn off the main water supply valve to stop 
water from entering the tank due to a by-pass problem or 
defective  cold  water  inlet  valve.  Also,  check  for  clogged 
drain  valve  opening.  Heater  must  be  completely  drained 
before introducing UN•LIME.
8.  Remove  the  cleanout  cover  and  place  a  clean  plastic 
bucket next to the cleanout opening.
Partially  open  the  cold  water  inlet  valve  to  allow  time  to 
accomplish the following and then close the valve.
DELIMING SOLVENTS
UN•LIME is recommended for deliming.  UN•LIME is a patented 
food grade acid which is safe to handle and does not create the 
harmful fumes which are associated with other products.
UN•LIME  may  be  obtained  from  your  dealer,  distributor  or 
water  heater  manufacturer.  Order  Part  Number  9005416105,   
1 gallon, packed 4 gallons per case or Part Number 9005417105, 
5 gallon  container.
NOTE: Un•Lime is not available for use in Canada.
Hydrochloric base acids are not recommended for use on glass 
lined tanks.
Observe handling instructions on label of product being used. 
TANK CLEANOUT PROCEDURE
The  following  practices  will  ensure  longer  life  and  enable  the 
unit to operate at its designed efficiency:
1.  Once a month the heater should be flushed. Open drain valve 
and allow two gallons of water to drain from heater. Inlet water 
valve should remain open to maintain pressure in tank.
2.  A  cleanout  opening  is  provided  for  periodic  cleaning  of  the 
tank. Gas must be shut off and heater drained before opening 
cleanout.
To clean heater through cleanout opening, proceed as follows:
3.  Drain heater.
4.  Remove outer cover plate from lower side of heater jacket.
5.  Remove six (6) hex head screws securing tank cleanout plate 
and remove plate.
6.  Remove  lime,  scale,  or  sediment  using  care  not  to  damage 
the glass lining.
7.  Inspect  cleanout  plate  gasket,  if  new  gasket  is  required, 
replace with part no. 9004099215.
8.  Install  cleanout  plate.  Be  sure  to  draw  plate  up  tight  by 
tightening screws securely.
9.  Replace outer jacket cover plate. 
In some water areas the sediment might not be removed by this 
method  and  may  result  in  the  water  heater  making  rumbling  or 
boiling  noises.  To  dissolve  and  remove  these  more  stubborn 
mineral deposits, UN•LIME Professional Delimer should be used.
DELIMING USING FLO- JUG METHOD
UN•LIME in the 5 gallon size is recommended for deliming of all 
models.  Contact  your  local  dealer,  distributor  or,  water  heater 
manufacturer:
Prepare the Water Heater
To  delime  the  water  heater  using  the  Flo-Jug  method,  first 
prepare the heater for deliming.
Explosion Hazard
Flammable hydrogen gases
may be present .
Keep all ignition sources away
from faucet when turning on
hot water. 
						

							34
FIGURE 27.
PILOT BURNER
At  least  once  a  year,  check  the  pilot  burner,  Figure  29,  and  the 
main  burner,  Figure  30,  for  proper  operation.  See  Figure  28  for 
the location of the Pilot Burner and the Main Burners. For access 
to pilot, unfasten two screws to burner cover and remove.  Locate 
the burner with pilot and remove screw holding burner to manifold. 
Unfasten pilot tubing from valve and slide out burner and pilot.
Servicing  of  the  pilot  burner  includes  keeping  pilot  free  of  lint, 
cleaning the burner head, the primary air opening and the orifice 
of the pilot burner.
FIGURE 28.
FIGURE 29.
Pilot burner flame is affected by:.
1.  Low gas pressure.
•  Adjust  pilot  flame  by  means  of  the  pilot  gas  adjustment 
located on the gas control valve. See Figure 31.
•  The pilot flame should envelop sensing device with 5/8” (1.6cm) 
flame, Figure30. Remove pilot adjustment cover screw, Figure 
31.  Turn  inner  adjustment  screw  clockwise  to  decrease,  or 
counterclockwise  to  increase  pilot  flame.  Be  sure  to  replace 
cover  screw  on  gas  control  valve  after  adjustment  to  prevent 
possible gas leakage.
2.  Clogged pilot burner orifice.
•  Clean or replace orifice. A clogged orifice will restrict gas flow.
While  the  water  is  being  run  through  the  tank,  insert  a 
stiff  wire,  copper  tube  flattened  at  one  end  or  an  opened 
wire  coat  hanger  through  the  cleanout  opening  and 
scrape  out  any  loose  deposits  of  scale  or  sediment.  This 
is  an  economical  way  to  avoid  unnecessary  usage  of  the 
deliming solution.
