andrews 32/143 Installation Manual, Operation And Service Manual
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andrews 32/143 Installation Manual, Operation And Service Manual

Gas fired storage water heaters
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This manual must be kept with the appliance
Part No E132
Gas Fired Storage
Water Heaters
Installation guide, operation
and service manual

Natural Gas

HI-FLO RANGE
Models 32/143, 65/173, 81/264, 62/341, 54/418, 54/440
Permanent Pilot, Auto Ignition with Flue Damper 'E'/'F' Series, 'G' Series
STANDARD RANGE
Models 24/39, 32/40, 40/61, 63/62, and 84/87
Permanent Pilot, Auto Ignition
Working towards
a cleaner future
October 2013

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  • Page 1: Natural Gas

    Installation guide, operation and service manual Natural Gas HI-FLO RANGE Models 32/143, 65/173, 81/264, 62/341, 54/418, 54/440 Permanent Pilot, Auto Ignition with Flue Damper ‘E’/‘F’ Series, ‘G’ Series STANDARD RANGE Models 24/39, 32/40, 40/61, 63/62, and 84/87 Permanent Pilot, Auto Ignition...
  • Page 2 The attention of U.K. users is drawn to their responsibilities under the Health and Safety Regulations 1993. All installation and service on the Andrews Water Heater must be carried out by properly qualified personnel, and therefore no liability can be accepted for any damage or malfunction caused as a result of intervention by unauthorised personnel.

  • Page 3: Table Of Contents

    CONTENTS PAGE SECTION 1 GENERAL AND SAFETY INFORMATION General Information British Standards Health and Safety Regulations 1993 Legionellae in Water Heaters SECTION 2 TECHNICAL DATA Standard Range Hi-Flo Range SECTION 3 INSTALLATION Introduction Draught Diverter Location Gas Supply Electrical Supply Flue Systems Air Supply and Ventilation Water Quality and Treatment...

  • Page 4: General And Safety Information

    SECTION 1 GENERAL AND SAFETY INFORMATION GENERAL The Andrews Water Heater has been designed for use with NATURAL GAS only and is manufactured to give an efficient, reliable and long service life. INFORMATION To ensure the continued, trouble-free operation of your heater at maximum efficiency, it is essential that correct installation, commissioning, operation and service procedures are carried out strictly in accordance with the instructions given in this manual.

  • Page 5: Health And Safety Regulations 1993

    1993 Andrews Water Heaters should only be used in the manner and purpose for which they were intended and in accordance with the instructions in this manual. Although the heaters have been manufactured with paramount consideration to safety, certain basic precautions specified in this manual must be taken by the user.

  • Page 6: Technical Data

    SECTION 2 TECHNICAL DATA STANDARD ANDREWS MODEL NO. 24/39 32/40 40/61 63/62 84/87 RANGE Storage Capacity Recovery thro' 44ºC/80ºF gal/h Recovery thro' 56ºC/100ºF gal/h Heat Input Gross 12.5 Btu/h 40,944 42,650 65,000 65,000 88,712 Heat Input Net 11.4 Btu/h 37,532 38,900 58,004 58,004 81,888...

  • Page 7: Hi-Flo Range

    TECHNICAL DATA SECTION 2 ANDREWS MODEL NO. 32/143 65/173 81/264 62/341 54/418 54/440 Hi-Flo Storage Capacity 295* 368* 282* 245* RANGE Recovery thro' 44ºC/80ºF 1199 1549 1900 1998 gal/h Recovery thro' 56ºC/100ºF 629* 1239* 1520* 1598* gal/h Recovery thro' 72ºC/130ºF...

  • Page 8: Installation

    ⁄ in BSP (Hi-Flo only). 2 - 1 ⁄ in x 3in Nipples (32/143 Model only). ASSEMBLING The draught diverter must be assembled with the legs provided. Attach the legs to the draught diverter with the nuts and bolts provided.

  • Page 9: Gas Supply

    GAS SUPPLY THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL MUST ONLY BE USED WITH NATURAL GAS. The installation of the gas supply must conform, depending on it's size, to the requirements of British Standards and Codes of Practice listed in Section 1 of this manual.

  • Page 10: Electrical Supply

    It is recommended that screen cable is used where the volt-free contacts are to be connected from an external supply. This will eliminate the risk of possible interference from nearby high voltage cables. Data sheets available for Hi-Flo and Standard Range, Automatic Ignition Control System. Contact Andrews Water Heaters.
  • Page 11 INSTALLATION SECTION 3 Fig3a. Standard Range Fig3b. Hi-Flo Range...

