Atwood Water Heater Service PDF
Atwood Water Heater Service PDF
Atwood Water Heater Service PDF
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.
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.
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
2
TABLE OF CONTENTS
3
Aftermarket Gas Water Heaters
Includes Doors & Switches (when appropriate)
G6A-7 ----------------------------------6 gal. w/pilot
GC6AA-8 ------------------------------6 gal. combo w/pilot
GC6AA-10E ----------------------------6 gal. electronic gas combo
GCH6A-10E ----------------------------6 gal. electronic gas combo w/heat exchange
G6A-8E --------------------------------6 gal. electronic
GH6-7 ----------------------------------6 gal. w/pilot, heat exchange
GH6-8E --------------------------------6 gal. electronic w/heat exchange
G10-2 ----------------------------------10 gal. w/pilot
GC10A-2 ------------------------------10 gal. combo
G10-3E --------------------------------10 gal. electronic
GC10A-4E ----------------------------10 gal. electronic combo
GCH10A-4E --------------------------10 gal. 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?
· What is minimum millivolt output of the thermocouple required for proper gas control operation?
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
Fill here
THERMOSTAT WRENCH
7
6
5
4
3
2
1
Correct 0
water 1
level 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.
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.
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.
Pilot Flame
Pilot Orifice (inside)
Thermocouple
Air Shutter
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.
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
Pilot Flame
Flame Spreader
Gas Valve
ner Tube
Main Bur
der
Orifice Hol
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
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.
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.
12
BOLT-IN 110VAC Trouble-Shooting
Heating Element, Thermostat & ECO Wiring Schematic
UP
Switch
Hot Lead ( 1 )-BLACK BLACK
Manual Reset
Ground Lead ( 3 )-GREEN High Temperature
ECO
Ground Limit Switch
Temperature
Adjustment Dial
Re-Set Common Lead ( 2 )-WHITE BLACK Fixed Thermostat
Button
Element
Early model water heaters with 110 VAC heating In the case where the 110VAC portion of the water
capacity used a bolt-on heating element and a one heater is not heating water, the following diagnostic
piece thermostat/E.C.O.. steps and repairs should be investigated:
This 110 VAC system has an adjustable rectangular Turn POWER OFF to the appliance before
thermostat that is surface mounted to the inner tank removing junction box cover.
and retained by a steel clip. The temperature settings Perform the following steps with POWER ON to
are HI, MEDIUM, and LOW. If the thermostat is water heater.
making unobstructed contact with the aluminum tank 1. Verify switch-A is in ON position.
and it is set to the HI position, it should heat the water 2. Insure there is 110VAC to the unit (measure
to 130° F. It will take longer to heat a tank of water on voltage across the black and white lead to the
electric than gas. appliance with POWER ON). If none, trace wiring
The heating element was changed in 1996 from back and make appropriate wire repair.
1500W to 1400W bringing the amperage draw down Perform the following steps with POWER OFF to
to 12.7 amps and allowing more cushion for the water heater.
15 amp circuit breaker that is normally placed in line. 3. ECO Re-set Button-D should be depressed.
This change adds a few minutes to the heating time. 4. Check for continuity between screw-B and screw-
There are 110 VAC aftermarket conversion kits being C of thermostat. If none, replace thermostat.
offered by distributors in which the heating element is 5. If water is insufficiently hot, check ECO /
screwed into the tank where the drain plug is located. Thermostat-E is on high.
We do not offer such a kit. Our kit includes the tank 6. Verify a good wire connection between thermostat
with the 110 VAC components already installed in it. 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 110VAC Trouble-Shooting
Heating Element, Thermostat & ECO Wiring Schematic
UP
G F C B D E
Switch
Hot Lead ( 1 )-BLACK BLACK
Current production water heaters with the 110 VAC When the 110VAC portion of the water heater is not
heating option use a screw-in heating element, a heating water, the following diagnostic steps and
separate pre-set thermostat and a separate ECO. repairs should be investigated:
The screw-in heating element is rated at 1400 watts Turn POWER OFF to the appliance before removing
just like the bolt-on element. It is an incalloy element junction box cover.
and can be run for a limited amount of time in a dry Perform the following steps with POWER ON to
tank without shorting out. water heater.