Repeat the opening and closing of the cold water inlet valve 
as  necessary  but  be  sure  the  heater  is  completely  drained 
when ready to introduce the UN•LIME.
Upon completion, reinstall the cleanout cover and use a new 
cleanout cover gasket (part number 9004099215).
Remove the drain valve.
9.  Install the long plastic male adapter insert fitting into the drain 
valve opening of heater after applying Teflon tape or paste to 
threads. Tighten firmly by hand and use wrench or adjustable 
pliers to check for secure connection. Do not over tighten to 
avoid damage to threads and fittings.
Prepare the Up-N-Down Transfer Kit
The next step is the preparation on the Up-N-Down Transfer Kit, 
if you have not already done so:
1.  With  the  5  gallon  Up-N-Down  container  in  the  vertical 
position,  unscrew  the  plastic  vent  cap  in  the  handle  and 
pierce  the  plastic  membrane  over  the  vent  boss  under  the 
cap to allow the container to vent.
Note:  If your container does not have the vent cap and vent 
b o s s, dr ill a 3 /16 ” h o l e in t he handl e.  W hen you have fi nishe d 
deliming  you  will  be  able  to  plug  this  drilled  vent  with  the 
stainless steel screw that is supplied with the kit.
2.  Remove  the  container’s  cap  and  cut  the  plastic  membrane 
located in the 3/4” IPT opening in the cap.  Take care to not 
damage the threads.
3.  Find the 3/4” male adapter, apply teflon tape to the threaded 
end and screw it into the 3/4” IPT opening in the cap.
4.  Put  cap  with  male  adapter  back  on  the  container  and  slide   
3/4” hose over end of male adapter and fasten in place using 
hose clamp provided.
Delime using Flo-Jug Method
5.  Slide  the  hose  clamp  over  end  of  hose  and  slide  hose  over 
the  male  adapter  in  the  water  heater  drain  opening  and 
secure in place using hose clamp.
6.  Lift  container  to  the  “Pour”  Position,  see  Figure  27,  being 
careful  to  keep  the  vent  in  the  handle  above  the  liquid  level 
and pour the UN•LIME into the heater.
7.  Lower container, you may have to place the container on its 
empty carton to prevent the UN•LIME from flowing back into 
the container.
8.  Let  UN•LIME  remain  in  the  heater  for  5  minutes  and  then 
lower the container to the “Drain” Position, see Figure 27.
9.  Deliming activity is indicated by foaming on the surface of the 
UN•LIME. If there is deliming activity, repeat steps 6 thru 8.
Normally,  lime  removal  will  be  completed  within  one  hour.  
Severe build-up of lime may take longer than an hour to complete 
descaling.
Note:  To  check  UN•LIME  for  continued  use,  place  some  scale 
or  white  chalk  in  a  glass  with  a  small  amount  of  UN•LIME.    If 
the  material  is  vigorously  dissolved  by  the  UN•LIME,  it  can  be 
reused; if not, the UN•LIME should be replaced.  
						

							35
GAS CONTROL VALVE
Figure 31 shows the two types of combination gas control valves
used on these heaters.
If  gas  control  valve  becomes  defective,  repairs  should  not  be 
attempted. A new valve should be installed in place of defective one.
LP VALVE
NATURAL VALVEFIGURE 31.
SERVICE
The installer may be able to observe and correct certain problems 
which may arise when the unit is put into operation.  HOWEVER, 
it  is  recommended  that  only  a  qualified  service  technician  or 
qualified agencys, using appropriate test equipment, be allowed 
to service the heater.
As  preliminary  step,  check  wiring  against  diagram,  check  for 
grounded, broken or loose wires.  Check all wire ends to be sure 
that they are making good contact.ELECTRICAL SERVICING
LABEL ALL  WIRES  PRIOR TO  DISCONNECTION  WHEN  SERVICING  
CONTROLS.  WIRING  ERRORS  CAN  CAUSE  IMPROPER  AND 
DANGEROUS OPERATION.
VERIFY PROPER OPERATION AFTER  SERVICING.
Pilot sensing device must sense a flame before sparking will stop.
Loose  wires  or  a  draft  may  cause  intermittent  or  abnormal 
sparking.  To  eliminate  this  condition,  first  correct  loose  wiring 
condition, and then, if necessary, increase pilot flame.