  • Page 12: Flue Systems

    SECTION 3 INSTALLATION FLUE Detailed recommendations for flue installation are given in BS 6644, BS5440 Pt 1 and British Gas publication IM/11 - Flues for Commercial and Industrial Gas Fired Boilers and SYSTEMS Air Heaters. The flue connection is designed for BS 835 type heavy duty flue, but light quality flue pipe, mild steel or stainless steel sheet may be used using the appropriate adapter.
  • Page 13 *A minimum of 600mm of vertical flue directly above the draught diverter should be provided where possible on all natural draught flue installations. If this dimension cannot be achieved please contact Andrews Water Heaters. Please note this is not required where a common flue header is used on multiple installations.

  • Page 14: Air Supply And Ventilation

    SECTION 3 INSTALLATION Minimum Heights from Roof to Base of Flue Terminal Not within 1.5m (5ft) of a Within 1.5m (5ft) of a vertical surface of a vertical surface of a structure ≠ on the roof structure ≠ on the roof Type of Roof Internal Route External...
  • Page 15 INSTALLATION SECTION 3 AIR SUPPLY IMPORTANT! 1. The effective area requirements specified in the table are related to the maximum net input of the heater(s) and are equivalent to those specified in BS 6644 and VENTILATION IGE/UP/10 Pt.1. 2. The free area of the grilles should not be less than the size of the recommended ventilation opening.

  • Page 16: Water Quality And Treatment

    BEMS version is available, which provides a remote warning signal. These anodes are available as an optional extra on all Andrews heaters. In hard water areas, scale formation can occur in hot water systems and hot water heaters and the higher the temperature and volume of water used, the more problematic the scale build-up can be.

  • Page 17: Water Connections - Hydrojet System

    INSTALLATION SECTION 3 WATER CONNECTIONS Hydrojet System The upper “jet ports” direct the flow outward to begin the dynamic mixing action. The lower “jet ports” direct the flow inward to increase the turbulence. Tank Heater Casing All models now incorporate the new Mini Hydrojet system on cold inlet side connections.

  • Page 18: Vented Systems, Standard Range

    SECTION 3 INSTALLATION WATER VENTED SYSTEMS, STANDARD RANGE CONNECTIONS The water heater must be supplied from a cold water feed cistern and the hot water supply pipe must be fitted with an open vent pipe in accordance with BS 5546 and BS 6644.
  • Page 19 INSTALLATION SECTION 3 Fig 6A. Fig 7.

  • Page 20: Correx Powered Anodes

    SECTION 3 INSTALLATION CORREX FITTING AND OPERATING INSTRUCTIONS POWERED THE INTRODUCTION OF THIS KIT HAS THREE MAIN ADVANTAGES TO BE ANODES CONSIDERED a) LOW MAINTENANCE COSTS (Correx is non sacrificial, therefore no anode maintenance is needed). b) LOW RUNNING COSTS – LESS THAN 35kWH PER YEAR. c) BETTER PROTECTION PARTICULARLY IN AREAS OF LOW ELECTRICAL CONDUCTIVITY.
  • Page 21 AND LPG Powered anode fittings pack – Part No. B184 MODEL No. CORREX ANODES/SIZE 2 – Correx powered anodes E048 32/143 2 x 800mm 1 – Potentiostat E010 65/173 2 x 800mm 2 – 1 " BSP Sq. tees C856 2 –...

  • Page 22: Unvented Systems, Standard Range

    CONNECTIONS Unvented Systems should be fitted by an Approved Installer When used in an unvented system, the Andrews Water Heater will supply hot water at a pressure of 3.5bar (50.8lbf/in ) provided that this pressure is available at the mains feed.
  • Page 23 INSTALLATION SECTION 3 WATER CONNECTIONS Fig 9. Fig 10.

