A.O. Smith GPVL-50 Service Handbook
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A.O. Smith GPVL-50 Service Handbook

Residential gas water heaters power vented gas models with hot surface ignition not for use in manufactured (mobile) homes
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RESIDENTIAL GAS WATER HEATERS
1206
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES

TABLE OF CONTENTS

Note: References to the Manual refer to the "Installation
and Operating Manual".
Service Handbook
POWER VENTED GAS MODELS
WITH HOT SURFACE IGNITION
322153-000 Rev. 00
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Summary of Contents for A.O. Smith GPVL-50

  • Page 1: Table Of Contents

    Service Handbook RESIDENTIAL GAS WATER HEATERS POWER VENTED GAS MODELS WITH HOT SURFACE IGNITION NOT FOR USE IN MANUFACTURED (MOBILE) HOMES TABLE OF CONTENTS GENERAL INFORMATION CHECKING THE GAS SUPPLY PRESSURE LEAKAGE CHECKPOINTS TEMPERATURE ADJUSTMENT ANODE ROD REMOVAL/REPLACEMENT DIP TUBE REMOVAL/REPLACEMENT DOOR-BURNER ASSEMBLY REMOVAL/ REPLACEMENT FLAME SENSOR AND IGNITER REMOVAL/...

  • Page 2: General Information

    GENERAL INFORMATION Draw effi ciency is the quantity of hot water available to the Formulas and Conversions: consumer before the outlet water temperature decreases BTU (British Thermal Unit) is the heat required to raise 1 by 25F° (14C°). A 40 gallon water heater will typically pound of water 1F°...

  • Page 3: Checking The Gas Supply Pressure

    CHECKING THE GAS SUPPLY PRESSURE Gas pressure checks are done with fl owing gas using a gas pressure manometer capable of reading pressure in inches of water column. Supply gas pressure checks are measured before the gas control valve and as close to the water heater as possible. Manifold (main burner) gas pressure is measured at the pressure tap on the bottom of the gas control valve (see Figure 1).

  • Page 4: Leakage Checkpoints

    LEAKAGE CHECKPOINTS A. Water at the blower assembly is water vapor which has condensed out of the combustion products. This is caused by a problem in the vent or blockage in the drain coupling. B. Condensation may be seen on pipes in humid weather or pipe connections may be leaking.

  • Page 5: Temperature Adjustment

    TEMPERATURE ADJUSTMENT Safety temperatures at the point of use to exceed the thermostat Due to the nature of the typical gas water heater, the setting by up to 30F° (16C°). If you experience this type of water temperature in certain situations may vary up to use, you should consider using lower temperature settings 30F°...

  • Page 6: Anode Rod Removal/Replacement

    ANODE ROD REMOVAL/REPLACEMENT ANODE ROD Installing Anode Rod: Use Tefl on tape or an approved pipe sealant on ® Important: Use only factory authorized replacement parts. threads of the new anode rod. If you lack the necessary skills to properly perform the Place the anode rod in the spud (top of the tank) and installation, you should not proceed, but get help from a turn clockwise until the threads are hand tight.

  • Page 7: Dip Tube Removal/Replacement

    DIP TUBE REMOVAL/REPLACEMENT DIP TUBE After turning off the hot-water faucet, check for water leaks around dip tube and immediately correct any if Important: Use only factory authorized replacement parts. found. If you lack the necessary skills to properly perform the Reinstall the pipe insulation removed in step 4 removal installation, you should not proceed, but get help from a process.

  • Page 8: Door-Burner Assembly Removal/Replacement

    DOOR-BURNER ASSEMBLY REMOVAL/REPLACEMENT INNER DOOR/MANIFOLD/BURNER ASSEMBLY Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualifi ed service technician. Tools required: • 3/4”...
  • Page 9 Re-installing Inner Door/Manifold/Burner Assembly BURNER SUPPORT STRAIGHT SLOT CURVED SLOT FOR BRACKET - FOR 40-50K 60-75K BURNERS Insert the manifold/burner assembly in the LOCATED IN THE BURNERS WITH WITH OFFSET burner chamber compartment, making sure CENTRE OF THE STRAIGHT MANIFOLD TUBES that the tip of burner manifold tab engages in CHAMBER.

  • Page 10: Flame Sensor And Igniter Removal/Replacement

    FLAME SENSOR AND IGNITER REMOVAL/REPLACEMENT FLAME SENSOR AND/OR HOT SURFACE IGNITER Remove and discard the old fl ame sensor and/or hot surface igniter assembly. Important: Use only factory authorized replacement parts. Install the new Flame Sensor and/or Hot Surface If you lack the necessary skills to properly perform the Igniter.
  • Page 11 Reconnect the manifold tube to the gas control valve/ BURNER SUPPORT STRIGHT SLOT FOR CURVED SLOT FOR BRACKET - 40-50K BURNERS 60-75K BURNERS thermostat (Note: Do Not apply any thread sealant LOCATED IN THE WITH STRAIGHT WITH OFFSET at this connection). To prevent any cross threading CENTRE OF THE MANIFOLD TUBES MANIFOLD TUBES...