1. Verify switch is in ON position.
CAUTION: If the heating element is allowed to run
with a dry tank, allow the tank to cool down for 2-3 2. Insure there is 110VAC to the unit (measure
hours before adding water. Adding water before voltage across the black and white lead to the
the tank cools sufficiently could collapse the tank. appliance with POWER ON). If none, trace wiring
back and make appropriate wire repair.
The thermostat and ECO are pre-set surface-mounted Perform the following steps with POWER OFF to
discs. The thermostat is set at 140° F and is the same water heater.
thermostat used on the gas side of the electronic 3. Manual reset ECO high limit switch-A should be
ignition water heaters. The ECO is a backup depressed. Check for continuity between
thermostat and will trip if the thermostat fails and the TERMINAL B and TERMINAL C of ECO.
water temperature exceeds 170° F.
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 self-
tapping 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
ELECTRONIC IGNITION MODELS
QUESTIONS
The following questions should be answered during this portion of the manual:
· 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?
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.
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.
7
6
5
4
3
2
1
Correct 0
water 1
level 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.
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
• 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.
• Electrodes
A normally closed safety temperature switch that
Creates a spark to ignite gas. If the electrodes do not
sends voltage to solenoid valve. The switch opens if
sense a flame in 6-8 seconds, a signal is sent to the
the water temperature exceeds 180°F.
board to shut the gas valve down and the system goes
into safety lock-out.
NOTE: If this situation exists, the ON/OFF switch must be
• Gas Valve turned off and back on again.
The dual solenoid valve that opens and sends gas to
electrodes when a minimum of 10.5 VDC is applied to it.
18
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
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
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.
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 THERMAL CUT-OFF DEVICE
multi-meter. This test must be performed with the Current Atwood direct ignition water heaters are equipped
circuit board removed, and the meter set to the ohms with a thermal cut-off device. This device is located on the
scale. This will check the continuity of all tracks on incoming power wire and is connected to the thermostat. The
the harness connection of the board. thermal cut-off is designed to permanently break circuit and
The following steps should be used to test each track. shut down the water heater before excessive heat can cause
A. Cross leads of meter to ensure it is registering damage due to obstructions in the main burner tube or flue
continuity. tube caused by spiders or mud wasps. These obstructions
B. TO TEST POWER TRACK: can cause the main burner flame to burn outside the main
Place negative lead of the multi-meter to ground (green burner tube. When the flame or the heat from the flame
wire) track of edge connection and positive lead of the contacts the thermal cut-off, the circuit will open.
multi-meter to top power (brown wire) track of edge If there is no heat damage to the thermal cut-off, and if it is
connection. If no continuity, board is defective. *Atwood determined defective, Atwood will cover the replacement of
does not warranty this installation related failure. this device under warranty. We will allow .25 hour at your
C. TO TEST LAMP TRACK: Atwood approved warranty rate. If there is heat damage the
Place negative lead of the multi-meter to ground (green device performed its safety feature and no warranty labor will
wire) track of edge connection and positive lead of the be allowed. Any obstructions should be removed, alignment
multi-meter to lamp (blue wire) track of edge checked and gas pressure taken before a new thermal cut-off
connection. If no continuity, this indicates blown lamp is installed.
track. Circuit board will still fire unit but lamp light will
not come on. This is caused by a short in the blue wire Note: When replacing a thermal cut-off, also examine the grill
between the unit and the switch. Wiring must be in the access door while the door is in the closed
corrected before the board is replaced. *Atwood does position. The wide aluminum band of the grill should
not warranty this installation related failure. be at the bottom. If it is at the top, this condition may
D. TO TEST VALVE TRACK: trap exhaust heat and possibly also cause thermal cut-
Place negative lead of the multi-meter to ground (green off to trip. To correct, remove the grill from the door
wire) track of edge connection and positive lead of the and snap back in place with the wide aluminum band at
multi-meter to valve (red wire) track of edge connection. the bottom.
