Condensing Water Heater Service Manual 37 100000354
KA Series Component Replacement Instructions
RC98HPe
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 gas manifold
5. Disconnect high tension cord from electrode.
Remove one screw for ignitor bracket. Remove
ignitor bracket from manifold.
6. Disconnect flame rod connectors. (yellow and red)
7. Remove seven pan head screws from manifold (six
screws on the outer edge, one screw in middle),
and three machine screws, at bottom of manifold, to
gas valve.
8. Disconnect the four connectors from the solenoids
at bottom of manifold. Remove manifold plate.
9. Remove eight screws for the combustion chamber
sight glass plate. Remove plate.
10. Remove two screws attaching the burner to the
heat exchanger. Pull out the burner.
Disconnect water lines
11. 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.
12. Remove two screws and two brackets at by-pass
valve assembly.
13. Remove lower clip from drain connecting pipe.
14. Remove the clip on the heat exchanger inlet pipe on
the right side of heat exchanger. Remove the two
anti frost heaters from pipe. Remove heat
exchanger inlet pipe.
15. Disconnect condensate tube from upper heat
exchanger.
Manifold
(Step 7)
By-pass
valve
(Step 12)
Water outlet
(Step 11)
Ignitor
(Step 5)
Flame Rod
Connectors
(Step 6)
Solenoid
connectors
(Step 8)
Machine
screws
(Step 7)
Combustion
chamber
sight glass
plate
(Step 9)
Drain pipe clip
(Step 13)
These instructions are for replacing the lower (primary) heat exchanger or the upper (secondary) heat exchanger.
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