Condensing Water Heater Service Manual 34 100000354
KA Series Component Replacement Instructions
RC80HPi
Heat Exchanger
1. Turn off gas supply.
2. Turn off water supply. Drain all water from the
appliance.
3. Turn off 120V power supply.
4. Remove four screws securing the front panel.
Remove front panel.
Remove controller assembly
5. Remove temperature controller. Remove two
screws for temperature controller bracket. Remove
bracket.
Remove gas manifold
6. Disconnect high tension cord from electrode.
7. Disconnect flame rod wires. (yellow and red)
8. Remove three machine screws where manifold
meets the gas valve, then remove six screws from
the manifold.
9. Disconnect ignitor module harness, mounted on
manifold. (gray/gray)
10. Disconnect the two solenoid wire harnesses at
bottom of manifold. Remove manifold plate.
11. Remove eight screws for the combustion chamber
sight glass plate. Remove plate.
12. Remove two screws attaching the burner to the heat
exchanger. Pull out the burner.
Remove fan
13. Disconnect fan harness.
14. Remove two screws from fan assembly.
15. Remove fan.
Disconnect water lines
16. Remove one screw from hot water line bracket.
Remove bracket by rotating and moving it up toward
the bend in the tube where the diameter is smaller.
17. Remove two screws and two brackets at by-pass
valve assembly.
18. Remove clips from drain connecting pipe. Remove
drain connecting pipe.
Manifold
(Step 8)
By-pass
valve
(Step 17)
Water outlet
(Step 16)
Ignitor
(Step 6, 9)
Flame Rod
Connectors
(Step 7)
Solenoid
connectors
(Step 10)
Machine
screws
(Step 8)
Combustion
chamber
sight glass
plate
(Step 11)
Drain pipe clip
(Step 18)
Fan
(Step 13-15)
These instructions are for replacing the lower (primary) heat exchanger or the upper (secondary) heat exchanger.
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