If no continuity, this indicates a blown valve track.
• If the valve wire is shorting under the flue box –
Atwood will warranty the board. THERMOSTAT
• If the E.C.O. terminals are contacting the drawn pan The thermostat on this water heater is pre-set at 140° F. The
– Atwood will warranty the board only if the inner water heater will cycle off when the water temperature
tank of the water heater was installed flush on the reaches 140° F. and will generally take 20-25 minutes to
floor of the coach. reach this temperature. It will cycle back on when the water
temperature cools down to approximately 115° F. In the latter
• If the inner tank of the water heater does not rest
part of the heating cycle though, it is very common for the
flush against the floor of the coach –*Atwood does
pressure-temperature relief valve to weep. Refer to the page
not warranty this installation related failure.
covering weeping relief valves to remedy this situation.
* Installation related failures on circuit boards are the
responsibility of the coach manufacturer. If a customer is dissatisfied with the temperature of the
** Non potted circuit boards can be checked by turning the water, first check the water temperature with a cooking
board over and visually inspecting each track for a burn thermometer and verifying that the initial cycle is within the
mark or break in the track itself. A burn mark or broken time noted above. If not, an adjustable thermostat may be
track indicates the board is blown. Depending on which purchased allowing the water temperatures to be adjusted
track is blown determines whether it is covered under from 110 - 150° F. It fits in place of the original thermostat.
Atwood’s warranty as stated in section B, C and D.
23
Water Heater Wiring Schematics
White
Ground
Brown Blue
White
Red Non-ignition
Circuit Light
Board Orange
Green
REMOTE
White SWITCH
Valve
Sparker Wire Connection
Red
Brown
Circuit
4
Board 5
Red 6
ECO TSTAT
Red 1
2
3
Red
Valve White
GREEN SWITCH
GREEN BATTERY
Spark & Sense CAUTION
When servicing controls, label all wires prior to disconnection.
Wiring errors can cause personal injury or property damage.
Dotted lines are wired by customer Verify proper operation after servicing.
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?
· What are the proper draining procedures to help reduce lime deposits and extend tank life?
· What functions do the retaining rings serve when replacing an inner 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.
1/2" N.P.T.
Cold Water Inlet Drain Plug
27
WATER HEATER TERMINOLOGY
Terminology Definition Terminology Definition
AGA American Gas Association Main Burner a gas and air mixing tube
Access Door hinged cover on outside of water Main Burner Air Shutter the slotted sleeve on tube that
heater allows for gas and air adjustment
By Pass Kit a combination of hoses and valves Main Burner Orifice a precision drilled fitting that
that can aid in the winterization of regulates the BTU's of
the water heater combustion
CGA Canadian Gas Association N.P.T. (Nat'l Pipe Thread) a plumbing measurement standard
Calibration the condition determining whether
Pilot Assembly A gas tube, orifice & thermocouple
the thermostat is registering
temperatures properly Pilot Orifice a precision drilled thimble shaped
Cam-Loc Fastener a door securing device component that meters gas flow
to pilot
Circuit Board an electronic panel that controls the
spark, solenoid valve and senses Pilot Relight Ignition Module 12 volt electronic panel that
the main burner flame provides spark ignition and flame
sense to maintain pilot flame
Drawn Pan metal pan attached to the water
heater tank and fastened to coach Pressure-Temperature a pressure and temperature safety
sidewall to isolate combustion to Relief Valve device used on water heating
outside of coach vessels.