MAIN BURNER
The  main  burner,  Figure  30,  should  display  the  following 
characteristics:
• Cause rapid ignition and carry over of flame across entire burner.
•  Give reasonably quiet operation during ignition, burning and extinction.
• Cause no excessive lifting of flame from burner ports.
If the 
preceding  burner  characteristics  are  not  evident,  check  for 
accumulation  of  lint  or  other  foreign  material  that  restricts  or  other 
foreign material that restricts or blocks air openings to burner
 or heater.
To clean main burners:
1.  Remove main burners from unit.
2.  Check that burner venturi and ports are free of  foreign matter.
3.  Clean burners with bristle brush and/or vacuum cleaner 
  DO  NOT distort burner ports or pilot location.
4.  Reinstall burners in unit. Make sure front and rear of burners
  are installed correctly in burner support brackets.
Also check for good flow of combustion and ventilating air to the unit.
TYPICAL PILOT AND MAIN BURNER FLAMES
FIGURE 30.  
						

							36
receptacle.  Do  not  push  meter  leads  into  harness  receptacle. 
This  opens  the  pins  and  will  create  connection  problems.  See 
the  following  EFFIKAL  RVGP-KSF-SERIES  FLUE  DAMPER 
TROUBLE SHOOTING GUIDE.
Green LED  Flash Code a   Indicates   Next Syste m A ction   Reco mmended  Service  Act ion   
OFF     No “Call for Heat”     Not applicab le     None   
Flash  Fast     Power  up   -   in ter nal  check     Not applicab le     None   Heartbeat    Norma l startu p  –   ig niti on   
seque nce starte d (incl udi ng  
prep urge)     Not appl
icab le     None   
4 Seco nds  
ON the n “ x”  
fl ash es    Devi
ce in run  mode. “ x” =  flame  
cu rre nt to t he  ne arest   μ A.     Not appl
icab le     None   
2    5 minute Retry D elay   -   Pil ot f lame  
n ot d etected d uring tri al for i gnit ion     In
iti ate n ew tri al for i gnit ion  after  
retry del ay compl eted.    If system fai
ls to  ligh t o n n e xt tri al  
for i gniti on  ch eck  gas s uppl y, pi lot  
bu rner, spark a nd  flame sense  
wi rin g, fl ame rod co ntami nat ed or  
ou t o f posi tion , b urn er gro und  
connecti on.   3    Recycle  -   Fl ame fail ed during r un    Initi ate n ew tri al for i gnit ion . Fl ash   
code wi ll rema in  t hro ug h t he  
i gn it ion  tri al u ntil fl ame  is proved.    If system fai
ls to  ligh t    o n n e xt tri al  
for i gniti on , ch eck gas s uppl y, pi lot  
bu rner, fl ame se nse wi ring,  
con tami nati on  of fl ame rod, b urn er  
ground co nnecti on.   
4     Flame sen sed out of seq ue nce     If situati on  sel f corrects wi thin  10  
seco nds, co ntrol  ret urn s to  normal   
seque nce. If fl am e o ut of  
seque nce remai ns l on ger t han 10  
seco nds, co ntrol  will resu me  
n orm al operati on 1  ho ur aft er error  
i s corrected.     Ch
eck for pi lot f lame. Repl ace gas  
val ve i f pilot f lame presen t. If n o  
pil ot fl ame, cyc le “Call  for Heat.” If  
error repeats, re place con  trol.   
6     Control  In ter nal  Error      Control  remai ns i n wai t mode.  
W hen  the fa ult corrects, co ntrol   
resumes  normal  operati on.    Cycl
e “Call  for Heat”. If error  
repeats, repl ace control .   
7     Flame rod sh orted to gro und     Control  remai ns i n wai t mode.  
W hen  the fa ult    corrects, co ntrol   
resumes  normal  operati on.    Ch
eck fl ame sense l ead wire for  
damage or s horti ng. C heck t hat  
fl ame rod i s in  proper posi tion .  
Ch eck fl ame rod cerami c for  
cracks, damage  or tracking.   8   Low seco ndary v oltage su ppl y    Con trol  remai ns i n wai t mo de.  When  the fa ult corrects, co ntrol   
resumes  normal  operati on.   Ch eck tra nsforme r and AC l in e for  proper i np ut vol tage to t he  co ntrol .  
Ch eck wi th full system l oad on the  
tran sformer.   
  a   Fl ash  Code Desc ripti on s:   
-    Fl ash  Fast: rapi d blin ki ng.    
