Atwood Mobile Products 94605 manual

1 September 2003 INTRODUCTION The 2004 edition of the Atwood W ater Heater Service Manual is a resour ce created to help service technicians identify Atwood product by serial number , diagnose service problems and ef ficiently and effectively pr ocess warranty claims. In 2003, Atwood relocated the Switch, Thermostat and ECO that was installed on th[...]

2 NOTES THIS P AGE INTENTIONALL Y LEFT BLANK[...]

3 T ABLE OF CONTENTS Atwood W ater Heaters Atwood Letter 1 Aftermarket Model Identification 4 Pilot Models Questions 5 Model Number Explanation / Features 6 Recommended T ools & Equipment 7 Gas Thermostat Controls & Pilot Assemblies 8 Pilot Sequence of Operation 9 Pilot & Main Burner 10 T r ouble Shooting Guide 11 Engine Heat Exchange S[...]

4 Aftermarket Gas W ater 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 G6[...]

5 PILOT MODELS QUESTIONS The following questions should be answered during this portion of the manual: · Ar e the Robertshaw and White Rodgers thermostat gas control valves inter -changeable? · What is the minimum gas pr essure requir ed for proper water heater operation? · Where on the water heater gas contr ol can gas pressur e be tested? · C[...]

6 Atwood 6 and 10 gallon Pilot W ater Heaters Atwood water heaters are designed and appr oved for use only in recr eation vehicles (travel trailers, 5th wheels, motor homes, etc.). They are of fered in two sizes: 6 and 10 gallon capacities. TYPE OF GAS IGNITION - This unit is ignited outside of the trailer by a match, piezo ignitor or other ignitio[...]

7 Recommended T ools and Equipment U-T ube Manometer - This is the most accurate device for measuring gas pr essure. If you use a dial-type manometer , it should be calibrated periodically with this type of manometer . Thermostat Wr ench - This tool allows for easier and safer r emoval of the gas thermostat control. An adjustable version for differ[...]

8 Gas Thermostat Controls and Pilot Assemblies Only two makes of gas controls have been used on our pilot model water heaters. They ar e the Robertshaw “Unitrol” and White Rodger (formerly Jade or ITT). The Robertshaw control came in two dif ferent sizes of gas inlets: 3/8˝ inverted flar e and 3/8˝ N.P .T . The inverted inlet control is no lo[...]

9 Pilot Sequence of Operation PILOT OPERA TION • 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 therm[...]

10 Pilot and Main Burner Pilot Adjustment Only the gas pressur e, gas valve and the pilot orifice regulate the height of the pilot flame. Early model gas controls have a pilot adjustment scr ew , but this scr ew has very little effect on the pilot. The pilot adjustment has been removed fr om the current White Rodger contr ol. The flame should be hi[...]

11 Guides are only intended for use on Atwood ® pr oducts by service technicians who have successfully completed Atwood ® training. This guide should be used in conjunction with the appropriate Instruction Manual pr ovided with the product and any applicable Industry standar ds. This is not intended to be a complete list. Please direct questions [...]

12 Engine Heat Exchange System 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 electr onic water heater on gas while in transit is a dangerous practice. This system consists of a U-shaped aluminum tube that is[...]

13 Ground Switch Element Fixed Thermostat Manual Reset High Temperature Limit Switch ( 3 )-GREEN ( 1 )-BLACK BLACK ( 2 )-WHITE BLACK Hot Lead Ground Lead Common Lead Early model water heaters with 110 V AC heating capacity used a bolt-on heating element and a one piece thermostat/E.C.O.. This 110 V AC system has an adjustable rectangular thermostat[...]

14 Current pr oduction water heaters with the 110 V AC heating option use a screw-in heating element, a separate pre-set thermostat and a separate ECO. The screw-in heating element is rated at 1400 watts just like the bolt-on element. It is an incalloy element and can be run for a limited amount of time in a dry tank without shorting out. CAUTION: [...]

15 ELECTRONIC IGNITION MODELS QUESTIONS The following questions should be answered during this portion of the manual: · What is minimum gas pressur e for proper water heater operation? · Where on the gas solenoid valve can gas pr essure be tested? · What is the minimum voltage needed for operation? · What is the proper wiring hook-up for the wa[...]

16 Atwood 6 and 10 gallon Electronic Ignition W ater Heaters Atwood water heaters are designed and appr oved for use only in recr eation vehicles (travel trailers, 5th wheels, motor homes, etc.). They are of fered in two sizes: 6 and 10 gallon capacities. TYPE OF GAS IGNITION - This unit is ignited inside of the trailer by a remote ON / OFF switch.[...]