  • Page 12: Burner And Orifice Removal/Replacement

    BURNER AND ORIFICE REMOVAL/REPLACEMENT BURNER Align the screw holes on the inner door/manifold assembly. Using the two screws removed in step 1 Important: Use only factory authorized replacement parts. of Removing Burner, install the new burner to the If you lack the necessary skills to properly perform the inner door/ manifold assembly (rotate the assembly to installation, you should not proceed, but get help from a visually check the top portion of the burner assembly...
  • Page 13 Reconnect all the electrical connections to the bottom of the gas control valve/thermostat, gently pushing each connector up until it snaps into place (see Figures 10 & 15). GASKET ON INSULATION REAR OF DOOR Reconnect the electrical power to the water heater in the wall outlet and turn the gas supply back “ON”...
  • Page 14 BURNER ORIFICE Installing Burner Orifi ce Using a ratchet with 1/2” socket, install the new Important: Use only factory authorized replacement parts. burner orifi ce (Note: the burner orifi ces have different If you lack the necessary skills to properly perform the threads dependent upon the gas type.
  • Page 15 DO NOT OPERATE THE WATER HEATER IF THE DOOR GASKET DOES NOT CREATE A SEAL BETWEEN MANIFOLD DOOR AND COMBUSTION CHAMBER. Reconnect the manifold tube to the gas control valve/ thermostat (Note: Do Not apply any thread sealant at this connection). To prevent any cross threading the manifold tube should be started by hand (turn clockwise for natural gas, counter-clockwise for L.P.).

  • Page 16: Door Gasket Replacement

    DOOR GASKET REPLACEMENT DOOR GASKET Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualifi ed service technician. Tools required: • 3/4” Open-End Wrench •...
  • Page 17 Replacing The Door Gasket. Re-installing Inner Door/Manifold/Burner Assembly Remove the paper cover on the new door gasket. This Insert the manifold/burner assembly in the will expose the gasket adhesive. burner chamber compartment, making sure Position the gasket on the freshly cleaned door that the tip of burner manifold tab engages in surface so that the adhesive fi...

  • Page 18: Control Module Removal/Replacement

    CONTROL MODULE REMOVAL/REPLACEMENT ELECTRONIC CONTROL MODULE Important: Do not remove the entire gas control assembly from the water heater. Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualifi...
  • Page 19 ELECTRONIC CONTROL MODULE DISCONNECT TEMPERATURE SENSOR CABLE HERE TABS THREADED CONTROL FITTING (DO NOT REMOVE FROM WATER HEATER) Figure 23...

  • Page 20: Valve Module Removal/Replacement

    VALVE MODULE REMOVAL/REPLACEMENT VALVE MODULE Important: Do not remove the entire gas control assembly from the water heater. Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualifi...

  • Page 21: Temperature Sensor And Cable Removal/Replacement

    TEMPERATURE SENSOR AND CABLE REMOVAL/REPLACEMENT TEMPERATURE SENSOR AND CABLE Important: Do not remove the entire gas control assembly from the water heater. Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualifi...

  • Page 22: Gas Valve Removal/Replacement

    GAS VALVE REMOVAL/REPLACEMENT GAS CONTROL VALVE Installing Gas Control Valve Do not apply any sealant tape to the gas control/ Important: Use only factory authorized replacement parts. thermostat threads that screw into the tank. The If you lack the necessary skills to properly perform the threads have a pre-applied white sealing material.
  • Page 23 ELECTRICAL CONNECTIONS MANIFOLD TUBE NUT HEX HEAD SCREWS NOTE: OUTER DOOR AND INSULATION NOT SHOWN FOR CLARITY. Figure 26 THREADED PIPE “HANDLE” Figure 27...

  • Page 24: Blower Removal/Replacement

    BLOWER REMOVAL/REPLACEMENT BLOWER Reconnect the electrical power to the water heater in the wall outlet and turn the gas supply back “ON” to Important: Use only factory authorized replacement parts. the gas control valve/thermostat. If you lack the necessary skills to properly perform the Restart the water heater by following the directions on installation, you should not proceed, but get help from a the “Lighting and Operating Instructions”...

  • Page 25: Rotating The Blower

    ROTATING THE BLOWER BLOWER EXHAUST DIRECTION Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualifi ed service technician. Tools required: • Ratchet with 11/32”...