  • Page 24: Vented Systems, Hi-Flo Range

    All Models. Front inlet/outlet water connections Models 32/143. Optional rear inlet/outlet water connections Assemble onto the 3/4 BSP thread, the 3/4 BSP coupler socket (1) and drain cock using a suitable jointing compound.
  • Page 25 Cold Inlet/Hot Outlet on models Automatic Air Vent 65/173 32/143 81/264 62/341 54/418 54/440 Front T & P Valve Tapping Cold Inlet/Hot Outlet All Models Optional Rear Drain & Cold Inlet/Hot Outlet Secondary Return Tappings 32/143 only Tapping Fig 11. Fig 12.
  • Page 26 SECTION 3 INSTALLATION WATER CONNECTIONS Fig 13. Fig 14.

  • Page 27: Unvented Systems, Hi-Flo Range

    CONNECTIONS Unvented Systems should be fitted by an Approved Installer When used in an unvented system, the Andrews Water Heater will supply hot water at a pressure of 3.5bar (50.8lbf/in ) provided that this pressure is available at the mains feed.
  • Page 28 SECTION 3 INSTALLATION If higher flow rates are required for the cold water services, a suitable tee fitting should WATER be fitted to the pipework, upstream of item C1. CONNECTIONS The pipework fitted to the tundish outlet should be at least 28mm diameter and should be terminated at a suitable drain (see Building Regulations 1991 Approved Document G3).
  • Page 29 INSTALLATION SECTION 3 WATER CONNECTIONS Fig 17. Fig 18.

  • Page 30: Commissioning

    SECTION 4 COMMISSIONING STANDARD CAUTION! DO NOT OPERATE THE WATER HEATER UNTIL THE STORAGE VESSEL IS COMPLETELY FILLED WITH WATER, WITH WATER RANGE RUNNING FROM ALL HOT TAPS. PERMANENT PILOT MODELS Open the main gas supply cock after all connections to the gas control are completed and test all connections, using proprietary leak detection fluid.
  • Page 31 COMMISSIONING SECTION 4 Shutting Off The Burner For long periods only (7 days or more) turn gas control knob to PILOT, depress slightly and turn clockwise to OFF. Turn off the gas service cock. For shorter periods, leave the heater under thermostat control. NOTE! If the pilot goes out for any reason, turn off heater and wait for 3 minutes before relighting.

  • Page 32: Hi-Flo Range

    SECTION 4 COMMISSIONING HI-FLO RANGE Lighting the Burner PERMANENT Open the main gas supply cock after all connections to the gas control are completed PILOT MODELS and test all connections using a manometer. Purge air from pipework and ensure there are no loose connections to burner or pilot pipe.
  • Page 33 COMMISSIONING SECTION 4 Shutting Off The Burner For long periods only, (7 days or more) turn control knob to PILOT, partially depress knob, then turn clockwise to OFF. Turn off gas service cock. For shorter periods leave heater under thermostat control. Checking Main Burner Pressure 1.
  • Page 34 SECTION 4 COMMISSIONING Lighting the burner STANDARD RANGE AUTO IGNITION Thermostat Control On/Off Switch MODELS Knob Gas Control valve Fig 23. 1. Ensure gas supply is on. 2. Set thermostat control knob to the required water temperature. (See below). 3. Ensure time switch if fitted is in the ON position. 4.
  • Page 35 COMMISSIONING SECTION 4 Checking main burner pressure 1. Turn gas supply OFF. 2. Release bleed screw A and connect pressure gauge tube (See Fig. 24) 3. Light burner as described previously. 4. Remove cap from port B and adjust pressure using exposed screw in accordance with data plate (See Fig.

  • Page 36: Auto Ignition

    SECTION 4 COMMISSIONING Hi-Flo RANGE Lighting the Burner AUTO IGNITION MODELS Gas control Pink MV Knob Black PV-MV Fig 25. Purple PV 1. Ensure gas supply is ON. 2. Turn gas control knob to ON position. 3. Using control thermostat, select required water temperature. 4.
  • Page 37 COMMISSIONING SECTION 4 HI-FLO Check correct shape and size of Pilot Flame No adjustment is provided for the pilot. The restrictor C on the gas control (see Fig. 22) RANGE should be turned fully conterclockwise to the fully open position. PERMANENT PILOT MODELS Fig 26.
  • Page 38 SECTION 4 COMMISSIONING USERS For your safety read before lighting the appliance SAFETY WARNING GUIDE 1. Always follow manufacturers instructions when lighting the appliance. Failure to so may result in damage to property, personal injury or loss of life. 2. Before lighting check all round the appliance area for gas. Be sure to check at low level because some gas (i.e.