DSI direct spark ignition a.k.a. Ring and Gasket retaining fiber & metal rings that
electronic ignition secure combustion pan to tank
E.C.O. (energy cut off) high temperature re-set shut off Sight Glass burner flame viewing port on
device access door
Electrolysis electro chemical corrosive process Spark Probe Assembly a spark electrode & flame sensing
that can cause pinholes in tanks
Thermal Cut-Off heat sensing diode that cuts
Fenwal Tester a diagnostic circuit board analyzer power to circuit board if a flame
Flame Spreader a round deflective piece found at backs out of the burner tube or
the combustion end of main burner. flue tube normally caused by an
obstruction in these areas
Flue Box a chamber that separates air intake
and exhaust Thermostat (gas) a temperature sensitive device for
turning on and off the flow of gas
Flue Tube combustion and water heating
(T-stat)
surface area on inside of tank
Flying Lead flame sensing wire that is Thermostat (120 volt AC) a surface mount temperature
sometimes found hard wired to sensitive device that turns on/off
circuit board heating element
Front of Water Heater access door side of water heater Thermostat (12 Volt DC) a surface mount temperature
sensitive device that turns on/off
Gas Solenoid Valve a 12 volt DC device that turns on or the voltage to the circuit board
off the flow of gas
Thermocouple a device, when heated, generates
Immersion Element an AC electrical heating coil that is millivolts of electricity
immersed directly into water
UL Underwriters Laboratories
Inverted Flare type of connection using double
flare fitting and tube nut "U" Tube also referred to as a flue tube on
some water heater models
Inner Tank patented, designed vessel for
heating water Winterization process of preparing a water
®
Jade Knob Clip a horse shoe retainer clip on main heater for cold winter storage
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 Mobile Products warrants to the original owner and subject
Atwood water heater, furnace, range, hardware or detector
to the below mentioned conditions, that this product will be free of warranties can be submitted in one of two ways.
defects in material or workmanship for a period of two years from
the original date of purchase. Atwood’s liability hereunder is limited If you are already set up with an owner care program with an
to the replacement of the product, repair of the product, or OEM, you should submit the faulty part and claim through
replacement of the product with a reconditioned product at the
discretion of the manufacturer. This warranty is void if the product their system.
has been damaged by accident, unreasonable use, neglect,
tampering or other causes not arising from defects in material To submit a claim directly through Atwood the following
workmanship. This warranty extends to the original owner of the information is required:
product only and is subject to the following conditions:
1. For a period of two years from the date of purchase, Atwood will 1. Owner’s Name and Address.
replace the complete water heater if the inner tank leaks due to 2. Date of Purchase - obtain from copy of original bill of sale.
corrosion. This warranty includes reasonable labor charges
required to replace the complete water heater. 3. Model and Serial Number - The model and serial number,
2. For two years from the date of purchase, Atwood will repair or which is located on every water heater, furnace and range
replace any part defective in material or workmanship. This
warranty includes reasonable labor charges, required to remove
is required on all Atwood appliance claims.
and replace the part. Service calls to customer’s location are not 4. Manufacturer, Model, Year and VIN # of RV.
considered part of these charges and are, therefore, the
responsibility of the owner. 5. Work Performed - Describe in detail findings of existing
3. This warranty does not cover the following items classified as problem and corrective measure taken.
normal maintenance:
a. adjustment of gas pressure 6. Return Parts - A “MUST RETURN” parts list is attached.
b. cleaning or replacement of burner orifice Failure to return parts listed will result in denial of your
c. cleaning or adjustment of burner tube warranty claim.
d. cleaning or adjustment of flue
e. cleaning or adjustment of pilot and thermocouple 7. Return Good Number - a Return Goods Number (RGN)
f. adjustment of pressure-temperature relief valve must accompany all returned parts. This number may be
4. In the event of a warranty claim, the owner must contact, in
advance, either a certified Atwood Service Center or the
obtained by calling the Atwood Mobile Products Service
Atwood Service Department. Warranty claim service must be Department at 1-800-825-4328. The RGN must be clearly
performed at a certified Atwood Service Center (a list will be marked on the outside of each carton. Failure to do so will
provided at no charge) or as approved by the Consumer Service
Department, Atwood Mobile Products, 4750 Hiawatha Drive,
result in your shipment being refused at our receiving
Rockford, IL 61103-1298 USA. Phone: (815-877-5700). department.
