Page 2 - ALL TECHNICAL AND WARRANTY QUESTIONS
2 ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, CONTACT A. O. SMITH WATER HEATERS RESIDENTIAL TECHNICAL ASSISTANCE AT 1-800-527-1953 OR WWW.HOTWATER.COM.
Page 3 - SERVICE HANDBOOK
3 Your safety and the safety of others is extremely important in the servicing of this water heater. Many safety-related messages and instructions have been provided in this handbook and on the water heater to warn you and others of a potential hazard. Read and obey all safety messages and instructi...
Page 4 - Fire or Explosion Harzard; Improper installation and use may result; Breathing Hazard - Carbon Monoxide Gas
4 Fire or Explosion Harzard Do not store or use gasoline or other flammable vapors andliquids in the vicinity of this or any other appliance. Avoid all ignition sources if you smell Natural or LP gas.Do not expose water heater control to excessive gaspressure. Use only gas shown on rating plate. Mai...
Page 5 - TABLE OF CONTENTS; KNOW YOUR WATER HEATER:; Burner Ori
5 TABLE OF CONTENTS INTRODUCTION: Service Handbook Introduction ...........................................................................................................................3 Warnings and Cautions ............................................................................................
Page 6 - BASIC INSTALLATION & OPERATION; Figure 1
6 Exhaust Vent to Ouside of Building Union Union Water Shut-Off Valve Water Supply- Cold* Expansion Tank Pressurize to Equal Supply Water Pressure* (Relieve water pressure on the expansion tank before adjusting air pressure.) Temperature-Pressure Relief Valve with discharge piped to an adequate drai...
Page 7 - COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS; Combustion Air Requirements:; WARNING; Carbon Monoxide Warning; fl; Uncon
7 COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS Table 1: BTUH Input Minimum Square Feet with 8’ Ceiling Typical Room with 8’ Ceiling 30,000 188 9 x 21 45,000 281 14 x 20 60,000 375 15 x 25 75,000 469 15 x 31 90,000 563 20 x 28 105,000 657 20 x 33 120,000 750 25 x 30 135,000 844 28 x 30 IMPORTANT:• The...
Page 8 - All Air from Inside the Building:; Louvers and Grilles:
8 COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS All Air from Inside the Building: When additional air is to be provided to the con fi ned area from additional room(s) within the building, the total volume of the room(s) must be of suf fi cient size to properly provide the necessary amount of fresh air...
Page 9 - cal and state codes, the “National Fuel
9 COMBUSTION AIR AND VENT SYSTEM REQUIREMENTS Vent Connectors: 1. Type B, Double wall, U.L. Listed Vent Pipe.2. Single wall Vent Pipe. Maintain the manufacturer’s speci fi ed minimum clearance from combustible materials when using type B double wall vent pipe. Vent connectors made of type B, double ...
Page 10 - Vertical Exhaust Gas Vent:
10 • The connector must be firmly attached and sealed to prevent it from falling out. • To aid in removing the connector, a thimble or slip joint may be used. • The connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chi...
Page 11 - KNOW THE WATER HEATER’S COMPONENT PARTS; Electronic Control Display (Upper Control); by a; 4 VAC power supply transformer; and uses a temperature sensing probe to open or close the flow
11 KNOW THE WATER HEATER’S COMPONENT PARTS Figure 11. Electronic Control Display (Upper Control) The Electronic Control Display panel used on this water heater provides an easy-to-read, eye level display for temperature adjustment, fault code diagnostics and recall, powered anode rod operation and s...
Page 13 - Flammable Vapor Cut Off Switch (FV Sensor); FV Sensor; HOW THE WATER HEATER’S COMPONENT PARTS ARE CONNECTED
13 KNOW THE WATER HEATER’S COMPONENT PARTS Flammable Vapor Cut Off Switch (FV Sensor) The water heater is equipped with a FV sensor, for detecting the presence of flammable vapors (e.g. spilled gasoline). When the sensor detects those vapors, the heater will shut down and not operate. If flammable v...
Page 15 - FILLING, DRAINING AND FLUSHING THE WATER HEATER TANK; temperatures. To drain the tank, perform the following steps:
15 FILLING, DRAINING AND FLUSHING THE WATER HEATER TANK It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during operation. The water heater should be drained if being shut down during freezing temperatures. To drain the tank, perform the fol...
Page 16 - LIGHTING INSTRUCTIONS; FOR YOUR SAFETY READ BEFORE OPERATING
16 LIGHTING INSTRUCTIONS Read and understand these directions thoroughly before attempting to operate the water heater. Make sure the view port is not missing or damaged. Make sure the tank is completely filled with water before operating the water heater. The gas control valve/thermostat has an “On...
Page 17 - Adjusting the Temperature Set Point -; The thermostat of this water heater has been factory set at its; Water; Table 2; COOLER
17 ADJUSTING THE TEMPERATURE ON THE ELECTRONIC CONTROL DISPLAY Adjusting the Temperature Set Point - The thermostat of this water heater has been factory set at its lowest position. It is adjustable and must be reset to the desired temperature setting to reduce the risk of scald injury. The electron...
Page 18 - USING THE ELECTRONIC CONTROL DISPLAY; Fault Code Diagnostics:; Entering; Field Service Mode
18 USING THE ELECTRONIC CONTROL DISPLAY How to select or change the temperature scale from Fahrenheit (°F) to Celsius (°C). Figure 22. 1. The temperature scale defaults to Fahrenheit (°F). 2. To change to Celsius (°C), press the two temperature adjustment buttons at the same time for more than five ...