  • Page 39: Standard Range

    This is known as stacking. To counter this condition, an upper thermostat phial is fitted (not on Model 32/143) which senses abnormally hot water and shuts down the main burner until the water cools. Most modern commercial pipe installations include a circulating pump which keeps hot water moving continuously throughout the heater.

  • Page 40: Servicing

    SECTION 6 SERVICING Servicing must be carried out by a properly qualified person. INTRODUCTION Whilst giving these instructions for the care of the Heater, it is recommended that checks are carried out by the installer or local gas authority, at least annually. Ensure good ventilation by keeping the heater free of extraneous materials and clear of dust and lint.

  • Page 41: Gas Control Valve Standard Range

    SERVICING SECTION 6 8. Re-assemble in reverse order but note: i) The flueways and combustion chamber must be cleaned first. ii) Use an approved jointing compound when re-fitting burner injectors. 9. Light heater in accordance with lighting instructions. All gas joints must be checked using leak detection fluid.

  • Page 42: Cleaning The Storage Vessel

    SECTION 6 SERVICING CLEANING THE The storage vessel should be checked and cleaned annually. Scale formation in the base of the vessel may occur, particularly in hard water areas and is STORAGE normally associated with high usage and high water temperatures. It is characterised by a VESSEL rumbling noise when the main burner is lit.

  • Page 43: Replacing Components, Hi-Flo Range

    The gas valve must be fitted so that it is square relative to the centre line of the injectors. 8. Re-commission the heater as detailed in Section 4, Commissioning. USER- NOTE! These instructions apply to all models but Model 32/143 is not fitted with a limit sensor phial. ADJUSTABLE CONTROL 1.

  • Page 44: Gas Control Valve

    SECTION 7 REPLACING COMPONENTS, Hi-Flo RANGE 2. Disconnect thermopile and pilot supply pipe from gas control valve. THERMOPILE/ 3. Remove two screws and withdraw burner assembly. PILOT 4. Remove two screws and withdraw pilot assembly. BURNER/PILOT 5. Unscrew gland nut securing thermopile to it's bracket and withdraw. RESTRICTOR 6.

  • Page 45: Fault Finding

    FAULT FINDING SECTION 8 PERMANENT FAULT ACTION PILOT MODELS STANDARD AND WATER DOES (a) Check gas service cock is open. HI-FLO RANGES NOT GET HOT (b) Check water valves are open (c) Check pilot is alight (d) Check thermostat setting. reset to higher temperature) (e) Check gas pressures at burner and at gas inlet to appliance.

  • Page 46: All Models

    SECTION 8 FAULT FINDING ALL MODELS FAULT ACTION HEATER SOOTING, (a) Check gas burner pressure and injector size. If possible, YELLOW FLAME check heat input with meter and watch. (POOR COMBUSTION) (b) Clean burners and injectors. (c) Flue obstruction. Clean flue ways. (d) Check flue design and termination position.

  • Page 47: Auto Ignition Models, Hi-Flo Range

    FAULT FINDING SECTION 8 AUTO FAULT ACTION IGNITION UNITS (a) Check gas service cock is open. IGNITION AT PILOT (b) Electrical ON/OFF switch is not ON. STANDARD (c) Power to unit interrupted. RANGE (d) Thermostat set too low. (e) Check ECO for failure. Reset. (f) Check for 24V AC at intermittent pilot ignition control terminal No.

  • Page 48: Parts Lists And Illustrations

    SECTION 9 PARTS LIST AND ILLUSTRATIONS 63/62 only STANDARD Models 24/29, 32/40, 40/61, 63/62 63/62 only STANDARD Model 84/87...

  • Page 49: Standard Range

    PARTS LIST AND ILLUSTRATIONS SECTION 9 STANDARD MODELS 24/39 32/40 40/61 63/62 84/87 Model Ref. Part Numbers Description C654 C654 C654 C657 C657 Adaptor Ring C653 C653 C655 C656 C658 Draught Diverter C285 C285 C285 C285 C690 Hot Outlet Nipple C286 C292 C293...
  • Page 50 SECTION 9 PARTS LIST AND ILLUSTRATIONS Hi-Flo Model 32/143 Hi-Flo Models 65/173 and 81/264...
  • Page 51 PARTS LIST AND ILLUSTRATIONS SECTION 9 HI-FLO MODELS Model 32/143 65/173 81/264 Ref. Part Numbers Description E023 C500 C501 Draught Divider C333 C333 C333 Service Magnesium Anode C334 C334 Flue Connector, 150mm, BS 835 C432 Flue Connector, 200mm, BS 835...
  • Page 52 SECTION 9 PARTS LIST AND ILLUSTRATIONS Hi-Flo Models 62/341 and 54/418/440...
  • Page 53 Drain Cock, BS 2879, 3/4" C103 C103 Socket Coupler, 3/4" C474 C473/C492 Data Badge C543 Flue Baffle C543 Flue Baffle C235 C235 Andrews Label C487 C554 Top Cover C488 C488 Insulation Pad C490 E392 Flue Box Top Cover C694 C694 Cleanout Pad Seal...