-    Heartbeat: Consta nt ½ sec ond bri ght, ½  seco nd di m cycl es.  
-    4 seco nd sol id on  pulse fol lowed by “x ” 1 seco nd fl ash es indi cates fl ame cu rrent  to  the  nearest   μ A.  This i s on ly avail able  in  r un  mo de.   
-    A si ngl e fl ash  code  numbe r signifi es th at the L ED fl ashes X ti mes at 2H  z, remai ns o ff for two seco nd s, a nd t he n repeats t he seque nce.    
TROUBLESHOOTING
IGNITION MODULE
Before  calling  your  service  agent,  the  following  checklist  should 
be examined to eliminate obvious problems from those requiring 
replacement or servicing.
•  Check  that  “main  manual  gas  shut-off  valve”  is  fully  open 
and that gas service has not been interrupted.
•  Check  that  after  following  the  water  OPERATING 
INSTRUCTIONS,  the  “Top  Knob”  of  the  gas  control  valve 
is in “ON” position. • 
Check  electrical  supply  to  the  water  heater  for  possible 
blown (or tripped) fusing or power interruption.
•  Is  the  water  temperature  in  tank  below  the  thermostat  dial 
setting on the thermostat (calling for heat)?
•  It is possible that the high limit (E.C.O.) has functioned to shut 
off the  water heater . See FEATURES - Water  Temperature 
Control for reset procedure. Contact your serviceman if limit 
continues to function to shut off water heater.
FLUE DAMPER
Do not turn damper open manually or motor damage will result, 
use  the  service  switch.  All  readings  are  taken  from  harness   
						

							37
PIN END VIEW
24 V.A.C. NORMAL SEQUENCE OF OPERATION       
B. DAMPER HAS OPENED, 
 NO COMBUSTION
  VOLTAGE ACROSS:
  4 & 1; 4 & 2; 4 & 3:  1. Check for power at ignition module terminals.  If 24VAC power is present damper  
        is working properly.     
    2. Defective component in water heater after the flue damper.   
    3. If 24 VAC is not present at the ignition module, look for  loose or broken 
          connections between damper and ignition module.
    4.  If the connections from damper to ignition module seem  proper, replace damper    
     assembly. If a damper assembly  is not available, place the service switch in the   
     hold open  position. This  should keep the damper in the open position and allow   
     the customer to have automatic heat, until a replacement damper can be installed.
C. DAMPER ROTATES  
     CONTINUOUSLY  Change the entire damper assembly
D. DAMPER STICKS  1.  Make sure no screws obstruct the damper blade.
    2.  Make sure damper pipe assembly is not egg shaped.
    3.  Make sure damper rod is not rubbing on pipe assembly.  
          See figure on front page of this insert sheet
    ABNORMAL OPERATION
A. NOTHING WORKING
  NO VOLTAGE ACROSS:
  4 & 1  1. High Limit has tripped and is OPEN. Determine reason for tripping of high limit   
    2. Bad Transformer
    3. Loose or broken connections
    4. Blown fuse or circuit breaker
    5. Disconnect switch off
    6. Harness not plugged into water heater receptacle
A. FLUE DAMPER OPEN OR OPENING
 (Unit is calling for heat and damper disc should be in vertical position)
  VOLTAGE ACROSS:
  4 & 1  All Times that High Limit is closed 
  4 & 2  Calling for Heat  Open or Opening 
  4 & 3  During Combustion  Damper Open+
B. FLUE DAMPER CLOSED (Unit is not calling for heat and damper disc should be in horizontal position)
  NOTE: POSITION 4 IS COMMON AND POSITION 3 IS HOT 24VAC
  VOLTAGE ACROSS: 
  4 & 1  All Times that High Limit is closed
  NO VOLTAGE ACROSS:
  4 & 3 or 4 & 2  1.Thermostat not calling for heat.   
EFFIKAL RVGP-KSF-SERIES FLUE DAMPER TROUBLE SHOOTING GUIDE
Do not turn damper open manually or motor damage will result, use the service switch.
All readings are taken from harness receptacle.  Do not push meter leads into harness receptacle. 
 This opens the pins and will create connection problems.
 WARNING
Do not negate the action of any existing safety
or operational controls.
IMPORTANT: DAMPER MUST BE OPEN BEFORE COMBUSTION TAKES PLACE.  If all steps have  been tried and damper problems persists call Product Service and Support\
 800-456-9805.
NOTE: DAMPER DISC SHOWN IN OPEN POSITION.
