INSTALLATION AND SERVICE MANUALNUMBER 6500016

ocroBER 1983

DIRECT SPARK IGNITION - DIRECT VENTGAS WATER H EATER

FOR INSTALLATION IN RECREATIONALVEHICLES AND MOBILE HOUSING

FOR YOUR SAFETY, IF YOU SMELL GAS.1. OPEN WINDOWS.2, DON'T TOUCH ELECTRICAL SWITCHES.3. EXTINGU]SH ANY OPEN FLAM ES.4, IMMEDIATELY SHUT OFF GAS SUPPLY TO HEATER.

WARNINGDRAIN HEATER IF SUBJECT TO FREEZING TEMPERATURE. DONOT STORE OR USE GASOLINE, OR OTHER COMBUSTIBLEMATERIALS OR LIQUIDS NEAR OR ADJACENT TO THIS HEATEROR ANY OTHER APPLIANCE. THIS APPLIANCE SHALL NOT BEINSTALLED IN ANY LOCATION WHERE FLAMMABLE LIQUIDSOR VAPORS ARE LIKELY TO BE PRESENT.

INSTALLER: AFFIX THESE INSTRUCTIONS TOOR ADJACENT TO WATER HEATER.

OWNER: RETAIN THESE INSTRUCTIONS ANDWARRANTY FOR FUTURE REFERENCE.

R*reation Vehicle lndustry Assciation

oVr'MtytoR-FLoAmrnrcaWater Heaters

rfioR.FLO'TNDU5TRTES, TNE.

AIYIERIEANAPPL'ANCE Iu'IG.CARP.

18450 SOUTH MILES ROADCLEVELAND, OHIO 44128(216) 663-7300 . TELEX: 985-496

2341 MICHIGAN AVENUESANTA MONICA, CA. 90404Q13l 829-1755 . TELEX: 652-422

Ur "A).SE TSIETETw/

/rPPROV€O

t{ STAL LATION REQUI REMENTS*' : -::: aiion must conform with the require-- * -- : :' :ne authority having jurisdiction or in"'.* i.:::-:e of such requirements with the national" .* ;:s ccde. ANSI 2223.1-1974: and American

* r' :-: Standard For Recreational Vehicles -:':' : ' 1"7. in Canada C.S.A. 2240.4.

' -^e appliance shall be disconnected from:-e gas supply piping system during any:'3ssure testing of the system.

- -^e appliance and its gas connection shall:: leak tested before placing the appliance- cperation.

' - --n clearance from combustible materials: - : ::s. top, floor, and rear - 0 inches. Provide: : -'l' access to rearof heaterforservicing.

OUTER COACH WALL

lnsert heater into the framed opening. Frontof housing should be flush with outside wall.Secure to coach with nails at bottom and sidesof control housing compartment. Place caulk-ing to inside of housing frame. lnsert frameinto housing compartment and secure withth ree #1 0-2 4 x 31/2" screws.

To install door, locate holes in bottom of doorover pins on the lower control housing frame.Close door so that the latch protrudes throughthe slot in the door. Turn latch 90 degrees tofasten door.

DSI MODELSHinged Door

lnsert heater into framed opening. Place caulk-ing sealant between heater flange and outerwall of the coach to insure a water-tight bond.Secure heater to wall using (12) No. 8 x 3/q"

wood screws, screwed through holes in frontmounting panel of heater.

To install door, slip one hinge pin into slot oneach side of door, then insert other end of hingepins behind spring brackets on heater frame,close door so that latch protrudes throughslot in door. Turn latch 90 degrees to fasten thedoor.

A.

B.

FI6URE I

:':,'de an opening flush with floor in outer wall:':cachasshown.

'-l-l!: I

!ii

F/GURE

,', a I of coach should- f igure-1. Maintain

6 Gal. Models10 Gal. Models

contain framing as showninside dimensions listed

AB12e/+ 123/a16Vq 16t/a

B.

FDSI MODELS(separate door f rames)

FIGURE 2

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MANIFOLDNUT

FIGURE 7

GAS VALVE

THERMOSTAT ANDMANUAL TEST

This water heater is provided with a high tempera-ture cut-off device in the event of thermostatfailure. Temperature above 190'F will causemanual reset button to trip shutting down mainburner.

To activate burner, the water temperature must bebelow 100"F, push reset button to re-activatebu rn er.

RESET zuTTON

FIOURE 8

THERMOSTAT PRESET @(NON ADJUSTABLE)

LOCATED UNOER ACCESS COVER, ONREAR OF WATER HEATER.

BU RNER

All air shutters are pre-set at the factory to obtaina blue or orange-blue flame. lf it is necessary toadjust the air shutter, be sure to maintain the blueor orange-blue flame color. Do not allow theburner flame to burn with a yellow flame, becausesooting will occur.

AIR SIIIJTIER: TURN AIR STruTIER,TO OBTAIN PROPER BLUE FI-A,I,IE.

