A.O. Smith 100304126 User guide

COMMERCIAL / RESIDENTIAL GAS WATER HEATER

Service Handbook

PRINTED IN THE U.S.A. 0410 318556-000

SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE AGENT

500 Tennessee Waltz Parkway

Ashland City, TN 37015

FOR MODELS:

BTX 100, GDHE 50

SERIES 120 & 121

INSTALLATION CONSIDERATIONS - PRE SERVICE

CHECKS - WATER HEATER CONSTRUCTION -

OPERATION & SERVICE - TROUBLESHOOTING

TABLE OF CONTENTS

TABLE OF CONTENTS ..........................................................................1

INTRODUCTION ....................................................................................2

4XDOL¿FDWLRQV .....................................................................................2

6HUYLFH:DUQLQJ ................................................................................2

6HUYLFH5HPLQGHU ..............................................................................2

7RROV5HTXLUHG ...................................................................................2

INSTALLATION CONSIDERATIONS ..................................................... 3

,QVWUXFWLRQ0DQXDO ............................................................................. 3

&ORVHG:DWHU6\VWHPV ...................................................................... 3

7KHUPDO([SDQVLRQ ............................................................................3

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&RQWDPLQDWHG$LU ............................................................................... 3

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(OHFWULFDO5HTXLUHPHQWV .....................................................................6

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7RS9LHZ ............................................................................................ 9

&RPEXVWLRQ%ORZHU%XUQHU$VVHPEO\ ............................................ 9

OPERATION AND SERVICE ............................................................... 10

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%XUQHU$VVHPEO\ ............................................................................. 12

&RPEXVWLRQ%ORZHUDQG%XUQHU5HPRYDO .......................................14

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)ODPH6HQVLQJ&XUUHQW7HVW ......................................................19

,JQLWHU ...............................................................................................20

,JQLWHU&XUUHQW7HVW ....................................................................20

Venturi .............................................................................................22

Gas Valve ........................................................................................ 23

*DV9DOYH9ROWDJH7HVWV............................................................23

*DV9DOYH5HPRYDO ...................................................................24

Gas Pressure ................................................................................... 25

Gas Pressure Test .....................................................................26

*DV)ORZ7HVW ...........................................................................27

3UHVVXUH6ZLWFKHV ...........................................................................28

&RQVWUXFWLRQ2SHUDWLRQ ..........................................................28

&RQWURO6\VWHP0RQLWRULQJ ........................................................29

3UHVVXUH6ZLWFK7HVWV .....................................................................31

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3UHVVXUH7HVW'XULQJ2SHUDWLRQ ................................................32

7HPSHUDWXUH3UREH ..........................................................................35

7HPSHUDWXUH6HQVRU7HVW ..........................................................35

(&2&RQWLQXLW\7HVW ..................................................................36

&RQWURO6\VWHP+DUGZDUH ......................................................... 37

8,08VHU,QWHUIDFH0RGXOH ............................................... 37

&&%&HQWUDO&RQWURO%RDUG .............................................. 39

&&%&RYHU5HPRYDO$QG5HSODFHPHQW ............................. 40

&&%&LUFXLW%RDUG/D\RXW ................................................... 41

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:LULQJ'LDJUDP .......................................................................... 44

&21752/6<67(023(5$7,21 ................................................ 45

Overview .................................................................................... 45

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6WDWXV,FRQV ........................................................................ 47

2SHUDWLQJ6WDWHV ................................................................. 48

&RQWURO6\VWHP0HQXV .............................................................. 48

7HPSHUDWXUHV ...................................................................... 49

Heater Status ...................................................................... 50

'LVSOD\6HWWLQJV .................................................................. 51

+HDWHU,QIRUPDWLRQ .............................................................. 51

Current Fault ....................................................................... 52

)DXOW+LVWRU\ ........................................................................ 52

)DXOW2FFXUUHQFH ................................................................. 52

5HVWRUH)DFWRU\'HIDXOWV .................................................... 52

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6HTXHQFH2I2SHUDWLRQ)ORZ&KDUW .......................................... 55

TROUBLESHOOTING ................................................................... 56

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1RW(QRXJK+RW:DWHU ........................................................ 56

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&RQWURO6\VWHP8QUHVSRQVLYH ................................................... 57

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8,0,V,QRSHUDEOH ................................................................ 57

)DXOW0HVVDJHV ......................................................................... 58

AC Reversed ....................................................................... 58

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QUALIFICATIONS

QUALIFIED INSTALLER OR SERVICE AGENCY

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SERVICE WARNING

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INTRODUCTION

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INSTALLATION CONSIDERATIONS

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INSTRUCTION MANUAL

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TABLE 1

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,QVWDOOHG

2 Inch Pipe 3 Inch Pipe

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2”

3”

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FEATURES AND COMPONENTS

FRONT & BACK VIEWS

HEATING LOOP

RETURN LINE

CONNECTION

3/4 INCH NPT

DRAIN VALVE

TEMPERATURE

PRESSURE

RELIEF VALVE

FRONT VIEW BACK VIEW

EXHAUST ELBOW

(2 INCH PVC VENT

CONNECTION)

CONDENSATE

DRAIN CONNECTION

BLOCKED EXHAUST

SWITCH SENSING TUBE

HEATING LOOP

SUPPLY LINE

CONNECTION

3/4 INCH NPT

2 INCH PVC

INTAKE AIR

CONNECTION

TOP COVER

ON / OFF SWITCH

UIM

(user interface module)

CONTROL INTERFACE

COVER.