  • Page 26: Pressure Switch Removal/Replacement

    PRESSURE SWITCH REMOVAL/REPLACEMENT PRESSURE SWITCH Installing Pressure Switch Using a hex head screwdriver, secure the new pressure Important: Use only factory authorized replacement parts. switch to the bracket with the screws removed in step If you lack the necessary skills to properly perform the 8 above.

  • Page 27: Fv Sensor

    FV SENSOR FLAMMABLE VAPOR SENSOR When using a gas fi red water heater there is a risk of fl ammable vapors entering the combustion chamber, being ignited by the burner fl ame and causing a fl ashback. In order to detect such fl ammable vapors before they enter the combustion chamber, this water heater is equipped with a fl...

  • Page 28: Cleaning The Combustion Chamber

    CLEANING THE COMBUSTION CHAMBER Follow procedure outlined in “Removing Inner Door/ Manifold/Burner Assembly”. Use a vacuum cleaner/shop vac to remove all loose debris in the combustion chamber. Reassemble following the procedure under “Installing Inner Door/Manifold/Burner Assembly”.

  • Page 29: Cleaning The Blower

    CLEANING THE BLOWER BLOWER With all components clean and secure, reconnect the electrical power to the heater. In dusty and contaminated air conditions, the interior of Reset the thermostat to the desired temperature the blower and the blower wheel may require periodic setting and turn the gas control switch back to the cleaning.

  • Page 30: Technical Bulletins

    TECHNICAL BULLETINS WATER HAMMER GENERAL Water hammer is the destructive force, pounding noise and vibration in a piping system when water fl owing through a pipeline is stopped abruptly. When water hammer occurs, a high intensity pressure wave travels back through the piping system until it reaches a point of some relief. The shock wave will then surge back and forth between the point of relief and the point of stoppage until the destructive energy is dissipated in the piping system.
  • Page 31 CONDENSATION SYMPTOMS The water heater appears to be releasing water while the main burner is on or water is found surrounding the heater shortly after the water heater has been used. This section explains why fl ue gases condense and how you can differentiate between condensation and leaking. CAUSES Condensate is the result of air borne water vapor being chilled below the dew point.
  • Page 32 SMELLY WATER SYMPTOMS Rusty, brown, black, or yellow water appearing in the hot water. CAUSES The most common cause of “smelly water” is a non-toxic sulfate reducing bacteria, scientifi cally termed Divibrio Sulfurcans. This bacteria often enters the water system through construction or a break in ground piping.
  • Page 33 CHLORINATION PROCEDURE CAUSES The chlorination procedure is used to eliminate various bacteria that accumulate and grow in water heaters. These bacteria often cause odorous or discolored water conditions. TREATMENT The simplest treatment available is the shock-chlorination of the system. This is a surface treatment, and often requires repeated trials in heavily infected systems.
  • Page 34 THERMAL EXPANSION SYMPTOMS • Effects are only noticeable after hot water use followed by periods of no water use. • Relief valve drips during any recovery cycle when no hot or cold water is used. • Hot water pipes creak while water heater is recovering and all valves are closed. •...
  • Page 35 LEAKING TEMPERATURE AND PRESSURE RELIEF VALVE SYMPTOMS • Water seeping around the relief valve tank connection. • Leakage at the threaded portion of the relief valve connection. • Intermittent weeping and/or dribbling from the relief valve. • Large volume of hot water sporadically discharged from the relief valve. CAUSE The temperature and pressure relief valve (T&P) is a safety device limiting temperature and pressure levels in a water heater.

  • Page 36: Troubleshoting Chart

    TROUBLESHOTING CHART PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION BURNER FLAME TOO Insuffi cient secondary air Provide ventilation to water heater HIGH Orifi ce too large Replace with correct orifi ce Low gas pressure Check with gas utility company FLAME BURNS AT D e f e c t i v e g a s c o n t r o l Replace gas control (thermostat) ORIFICE...
  • Page 37 PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION Insuffi cient secondary air Provide ventilation to water heater. Check fl ue Low gas pressure way, fl ue baffl e and burner Orifi ce too large Check with gas utility company SMOKING AND CARBON Flue clogged Replace with correct orifi...
  • Page 38 GAS CONTROL LED STATUS CODES IGNITION STATE AND TIMING LED Flash Sequence Control Status IGNITION STATE TIMING Short fl ash 5 seconds (NG models) IDLE (no call for heat, Pre-purge once every four 15 seconds (LP models) no fault conditions) seconds HSI Warmup 10 seconds...
  • Page 39 This page intentionally left blank. May be used for notes or to record other installation information.

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