FIoURE 9

1400 F

EURNER FLAME

3

ln cases where sooting has occurred, there is a

;;.ri;ii'ty inii nit colndition mav b9 corrected

bv makinq the correct air shutter adjustment' lf

iri."oi,'iri"? ii"r" continues to burn vellow after,air.tino the air shutter, check for qn obstructioni"*ii.r; b;iler or the flue box' A stiff brush is rec'

ommlnOeO for the removal of soot deposits'. lfin"i"li *ot in the burner, check to make sure the

orl r"f r" is shutting off clean' This can be checked

tsi-tiiri"g tne otf--on switch to the off position'

ff,"i" srrdulo be no flame at the burner orificeor at the burner.

DRAINING ANDSTORAGE INSTRUGTION

lf RV is to be stored during winter months' the

*"iL, nLater must be drained to prevent damage

from freezing.1. Turn off Power & gas.2. Turn off f ressure pump on water system'3. Open boin not & cold water faucets'4. Open drain on water heater'S. F,5riow RV manufacture instructions for drain'

ing entire water system.

NOTE: Be certain to refill water heater with water

before re-lighting'

TEMPERATURE ANDPRESSURE RELIEF VALVE

The temperature and pressure relief valve is de-

;;;;.;J i5-op"n if the temperalure of the wat-

within the heater ,"""net 2tO"F,-or if the watLoi"iiur" in the heater reaches 150 pounds' Rec'

I;;i;;"l vehicle water systems are closed sys'

i;r; ino ouring the witer heating cvgle' th9

;;;.r;; buiro-ui in the water system will reach

Til;ilt. wnbn this pressure is reached' the

;;;t5;;'i.t'i.t valve will open and water will drip

fr;;"in; '*ir". inL otippins will-continue until

ii'rl'"r".trre is reduceo to netow 150 pounds' and

i;;;;;lr;;loses. rnis condition is normal and does

not indicate a defective relief valve'

BURNER COMPARTMENTMAINTENANCE

Periodically check control compartment and

,.r""n in door to see that no foreign material has

iccumufated to prevent flow of combustion and

i"ntirrting- iit. Periodically check burner f lame

;Gr;llt, a"nd compare with sketch under the burner

adjustment section.

WARNING:Do not store or use combustible materials or liq'

,iOt n"".or adjacent to this heater' The appliance

inirl not be initalled in any location where flam',rOi" liquids orvapors are likely to be present'

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SERVICE HINTS, DIAGNOSIS AND CORRECTIVE MEASURES

The onry tools required to service the 05-15 and 16 are a phillips- head screwdriver and a 20,000 oHMS/volt multi'

tester(Radio Shack i84bl3, AiiiLO wv-stAA, triplett modbt 310'C or equivalent)

WHAT'S WRONG

1. Lockout Occurs 3'10Seconds After lgnition

2. Flame Not EstablishedArcing To Ground

3. No SPark4. Arcing OtherThan

Across GaPWeak SPark

No FlameLow Flame Current

and/or Nuisance Lockouts

WHY

1. Reverse PolaritY2. System lmProPerlY

Grounded3. Gas Pressure Too High,

Causing Flame To LiftOff Burner.

4. Sensor Probe lncor-rectly Positioned lnFlame Pattern

Spark GaP Too SmallSpark GaP Too LargeCorroded Connector1. Cracked or DirtY

lnsulator2. Broken High Voltage

LeadHigh Voltage Lead TooClose To Metal SurfaceValve MalfunctionElectrode lmProPerlYPlaced1. Flame Current Falls

Below 2.5UA2. Low Gas Pressure

WHAT TO DO

ParagraPh 1, Preliminary ChecksParagraph 2

Check To lnsure lnPutPressure As SPecified OnMan ufacturer's Data Plate'ParagraPh 6

Paragraph 3AParagraph 3AParagraph 38Paragraph 3C

Paragraph 3C

Paragraph 3E

ParagraPh 4Paragraph 5

ParagraPh 6

Check To Ensure That Man'ifold Pressure Meets Man-ufacturer's SPec if i cations"

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DESCRIPTION

The Fenwal series 05-15 (12VDC) and 05-16 (24VC)direct spark ignition systems operate through athermostat to provide a means of ignition foi tne

ain burner on gas-fired equipment. fnis is ac-v.,rmplished by generating a spark between highvoltage electrode and ground. Once the f lame

-is

established, a flame rod monitors the main burnerflame (see figure#10). Refer to builetins No. 5-'t5A

:: t:::tor i nstaltation i nstructions.

TROUBLESHOOTING

Although the following tests can be made usinga standard volt meter, it is quicker and more con--venient to use a fenwal model O5-125539-001 testadaptor (see figure #11).