17 Recommended T ools and Equipment U-T ube Manometer - This is the most accurate device for measuring gas pr essure. 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 pr[...]

18 DSI Sequence of Operation • Gas Supply 11˝ W .C to solenoid valve is necessary  • 12VDC Batter y Voltage source to water heater or filtered side of Convertor  • ON/OFF Switch It supplies 12VDC to water heater  • Thermal Cut-Off A one shot heat sensing fuse that’ s normally closed and sends power to the thermostat. When trippe[...]

19 Guides are only intended for use on Atwood ® pr oducts by service technicians who have successfully completed Atwood ® training. This guide should be used in conjunction with the appropriate Instruction Manual pr ovided with the product and any applicable Industry standar ds. This is not intended to be a complete list. Please direct questions [...]

20 Electronic Ignition Water Heater (continued) Ef fective: 5/26/98 CAUSE SOLUTION EXCESSIVE OR INSUFFICIENT WA TER TEMPERA TURES By-pass kit valves not set properly ---------------------------- Place valves in proper position Thermostat not seated against tank ---------------------------- Reseat thermostat Defective thermostat --------------------[...]

21 Guides are only intended for use on Atwood ® pr oducts by service technicians who have successfully completed Atwood ® training. This guide should be used in conjunction with the appropriate Instruction Manual pr ovided with the product and any applicable Industry Standards. This is not intended to be a complete list. Please dir ect questions [...]

22 Intermittent Ignition Water Heater (continued) Ef fective: 8/21/00 5. CHECK THE AIR ADJUSTMENT . The burner tube has an adjustable air shutter on it at the end where it goes over the orifice. Position the air shutter so that it is 1/4 of the way open. W e are looking for a blue flame with small traces of yellow in the flame. If the flame is fair[...]

23 ** POTTED CHANNEL CIRCUIT BOARDS Atwood **potted circuit boar ds can be tested using a multi-meter . This test must be performed with the circuit boar d removed, and the meter set to the ohms scale. This will check the continuity of all tracks on the harness connection of the board. The following steps should be used to test each track. A. Cross[...]

24 W ater Heater Wiring Schematics Gas Solenoid Valves ECO Switch Non-Ignition Light Fixed Temperature Control Thermostat Remote Switch 12 volt DC Spark & Sense Thermal Cut-Off RED RED BLUE BROWN GREEN GREEN BROWN BROWN GREEN ( 6 ) ( 4 ) ( 3 ) ( 2 ) GREEN BLUE ( 6 ) ( 4 ) ( 3 ) ( 2 ) BATTERY REMOTE SWITCH BROWN Dotted lines are wired by custome[...]

25 GENERAL INFORMA TION QUESTIONS The following questions should be answered during this portion of the manual: · What causes the pr essure-temperature r elief valve to weep when unit is in heating cycle? · How can weeping pr essure-temperature r elief valves be reduced or eliminated? · What ar e the proper draining procedur es to help reduce li[...]

26 PRESSURE-TEMPERA TURE RELIEF V AL VE 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 [...]

27 FLUSHING YOUR WA TER HEA TER TO REMOVE THE ROTTEN EGG ODOR 1. T ur n off your main water supply . Drain you water heater tank. Reinstall drain plug. Remove the pressur e-temperature r elief valve. With a funnel use 4 parts white vinegar to two parts water . (In a 6 gallon tank that would be 4 gallons vinegar to 2 gallons water). 2. Cycle the wat[...]

28 T erminology Definition AGA American Gas Association Access Door hinged cover on outside of water heater By Pass Kit a combination of hoses and valves that can aid in the winterization of the water heater CGA Canadian Gas Association Calibration the condition determining whether the thermostat is registering temperatures properly Cam-Loc Fastene[...]

29 A TWOOD W A TER HEA TER LIMITED W ARRANTY Atwood Mobile Products warrants to the original owner and subject to the below mentioned conditions, that this product will be fr ee of defects in material or workmanship for a period of two years from the original date of purchase. Atwood’ s liability hereunder is limited to the replacement of the pr [...]

30 Return Goods Policy Effective August 7, 1995, all Atwood defective returns will no longer be repaired at the warehouses and returned to customers. Defective returns will be shipped back to the respective manufacturing facility for problem cause analysis within 30 days of sales. Full credit will be issued if the cause analysis determines Atwood i[...]