Effikal Pinouts    Adapter wire
& wire colors  Function colors in*
1. Brown  24 VAC HOT Black
2. Orange  Signal In Yellow
3. Yellow  Signal Out  Red
4. Black  24 VAC Common  White
        
						

							38
COMPLAINTCAUSE REMEDY
USER QUALIFIED SERVICE AGENCY
Water not hot enough. Thermostat set too low.
Set thermostat dial to a higher 
temperature.
Upper and/or lower temperature  probe out of calibration. Call qualified service agency. Check continuity and resistance 
(Ohms) of upper and lower 
thermostat probes. Replace probes  if out of specification.
Insufficient hot water Thermostat set too low.
Set thermostat dial to a higher 
temperature.
Upper and/or lower temperature  probe out of calibration. Call qualified service agency. Check continuity and resistance 
(Ohms) of upper and lower 
thermostat probes.  Replace probes  if out of specification..
Main manual gas shutoff valve  partially closed. Open main manual gas shutoff 
valve to fullest extent.
Heater too small for demand. Space usage to give heater time 
to restore water temperature.
Heater recovery is slower. Call qualified service agency. Check gas input. If incorrect, adjust 
gas pressure or replace main burner  orifice.
Draft hood not installed or one  or more baffles. Call qualified service agency. Install draft hood or baffles as 
furnished with unit.
Water temperature too hot. Thermostat set too high.Set thermostat to a lower setting.
Heater makes sounds: sizzling. Condensation on outside of 
tank - normal.
Rumbling. Sediment accumulation on 
bottom of tank. Drain a quantity of water through 
drain valve. If rumbling persists,  call a qualified service agency. Delime heater.
Ticking or metallic sounds. Expansion and contraction-
normal.
Pounding / water hammer. Air chambers in piping have 
become waterlogged. Thermal  expansion tank damaged, improperly charged, or  improperly sized. Drain piping system and refill. 
Heater must be off while this 
is being done. Check thermal 
expansion tank charge pressure 
when the water system pressure  is zero. Follow the manufacturer's
instructions for proper charging of the thermal expansion tank.
Combustion noises. Too much primary air.
Adjust shutters.
Overtired heater. Incorrect 
burners or orifice for types of  gas used. Call qualified service agency.
Check and correct as necessary.
Water leaks. Drain valve not closed tightly.
If drain valve cannot be closed 
tightly, replace.
If leakage source cannot be  corrected or identified, call  qualified service agency. Shut off gas supply to heater 
and close cold water inlet valve to  heater. Repair or in case of suspected tank 
leakage, be certain to confirm before  replacing heater.
Gas odors. Heater is overtired.Shut off gas supply to heater and 
call qualified service agency. Check for sooted flue passage.
Check for obstructed vent line.
Check backdraft or lack of draft.
Draft hood may be improperly installed or not sized properly.
Possible gas leaks. Shut off gas supply to heater and 
call gas company at once.
TROUBLESHOOTING CHECKLIST  
						

							39
c.  A  sulfate  reducing  bacteria  which  has  accumulated 
within  the  water  heater  (this  harmless  bacteria  is 
nontoxic to humans).
d.   An excess of active hydrogen in the tank. This is caused 
by the corrosion protective action of the anode rod.
Smelly  water  may  be  eliminated  or  reduced  in  some  water 
heater  models  by  replacing  the  anode  rod(s)  with  one  of  less 
active material, and then chlorinating water heater tank and all 
water lines.
Contact  the  local  water  heater  supplier  or  service  agency  for 
further  information  concerning  an  Anode  Rod  Replacement  Kit 
and this chlorination treatment.
If smelly water persists after anode rod replacement and chlorination 
treatment,  we  can  only  suggest  that  chlorination  or  aeration  of  the 
water  supply  be  considered  to  eliminate  the  water  problem.
Do  not  remove  the  anode  rod  leaving  the  tank  unprotected.  By 
doing so, all warranty on the water heater tank is voided.
“AIR” IN HOT WATER FAUCETS
HYDROGEN  GAS:  Hydrogen  gas  can  be  produced  in  a  hot 
water  system  that  has  not  been  used  for  a  long  period  of  time 
(generally  two  weeks  or  more).  Hydrogen  gas  is  extremely 
flammable and explosive. To prevent the possibility of injury under 
these  conditions,  we  recommend  the  hot  water  faucet,  located 
farthest away, be opened for several minutes before any electrical 
appliances  which  are  connected  to  the  hot  water  system  are 
used  (such  as  a  dishwasher  or  washing  machine).  If  hydrogen 
gas is present, there will probably be an unusual sound similar to 
air  escaping  through  the  pipe  as  the  hot  water  faucet  is  opened. 