  • Page 54: Hi-Flo Range

    SECTION 9 PARTS LIST AND ILLUSTRATIONS Unvented Systems Kit - Standard Range Unvented Systems Kit - Hi-Flo Range...
  • Page 55 PARTS LIST AND ILLUSTRATIONS SECTION 9 Unvented Ref. Part No. Description Systems Kit - B171 Unvented Systems Kit Complete Standard Range C780 Pressure Reducing Valve/Strainer C781 Check Valve / Expansion Valve C782 Expansion Vessel E462 Temperature/Pressure Relief Valve C783 Tundish C772 Adaptor B173...

  • Page 56: Auto System Kit

    SECTION 9 PARTS LIST AND ILLUSTRATIONS 24 Volt Auto System Kit B217 24 Volt Auto System Kit B258...
  • Page 57 HT Lead 24” 24 Volt Auto Part No. Description System Kit Hi-Flo Range E839 Pilot assembly C521 On/Off Switch C531 Label - Andrews C644 Label - Warning C989 Label - On/Off Label - Wiring Z090 Gas Control Valve r i c...

  • Page 58: Appendices

    APPENDICES HI-FLO AUTO IGNITION "G" SERIES ADDENDUM FEATURES OF HONEYWELL INTEGRATED CONTROLS SYSTEM Attractive digital water heater display on control panel for setting and displaying the temperature setpoint. Pressing temperature up and down buttons changes the temperature setpoint. Temperature format may be displayed in degrees F or degrees C.
  • Page 59 APPENDICES Specifications Power Supply Dedicated 120 VAC, 60 Hz., 15 A Current Draw Less than 5 Amps. Gas Supply Connection 1" NPT connection to gas valve for 370,000 Btu/hr. and over for natural gas, ¾" NPT for rest. Schedule 40 black iron pipe recommended. Approved Gas Type Natural or Propane.
  • Page 60 APPENDICES Sequence of Operation Thermostat calls for heat. The control board sends 24 volts from damper terminal #2 on the control plug to the flue damper. Flue damper begins to rotate open. Once the flue damper is fully open, the damper end switch closes and 24 volts is allowed to continue through damper to damper pin terminal #5.

