Condensing Water Heater Service Manual 40 100000354
KA Series Component Replacement Instructions
RC98HPi
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. Remove high tension cord from electrode. Remove
one screw for ignitor bracket. Remove ignitor
bracket from manifold.
7. Remove red and yellow flame rod connectors.
8. Remove seven pan head screws from manifold. (Six
screws on outer edge, one screw in middle and
three machine screws from bottom of manifold to
gas valve.)
9. Remove four connectors from the solenoids at the
bottom of the manifold. Remove manifold.
10. Remove eight screws for the combustion chamber
sight glass plate. Remove plate.
11. Remove two screws attaching the burner to the heat
exchanger. Pull out the burner.
Disconnect water lines
12. 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.
13. Remove two screws and two brackets at by-pass
valve assembly.
14. Remove lower clip from drain connecting pipe.
Manifold
(Step 8)
By-pass
valve
(Step 13)
Water outlet
(Step 12)
Ignitor
(Step 6)
Flame Rod
Connectors
(Step 7)
Solenoid
connectors
(Step 9)
Machine
screws
(Step 8)
Combustion
chamber
sight glass
plate
(Step 10)
Drain pipe clip
(Step 14)
These instructions are for replacing the lower (primary) heat exchanger or the upper (secondary) heat exchanger.
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