31 June 17, 2003 Flat Rate Schedule W ater Heaters TIME ALLOWANCE SCHEDULE in hours Replacement of: Standard Pilot Electronic Ignition Model Model Access Door ........................................................................................................ .30 ..................................................................................[...]

32 13 8 7 6 15 5 3 9 11 10 16 17 18 19 10 20 10 12 11 4 6 &10 gal. screw-in heating element 6 gallon bolt-on heating element 10 gallon bolt-on heating element 26 27 25 23 24 29 28 30 10 22 23 2 14 13 21 1 PILOT Water Heater 6 - 10 gallon First number in matrix refers to illustration number , the second is the part number .[...]

33 Pilot W ater Heaters REPLACEMENT P ART REFERENCE September 2003 GC6A, GC6A-3, GC6A-6, GC6A-7 G6A, G6A-2, G6A-3, G6A-6, G6A-6P , G6A-7, G6A-7P GH6-3, GH6-6, GH6-7 GC6AA-7, GC6AA-7P GC6AA-8, GC6AA-8P G610-3, G610-3E, GH610-3 G10B, G10C GC10A-2 GC10A-2P GC10-1, GC10-2, GC10-2P G10-1, G10-1P , G10-2, G10-2P G4SM 93212 Piezo Ignitor Kit - battery ope[...]

34 Pilot W ater Heaters REPLACEMENT P ART REFERENCE September 2003 GC6A, GC6A-3, GC6A-6, GC6A-7 G6A, G6A-2, G6A-3, G6A-6, G6A-6P , G6A-7, G6A-7P GH6-3, GH6-6, GH6-7 GC6AA-7, GC6AA-7P GC6AA-8, GC6AA-8P G610-3, G610-3E, GH610-3 G10B, G10C GC10A-2 GC10A-2P GC10-1, GC10-2, GC10-2P G10-1, G10-1P , G10-2, G10-2P G4SM 21 91238 Styrofoam tank cover - botto[...]

35 10 gallon bolt-on heating element 22 18 6 gallon bolt-on heating element 16 17 18 21 19 6 gallon screw-in heating element 24 23 25 10 gallon screw-in heating element 24 19 25 6 gallon screw-in heating element 10 gallon screw-in heating element ELECTRIC SIDE ELECTRIC W A TER HEA TERS[...]

36 Rear-mount 12VDC electronic thermostats Front-mount 12VDC electronic thermostats Brown Brown Red Red 15-A 1 12 8 9 10 11 11 5A 5 33 6 4 30 4A/B 29B 8A 7 12 2 3 12 12 13 15 14 31 ELECTRONIC Water Heater 6 - 10 gallon 26 28 8B 28 29A First number in matrix refers to illustration number , the second is the part number .[...]

37 Electr onic W ater Heaters REPLACEMENT P ART REFERENCE September 2003 91470 130° Fr ont Mount thermostat (not shown) ✗ ✗ ✗ ✗ ✗✗✗ ✗✗✗ ✗ ✗ ✗ ✗ 93105 Adjustable Thermostat (retrofits ✗ ✗ ✗ ✗ ✗ ✗✗✗ ✗✗✗ ✗ ✗ front-mount thermostats) (not shown) 92610 Gas Line Grommet (not shown) ✗ ✗ ✗ ✗ ?[...]

38 Electr onic W ater Heaters REPLACEMENT P ART REFERENCE September 2003 15-A 91802 Drawn Pan (Electronic 6 Gallon) ✗ ✗ ✗ ✗ ✗ ✗ 15-A 93871 Drawn Pan (Electronic 10 Gal.) ✗ ✗✗✗ ✗✗ ✗ 16 92857 110V AC ON / OFF Switch (6 Gal.) No Longer Available (Use 91092 or 91116) 16 92858 110V AC On/Off Switch (10 Gal.) No Longer Available[...]

39 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 COMBINA TION 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,[...]

40 ELECTRIC W A TER HEA TER ALL MARINE W A TER HEA TER CAP ACITIES 6 7 8 9 10 2B 3 4 5 Front Rear 2A 1 ITEM P ART # DESCRIPTION 1 92248 EHM4-SM Service T ank 91745 Plate 2 A 91740 ECO Switch (220V) 2 B /3 90037 Thermostat, ECO, plate, wires (110V) 2 C 92942 High Limit 3 92943 Thermostat (140 o ) 2/3 90037 Thermostat/ECO Kit 4 91874 Drain V alve 3/4[...]