There  must  be  no  smoking  or  open  flame  near  the  faucet  at  the 
time it is open.
HIGH WATER TEMPERATURE SHUT OFF SYSTEM
This  water  heater  is  equipped  with  a  manual  reset  type  high  limit 
(Energy  Cutout)  switch.  The  high  limit  switch  interrupts  the  main 
burner gas flow should water temperature reach 203°F (95°C).
In  the  event  of  high  limit  switch  operation,  the  water  heater 
cannot  be  restarted  unless  the  water  temperature  is  reduced 
to  approximately  120F  (49C). The  high  limit  reset  button  on  the 
front of the thermostat then needs to be depressed. See Figure 2 
for the location of the reset button.
START UP CONDITIONS
SMOKE/ODOR
It is not uncommon to experience a small amount of smoke and 
odor  during  the  initial  start-up.  This  is  due  to  burning  off  of  oil 
from metal parts, and will disappear in a short while.
STRANGE SOUNDS
Possible noises due to expansion and contraction of some metal 
parts during periods of heat-up and cool-down do not necessarily 
represent harmful or dangerous conditions.
Condensation causes sizzling and popping within the burner area 
during  heating  and  cooling  periods  and  should  be  considered 
normal. See “Condensation" section in this manual.
CONDENSATION
Whenever  the  water  heater  is  filled  with  cold  water,  some 
condensate will form while the burner is on.  A water heater may 
appear  to  be  leaking  when  in  fact  the  water  is  condensation.  
This usually happens when:
a.   A new water heater is filled with cold water for the first time.
b.   Burning  gas  produces  water  vapor  in  water  heaters, 
particularly  high  efficiency  models  where  flue  temperatures 
are lower.
c.   Large amounts of hot water are used in a short time and the 
refill water in the tank is very cold.
Moisture from the products of combustion condense on the cooler 
tank  surfaces  and  form  drops  of  water  which  may  fall  onto  the 
burner or other hot surfaces to produce a “sizzling” or “frying” noise.
OPERATIONAL CONDITIONS
HOT WATER ODOR
In each water heater there is installed at least one anode rod for
corrosion  protection  of  the  tank.  Certain  water  conditions  will 
cause  a  reaction  between  this  rod  and  the  water.  The  most 
common  complaint  associated  with  the  anode  rod  is  one  of  a 
“rotten  egg  smell”  in  the  hot  water.  The  smell  is  a  result  of  four 
factors which must all be present for the odor to develop:
a.   A concentration of sulfate in the supply water.
b.   Little or no dissolved oxygen in the water.
FOR YOUR INFORMATION  
						

							40
WATER PIPING DIAGRAMS
NOTES:
1 .  Pref erred  piping  diagram.
2 .  The t emperat ure and  pressure  relief valve  setting  shall not exceed  pressure  rating  of  any  component  in the  syst em.
3 .  Servic e v alv es  are s hown f or serv icing  unit. However , local  codes  shall govern t heir usage.
4 .  The  Tank  Temperat ure Cont rol should  be wired t o and  control the pump  between t he wat er heat er(s)  and the storage t ank(s).
5 .  The  wat er heat er’s  operat ing thermost at  should  be set  5 degrees F higher t han the Tank  Temperat ure Cont rol.MUL TI FLUE  - (1 UNIT) WITH VE RTICAL  STORAGE  TANK
LEGEND
TEMPERA TURE & PRESSURE
RELIEF V ALVEPRESSURE RELIEF V ALVECIRCULA TING PUMPTA NK  TE M PER AT URE CO NTR O LDRAIN
FULL  POR T BALL  VALV
E
TEMPERA TURE GAGEW ATER FLOW SWITCH
CHECK V
ALVE
W ARNING:  THIS DRA WING SHOWS SUGGESTEDPIPING CONFIGURA TION  AND OTHER DEVICES;
CHECK WITH LOCAL  CODES AND ORDINANCES
FOR  ADDITIONAL  REQUIREMENTS.
FINISHED
FLOOR
HOT W ATER
T O FIXTURES
COLD WATER
SUPPLY
EXPANSION
TANK
ALT. COLD WATER
CONNECTION
HOT
 WATER  RETURN
FROM  FIXTURES
PIPE T&P TO
OPEN DRAIN