5. Return parts (or water heater) must be shipped to Atwood 8. Return Freight - Atwood does not accept C.O.D.
“Prepaid”. Credit for shipping costs will be included with the
warranty claim. The defective parts (or water heater) become the shipments. Freight to return parts to Atwood should be
property of Atwood Mobile Products and must be returned to the indicated on your claim or repair order and you will be
Consumer Service Department, Atwood Mobile Products, 4750 reimbursed.
Hiawatha Drive, Rockford, IL 61103-1298 USA.
6. This warranty applies only if the unit is installed according to the 9. Travel Time - Because our warranty is based on the
installation instructions provided and complies with local and state customers ability to present the unit for service, and in an
codes.
7. The warranty period on replacement parts (or water heater) is the attempt to maintain our low cost products, reimbursement
unused portion of the original warranty period. for mileage, service calls and travel time WILL NOT BE
8. Damage or failure resulting from misuse (including failure to seek ALLOWED.
proper repair service), misapplication, alterations, water damage,
or freezing are the owner’s responsibility. 10. Payment for Warranty Service - All parts are replaced at
9. Atwood does not assume responsibility for any loss of use of no charge, freight prepaid upon our inspection. Labor, on
vehicle, loss of time, inconvenience, expense for gasoline,
telephone, travel, lodging, loss or damage to personal property
net 30 accounts is paid by credit memo within 30 days of
or revenues. Some states do not allow the exclusion or limitation receipt of parts.
of incidental or consequential damages, so the above limitations
or exclusions may not apply to you.
11. Flat Rate Schedule - A reasonable flat rate schedule for
10. Any implied warranties are limited to two (2) years. Some states warranty repairs has been set for each Atwood product
do not allow limitations on how long an implied warranty lasts, so and/or parts. Should unusual circumstances take you
the above limitation may not apply to you. This warranty gives
you specific legal rights and you may also have other rights which
beyond the standard time allowance, you must have prior
vary from state to state. approval by contacting the Atwood Mobile Products
11. Replacement parts (components or tanks) purchased outside of Service Department at 1-800-825-4328, and press option
the original water heater warranty carry a 90 day warranty. This
includes the part at no charge and reasonable labor charges to
5 after the recording.
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
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.
10
21
19
13
17
18
16
13
14
15
12
5 3 1
7
6
10
10
8
9 11
4
10
11
2
26
28
29
23
22 27
23
25
24 30
10 gallon bolt-on 6 gallon bolt-on 6 &10 gal. screw-in
heating element heating element heating element
32
GC6A, GC6A-3, GC6A-6, GC6A-7
GC6AA-7, GC6AA-7P
GC6AA-8, GC6AA-8P
REPLACEMENT PART REFERENCE
G10B, G10C
GC10A-2P
September 2003
GC10A-2
G4SM
93212 Piezo Ignitor Kit - battery operated (not shown)
Retrofits on all pilot model water heaters
92616 Robertshaw Pilot - not shown No Longer Available (use 91603)
92973 Inverted Flare Adapter (not shown) ✗ ✗ ✗
93923 E.C.O. No Longer Available (Use 92942)
92610 Gas Line Grommet (not shown) ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗
91346 Elbow Bushing - 1/4" inlet, 3/8" outlet No Longer Available