TEMPERATURE

PROBE - LOCATED

BEHIND CONTROL

INTERFACE COVER

TANK GLASSING

PLUG COVER.

USED FOR

MANUFACTURING

PURPOSES ONLY.

DO NOT REMOVE

GLASSING PLUG

FOR ANY SERVICE

OR MAINTENANCE.

COVER MAY BE

REMOVED IF LEAK

IS SUSPECTED.

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TOP VIEW

BLOWER

PROVER

SWITCH

CCB ENCLOSURE

(central control board)

3/4 INCH NPT

WATER OUTLET

WITH OUTLET

ANODE ROD

3/4 INCH NPT

WATER INLET

BLOCKED

EXHAUST

SWITCH

TEMPERATURE

PRESSURE

RELIEF VALVE

BURNER

SIGHT GLASS

FRONT

1/2 INCH

SUPPLY GAS

CONNECTION

BLOCKED

INTAKE AIR

SWITCH

COMBUSTION

BLOWER

2 INCH PVC

INTAKE AIR

CONNECTION

2 INCH PVC

VENT CONNECTION

JUNCTION

BOX - 120 VAC

POWER SUPPLY

CONNECTIONS

SECOND

ANODE ROD

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COMBUSTION BLOWER & BURNER ASSEMBLY

COMBUSTION

BLOWER

EXPLODED VIEW

GASKET

(SILICONE)

BLOWER

DISCHARGE

ORIFICE

GASKET

(FIBER)

BURNER SIGHT

GLASS AND

WIRING HARNESS

COVER PLATE

GASKET (SILICONE)

GASKET

GASKET (FIBER)

BURNER SIGHT GLASS

BURNER

ADAPTER

BURNER ADAPTER

WIRING HARNESS.

IGNITER/FLAME

SENSOR

IGNITER

BURNER

BURNER FLANGE

(FLOATING FLANGE)

FLAME

SENSOR

GAS VALVE

VENTURI ASSEMBLY

INTAKE AIR

ELBOW

ASSEMBLED VIEW

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OPERATION AND SERVICE

HOW IT WORKS

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BLOWER/BURNER

GAS VALVE

ASSEMBLY

COMBUSTION

AIR INTAKE

CONNECTION

HELICAL SHAPE

HEAT EXCHANGER

ARROWS SHOW

PATH OF FLUE

GASES THROUGH

THE HEAT

EXCHANGER

EXHAUST/VENT

OUTLET

INTERNAL VIEW

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Service Note:

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BLOWER MOTOR

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SPEED CONTROL

COMBUSTION BLOWER ASSEMBLY

BLOWER

HOUSING

3 PIN

WIRING

SOCKET

5 PIN

WIRING

SOCKET

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WIRING HARNESS

IGNITER/FLAME

SENSOR

BLOWER

FLANGE

BURNER

ADAPTER

BURNER

FLANGE &

GASKET

BURNER

BURNER ASSEMBLY

RIGHT SIDE VIEW

FLAME

SENSOR

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BURNER ADAPTER

WIRING HARNESS

IGNITER/FLAME

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BURNER ASSEMBLY

LEFT SIDE VIEW

IGNITER

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BURNER GROUND

WIRE

BURNER

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BLOWER FLANGE WITH BLOWER

DISCHARGE ORIFICE IN PLACE

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IGNITER/FLAME SENSOR

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BURNER SIGHT

GLASS

BURNER ADAPTER

WIRING HARNESS

IGNITER/FLAME

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BLOWER FLANGE WITH

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IGNITER/FLAME

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FLAME SENSING OPERATION

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IGNITER

BURNER

FLAME

BURNER

(MUST BE GROUNDED)

CERAMIC INSULATOR

FLAME SENSOR

METAL CONDUCTOR

CONTROL SYSTEM

APPLIES AC VOLTAGE

TO FLAME SENSOR

AC VOLTAGE FLOWS FROM THE FLAME

SENSOR TO THE BURNER. THE BURNER

MUST BE GROUNDED FOR CURRENT TO

FLOW. DURING THIS PROCESS THE AC

VOLTAGE IS “RECTIFIED” AND BECOMES

A DC VOLTAGE. DC MICRO AMP CURRENT

THEN FLOWS BETWEEN THE FLAME SENSOR

AND THE BURNER.

GAP BETWEEN THE FLAME SENSOR AND THE

BURNER SHOULD BE APPROXIMATELY 1/2 INCH

)LJXUH

MINIMUM FLAME SENSING CURRENT

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A.O. Smith 100304126 User guide

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