  • Page 61: Troubleshooting

    APPENDICES Troubleshooting CAUTION Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals Water Heater Fault: Water heater does not operate Display Error Code: Water heater display does not operate - blank display Check main power supply to water heater - fuse, circuit breaker, plug receptacle, line cord or wiring to water heater.
  • Page 62 APPENDICES Troubleshooting CAUTION Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals From previous page Error code #55 on display. Remove damper from heater and Does damper blade move to the full Does water heater begin to jump black &...
  • Page 63 APPENDICES Troubleshooting Using Control Display for Servicing the Water Heater ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY (FOR SERVICE PERSONNEL ONLY) The display has a “service mode” for changing the maximum setpoint and accessing information in aiding servicing of the water heater.
  • Page 64 APPENDICES Troubleshooting 1. Max Setpoint (Display/Change) Max Setpoint value in Water Heater Display °F Setpoint idle Operational Status SELECT 2a. Water Temperature Average (Displays average if there are two sensors - sensor temperature displayed if single sensor is used). Water Temp °F idle Status...
  • Page 65 APPENDICES Troubleshooting Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle) Heating Flame Current Status Operational SELECT 4. Setpoint (Display/Change) setpoint °F idle Operational Status SELECT °F/°C (Display/Change) setpoint °F °F/C° idle Status Operational SELECT Differential (Display only - shows the differential of the thermostat) Differential °F idle...
  • Page 66 APPENDICES Troubleshooting 7. Software Version (Display only) Soft idle Status Operational SELECT 8. Error Code History (Displays if there are present error codes or up to 10 previous error codes). Water Heater Display will show a “--“ if there are no error codes. WARNING Setting the water temperature to the maximum set point can...
  • Page 67 APPENDICES Troubleshooting Step 2: Press “Set” button to enter setting mode. “Max Setpoint” will flash to indicate setting mode. °F Setpoint idle Operational Status SELECT Step 3: Press the “UP” or “DOWN” buttons to change the maximum setpoint value. This will limit the maximum setpoint the user can select.
  • Page 68 APPENDICES Troubleshooting Step 5: 30 Seconds after the last button press, the Water Heater Display will go back to “User Mode”. It will read “Max Setpoint” without showing a temperature value if the temperature setpoint is at the maximum setting. The Water Heater Display can be set back to the “User Mode”...
  • Page 69 APPENDICES Troubleshooting Step 3: For water heaters using two temperature sensors, pressing the “Select” button again displays the Lower Sensor temperature reading. “Lower Sensor” will be displayed in the lower left side of the status window of the water heater display.
  • Page 70 APPENDICES Troubleshooting Step 2: Press the “Set” button to enter the setting mode. “Setpoint” will flash in the water heater display. setpoint °F idle Status Operational SELECT Step 3: To raise the temperature setpoint, press the “Temperature Up” button until the desired temperature is shown on the water heater display.
  • Page 71 APPENDICES Troubleshooting Step 5: When the desired setpoint is reached on the water heater display, press the “Set” button to confirm the new setpoint. “Setpoint” stops flashing in the water heater display. setpoint °F idle Operational Status SELECT To Display and Change Temperature Format (°F/°C): To Change Temperature Format in Display from °F to °C or °C to °F: Step 1: While in “Service Mode”, press “Select”...
  • Page 72 APPENDICES Troubleshooting Step 3a: Press “Temperature Up” button to change temperature format to °C °C °F/C° idle Status Operational SELECT Step 3b: Press “Temperature Down” button to change temperature format to °F °F °F/C° idle Status Operational SELECT Step 4: Press “Set” button to confirm °F or °C format. °F/°C will stop flashing °F °F °F/C°...
  • Page 73 APPENDICES Troubleshooting Step 5: Pressing “Select” button will return display to setpoint in format selected (°F or °C) immediately °F idle Status Operational Lower Sensor SELECT Error Codes and Error History Display: If there is an operating problem with the water heater, an error code number will appear on the water heater display with “Service Needed”...
  • Page 74 APPENDICES Troubleshooting To view previous error codes: Step 1: In “Service Mode press the “Select” button until the next display after the “Software Version”. If there are no current error codes, the display will show -- . °F idle Operational Status SELECT Step 2:...
  • Page 75 APPENDICES Troubleshooting Step 4: Press the “Temperature Down” button to change to the previous code index, code #9. idle Status Operational SELECT Step 5: Press the “Select” button for code index #9 to view if there are any code numbers. idle Status Operational...
  • Page 76 APPENDICES Troubleshooting ERROR CODE DEFINITIONS If the water heater has an operating problem, there will be a number in the water heater display with “Service Needed” shown below the error code number. Note the error code and the definition in the chart below.