PRELIMINARY CHECKS1. lnput polarity -lf a spark is present and the gas valve opens for

the flame establishing period but then locks outat the end of three to ten seconds, check theinput voltage at terminal 1 and 6 for the properp-olarity. Terminal 1 should be ,,hot,,; (12-VDC(:05-15) or 24YAC (05.16)) with respect to ground.Terminal 6 is neutral, or zero voltage, witn re-spect to ground (see f igure #11).

2. lmproper grounding -lf a flame is present during the trial for ignitionperiod but the system shuts down, insure thatthe burner is properly grounded. lf the burneris. not grounded, the flame monitoring signalwill not function and the system will-go intolockout. Check for loose or corroded teiminalsand replace if necessary. Ensure good elec-trical connection by scraping paint or anyother foreign matter off the area where groundconnection is made.

It is equally important to be certain that the elec-trode bracket assembly is properly grounded. Thebracket should be common with the ground leadon the input connector (ground terminal 6). lf thebracket is not properly grounded, damage to theignitor can result.

3. lnoperative high voltage -If there is no spark or sparking is intermittent,check the following, after disconnecting vol-tage to the system.

A. Check spark gap. Gap should be 1/8,, +1132" trom H.V. to ground. CAUTTON: neverreplace the component board without firstchecking to insure that the electrode hasthe proper gap. tf the gap is too wide, dam.age to the ignitor can result.

B. Check electrode leads and determine thereis no corrosion at the terminals. lf there iscorrosion, clean it off.

C. Check ceramic insulators for cracks, foreignmatter, and carbon. lf there are cracks, re-place electrodes. lf there is carbon or foreignmatter, clean it off.

D. Check high voltage lead wire for cracks orbreaks. lf there are cracks, breaks, or chaf-fing, replace high voltage wire.

TX€ffiAT

Block Diagram

SEQUENCE OF OPERATION

On a call for heat, voltage is applied to the ignitoracross terminals 1 (power) and 6 (ground) of tneinput connector. A high voltage spaiX is then gen-arated from the spark electrode to ground. Sim-

aneously, the gas valve is energized.

At the start of each heat cycle, there is a ,,trial forignition period" of three to ten seconds durationdepending upon the model ignitor used. Normally,main burner-flame will be established before theend of this period. Once the flame is established,sparking will cease and the,,flame rod,, will pro-vide flame monitoring for the remainder of 'theheat cycle. lf the flame is extinguished duringthis cycle, the ignitor will start sparking auto--matically in an attempt to re-establish the flame.lf this does not occur within the ,,trial for ignitionperiod", the system will go into lockout, Closingthe gas valve.

To measure llame currenl disconnecl sensor wire al the probeand rnseila DC mrcroampmel€r. ser es wrlh sensor probe

FlGURE lO

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FDS| 6 I (M)FRONT VIEW

7

PartNumber

RelerenceNumber Part Model

2000s09200051 1

200051 020045124700367370009537000963000041Not ReplaceableNot ReplaceableNot ReplaceableNot Replaceable4400031

43000244400013

3200550

280006837000973600042

3000086310003932001 984300034440002220001512000458200015326001 072600030260003326000312000084200009327000742700112440001 5

48000163200241320026928000323200244320024526000053200194420005920001503100040

23

Rear CoverAssy

Anode RodGas Supply lnlet-Manifold

Motor-Aid H eat- ExchangerTankFi berg lass I nsulation-BlanketJacketControl HousingFront Gas Supply-ManifoldGrommetPTR ValvePTR Valve Spud Flange

Gas ValveGas Valve Mounti ng-BracketBurner ManifoldBurner Orif ice

BurnerAssemblyBurnerAir ShutterElectrode AssemblyDrain ValveDrain Valve Spud FlangeDoor, Screen lncluded

Door Hinge PinDoor Hinge Pin FastenerDoor Latch BracketDoor Latch AssemblyFlue CollectorBack AssemblyFlue Collector Front

Rear lnlet Gas SupplyManifold GrommetControlCoverlgnition Control ModuleSpark CableThermostat & ECO BracketThermostatECOJunction Box CoverWiring HarnessSwitch & PlateDoor Housing Frame AssemblyBurner Support Bracket

FDSI6&DSI6FDSI 6M & DSI 6MDSIlODSI lOM \q6&106 Gallon10 Gallon

6&10FDSI 6DSt6&10(AllModels)

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1011

12

131415

16171B192021

2223242526

27

FDSI 6DSI 6DSIlODSt6 & 10 cDSl6&10DSt6&10(All Models)6 Gallon10 Gallon6 Gallon10 Gallon

28

2930313233343536373839

FDSI 6

NOTE: All screws in assembly are standard hardware items.

When ordering parts, be certain to specify the exact model number of your heater complete serial number, partnumber, and the name of the part from this list. All parts not covered by the warranty will be shipped C.O.D.(NOTE: Warranty covers mechanical parts for a period of one year only.)

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Printed bY HIP