91285 Jade Orifice fits 91603 Pilot (not shown) ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗
1 90960 Flue Box & Gasket ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗
2 92640 Grille, New Style in Door ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗
3 91602 Robertshaw Thermostat
(3/8" NPT inlet, 3/8" NPT outlet) ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗
4 91601 White Rodger thermostat
(1/4" NPT inlet, 3/8" NPT outlet) ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗
5 91044 45° Elbow 3/8" x 3/8" - OLD ✗ ✗ ✗
91347 Elbow - 1/4" x 3/8" inlet - NEW ✗ ✗ ✗ ✗ ✗ ✗
6 92615 Main Burner 6 Gallon ✗ ✗ ✗ ✗ ✗ ✗
93221 Main Burner 10 Gallon ✗ ✗ ✗ ✗
7 92742 Main Burner Orifice (6 Gal.) ✗ ✗ ✗ ✗ ✗
93914 Main Burner Orifice (10 Gal.) ✗ ✗ ✗
8 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" Measure drain coupling
14 92698 Petcock Drain Valve 1/8" Measure drain coupling
15 93804 Piezo Electrode - hard-wired ✗ ✗
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 ✗ ✗ ✗ ✗ ✗ ✗
93935 Drawn Pan 10 Gallon Pilot ✗ ✗ ✗ ✗
20 91604 Pressure Temperature Relief Valve ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗
21 91174 Fiberboard Jacket (6 Gal.) No Longer Available (Use 91240 & 91241)
91240 Styrofoam tank cover - top ✗ ✗ ✗ ✗ ✗ ✗
91241 Styrofoam tank cover - bottom ✗ ✗ ✗ ✗ ✗ ✗
93912 Fiberboard Jacket (10 Gal.) No Longer Available (Use 91238 & 91239)
33
GC6A, GC6A-3, GC6A-6, GC6A-7
GC6AA-7, GC6AA-7P
GC6AA-8, GC6AA-8P
G10B, G10C
REPLACEMENT PART REFERENCE
GC10A-2P
GC10A-2
September 2003
G4SM
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.) No Longer Available (use 910921 or 91116)
92858 110VAC On/Off Switch (10 Gal.) No Longer Available (use 91089 or 91182)
26 91092 110VAC On/Off Switch (6 Gal.) ✗ ✗ ✗
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) No Longer Available (use 92249)
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 No Longer Available (use 91591)
N/S 93299 Conversion to Pilot 10 gallon 110VAC No Longer Available (use 91596)
N/S 91591 Conversion to Pilot 6 gallon 110VAC ✗
N/S 91596 Conversion to Pilot 10 gallon 110VAC ✗ ✗
34
ELECTRIC SIDE
ELECTRIC WATER HEATERS
23
24
19 24
25
25
6 gallon screw-in 10 gallon screw-in
heating element heating element
16
19 18
17
18
22
21
6 gallon bolt-on 10 gallon bolt-on
heating element heating element
35
ELECTRONIC Water Heater
6 - 10 gallon
15
12
28
Red
15-A
31 Red
Brown Brown
14
4
6
30 29A
33 13
4A/B 29B
12
5 12
7
5A
8
9 10
11
11 3
2
8A
12
8B
Rear-mount Front-mount
12VDC 12VDC
28
electronic electronic
thermostats thermostats
26
First number in matrix refers to illustration number, the second is the part number.
36
GCH10A-2E, GCH10A-3E, GC10A-2E, GC10A-3E
GCH6-4E, GCH6-6E, GCH6-7E, GC6A-7E
GCH6A-10E, GC6AA-10E
GC10A-4E, GCH10A-4E
G610-3E, GH610-3E
GH10-2E, GH10-3E
GC10-1E, GC10-2E
G10-1E, GH10-1E
REPLACEMENT PART REFERENCE
G6A-2E, GH6-3E
G10-2E G10-3E
September 2003
37
GCH10A-2E, GCH10A-3E, GC10A-2E, GC10A-3E
GCH6-4E, GCH6-6E, GCH6-7E, GC6A-7E
GCH6A-10E, GC6AA-10E
GC10A-4E, GCH10A-4E
G610-3E, GH610-3E
GH10-2E, GH10-3E
GC10-1E, GC10-2E
G10-1E, GH10-1E
G6A-2E, GH6-3E
G10-2E G10-3E
REPLACEMENT PART REFERENCE
September 2003
38
SERVICE TANK KIT
PART NUMBERS
REPLACEMENT PART REFERENCE
September 2003
91411
91412
91591
91592
91593
91596
91641
91642
93950
93952
93953
94205
91059
91053
91060
91028
MODELS
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 ●
39
EHM 4-SM
ELECTRIC WATER HEATER
EHM 6-SM ALL MARINE WATER HEATER CAPACITIES
EHM 11-SM
EHM 20
1
2A
2B
3
ar
4
Re
n t
Fro
10
9
8
7