  • Page 77 APPENDICES WARNING The following procedure is for service and installation personnel only. Resetting lockout conditions without correcting the malfunction can result in a hazardous condition. If an error code is displayed (except for #4, low flame sense current), the water heater will be in a “lockout condition” with the water heater display showing the error code number and “Service Needed”...
  • Page 78 APPENDICES SERVICE PROCEDURE D24-I Thermostat Circuit Testing CAUTION DANGER Be Careful When Making Voltage 120 volt exposure. To avoid personal injury, Measurements or Jumping Terminals use caution while performing this procedure. Not to Damage or Deform Connectors or Connector Pins. This procedure assumes the flue damper is in working order.
  • Page 79 APPENDICES SERVICE PROCEDURE D24-I Thermostat Circuit Testing WARNING! Do not operate water heater without verifying that the overheating condition has been corrected. Condition: Water Heater Not Operating Display shows error code “65” High Water Temperature (over 200 deg. F) Continued Once cause of overheating condition has been diagnosed and corrected, the control may be reset Reconnect and switch on power to the water heater.
  • Page 80 APPENDICES SERVICE PROCEDURE D24-I Conditions: Upper or Lower Sensor Reading Thermostat Circuit Testing Faulty, High Water Temperature, or suspect thermostat is not accurate. Sensor Resistance Testing Upper Sensor 1. Determine resistance value of upper sensor. Test across grey wires. Upper thermister location (applicable models) 2.
  • Page 81 APPENDICES SERVICE PROCEDURE D24-II Pilot Operation Testing CAUTION DANGER Be Careful When Making Voltage 120 volt exposure. To avoid personal injury, Measurements or Jumping Terminals use caution while performing this procedure. Not to Damage or Deform Connectors or Connector Pins. Condition: Pilot will not light or stay lit, Error codes 62, or 63 shown on Water...
  • Page 82 APPENDICES SERVICE PROCEDURE D24-II Pilot Inspection Condition: Error code 57: Flame Rod Shorted to Ground Disconnect power. Shut off gas Check to see if pilot shield is touching supply to water heater. Slide out pilot flame sensor or flame sensor Check pilot flame sense wire for burner assembly (see section on touching pilot hood.
  • Page 83 APPENDICES SERVICE PROCEDURE D24-II Pilot Operation Testing CAUTION DANGER Be Careful When Making Voltage 120 volt exposure. To avoid personal injury, Measurements or Jumping Terminals use caution while performing this procedure. Not to Damage or Deform Connectors or Connector Pins. Condition: Pilot lights, no or low flame signal.
  • Page 84 APPENDICES SERVICE PROCEDURE D24-III Main Burner Operation Testing CAUTION DANGER Be Careful When Making Voltage 120 volt exposure. To avoid personal injury, Measurements or Jumping Terminals use caution while performing this procedure. Not to Damage or Deform Connectors or Connector Pins. Checking MV &...
  • Page 85 APPENDICES SERVICE PROCEDURE D24-III Main Burner Operation Testing CAUTION DANGER Be Careful When Making Voltage 120 volt exposure. To avoid personal injury, Measurements or Jumping Terminals use caution while performing this procedure. Not to Damage or Deform Connectors or Connector Pins. Condition: Main burner short cycles.
  • Page 86 APPENDICES SERVICE PROCEDURE D24-IV Main Burner & Pilot Removal and Inspection WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Gas Valve Wire Leads Main Burner Removal Burner Rack Gas Valve Mounting Control Knob...
  • Page 87 APPENDICES SERVICE PROCEDURE D24-IV Main Burner & Pilot Removal and Inspection Pilot Shield Pilot Burner Removal Step 1. With burner rack removed from heater, disconnect pilot tube connection from gas valve Step 2. Remove the two pilot burner mounting screws securing the pilot and pilot shield in place.
  • Page 88 APPENDICES SERVICE PROCEDURE D24-IV Control Board Replacement DANGER 120 volt exposure. To avoid personal injury, unplug while performing this procedure. Control board replacement Step 2: Unplug wire connections from board. Step 1: Disconnect Power Depress Wire connections plastic tabs Step 3: To remove board, tilt control panel to the right and slide control hook tabs from slots in control panel.
  • Page 89 APPENDICES SERVICE PROCEDURE D24-V Flue Baffle Removal, Inspection WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Step 1. Disconnect (unplug) water heater from electrical supply. Step 2. Disconnect venting from draft diverter and remove draft diverter from top of water heater.
  • Page 90 APPENDICES SERVICE PROCEDURE D24-VI Anode Removal and Inspection WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Step 1. Disconnect (unplug) water heater from electrical supply. Step 2. Turn “OFF”...
  • Page 91 APPENDICES See description and part number table overleaf. 16/16A 17/17A...
  • Page 92 APPENDICES Description Interpart Movex Number Ref No Control Box and Wiring Assy. (26) Z129 Lower T-Stat Sensor (25) Z130 Control Box and Wiring Assy. (26) Z131 Control Box and Wiring Assy. (26) Z132 Upper T-Stat Sensor (28) Z133 Lower T-Stat Sensor (25) Z134 Control Box and Wiring Assy.
  • Page 93 Notes...
  • Page 94 Notes...
  • Page 95 Notes...
  • Page 96 0087 RS 33961 Sales: Technical: Baxi Commercial Wood Lane, Erdington, 0845 070 1056 0845 070 1057 Birmingham B24 9QP Email: andrews@baxicommercialdivision.com www.andrewswaterheaters.co.uk...

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