Page 19 - Reviewing Fault Codes:; Field; Exiting; BEFORE RESETTING THE
19 USING THE ELECTRONIC CONTROL DISPLAY Reviewing Fault Codes: 1. Press the red up arrow button one time. 2. The display will show either E0 or E1. 3. If E0 is shown, there are no faults. By pressing the up arrow button again the display will exit the Field Service mode, or the control will exit aut...
Page 20 - ELECTRONIC CONTROL DISPLAY TROUBLESHOOTING
20 Please check guidelines below. For your safety, water heater service should be performed only by a qualified service person. Read the GENERAL SAFETY INFORMATION supplied by the water heater manufacturer. 1. “POWER” Flashing Communication Error The system has detected a communication error between...
Page 21 - CONTROL DISPLAY TROUBLESHOOTING
21 6. “P-SW”, “OPEN”, and “CLEAN SCREEN” Flashing The air pressure switch contacts remain open longer than 11 seconds after the combustion fan is energized. 1. Clean the screen on the combustion air intake chamber. Turn the power “OFF” for 10 to 20 seconds then “ON” again to clear 2. Ensure the pres...
Page 23 - TROUBLESHOOTING FLOWCHART
23 Please Note: The control continually monitorsinternal circuits and extern al sensors.Error codes noted abov e, and those forself-diagnostic faults can be found onpages 20 through 22. APPLY POWER TO APPLIANCE YES REQUEST FOR HEAT PRESENT? NO IS PRESSURE SW ITCH PROVEN OPEN WITHIN 5 SECONDS? NO COM...
Page 24 - EXTERNAL INSPECTION AND CLEANING; Cleaning the Air Intake Chamber Screen:; Air Intake Chamber; Cleaning the Combustion Chamber and Air
24 EXTERNAL INSPECTION AND CLEANING Cleaning the Air Intake Chamber Screen: • At least twice annually the air intake chamber screen should be inspected for any dust or debris that may have accumulated on the louvers. NOTE: If the water heater is located in an area that is subjected to lint, pet hair...
Page 25 - ELECTRONIC CONTROL DISPLAY REMOVAL / REPLACEMENT; Removing the Electronic Control Display:; SWITCH; UNPLUGGED
25 ELECTRONIC CONTROL DISPLAY REMOVAL / REPLACEMENT Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualified service technician. Removing the Electronic Control Display: 1. S...
Page 26 - POWERED ANODE ROD REMOVAL / REPLACEMENT; Removing the Powered Anode Rod:
26 POWERED ANODE ROD REMOVAL / REPLACEMENT Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualified service technician. Tools required: Ratchet with 1-1/16” Socket, Pliers, a...
Page 27 - Installing the Powered Anode Rod:
27 Installing the Powered Anode Rod: 8. Use Teflon ® tape or an approved pipe sealant on threads of the new powered anode rod. 9. Prior to installing, it will be necessary to use pliers to bend up approximately 90° the electrical male connector on the top of the powered anode rod. The electrical con...
Page 28 - PRESSURE SWITCH REMOVAL / REPLACEMENT; Removing the Pressure Switch:
28 PRESSURE SWITCH REMOVAL / REPLACEMENT Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualified service technician. Tools required: Phillips Head Screwdriver. Removing the ...
Page 29 - TRANSFORMER REMOVAL / REPLACEMENT; Use only factory authorized replacement parts.; Removing the Transformer:
29 TRANSFORMER REMOVAL / REPLACEMENT g COOLER HOTTER Electronic Control Display Figure 40. ON/OFF SWITCH ON OFF Figure 41. UNPLUGGED Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help f...
Page 30 - Installing the New Transformer:
30 Installing the New Transformer: 10. Insert the wiring connector that goes to the gas control valve/thermostat through the wire protector on the side of the transformer box (Figure 44). 11. Attach the two (2) flag terminal connectors to the transformer by aligning and pressing down (Figure 44). 12...
Page 31 - AIR INTAKE CHAMBER BOX REMOVAL / REPLACEMENT; Removing the Air Intake Chamber Box:
31 AIR INTAKE CHAMBER BOX REMOVAL / REPLACEMENT Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualified service technician. Tools required: Phillips Head Screwdriver. Removi...
Page 34 - WIRING HARNESS REMOVAL / REPLACEMENT
34 WIRING HARNESS REMOVAL / REPLACEMENT Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualified service technician. Tools required: Phillips Head Screwdriver. Removing the A...
Page 37 - AIR INTAKE CHAMBER FAN REMOVAL / REPLACEMENT; Removing the Fan from the Air Intake Chamber:
37 AIR INTAKE CHAMBER FAN REMOVAL / REPLACEMENT Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualified service technician. Tools required: Phillips Head Screwdriver. Removi...
Page 39 - PRESSURE TUBING REMOVAL / REPLACEMENT
39 PRESSURE TUBING REMOVAL / REPLACEMENT Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualified service technician. Tools required: Phillips Head Screwdriver. Removing the ...
Page 43 - FLAME SENSE/HOT SURFACE IGNITER REMOVAL / REPLACEMENT; Replacing the Flame Sense/Hot Surface Igniter
43 FLAME SENSE/HOT SURFACE IGNITER REMOVAL / REPLACEMENT Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualified service technician. Tools required: 3/4” Open-End Wrench or ...
Page 44 - BURNER REMOVAL / REPLACEMENT
44 BURNER REMOVAL / REPLACEMENT Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualified service technician. Tools required: 3/4” Open-End Wrench or Crescent Wrench, Phillips...
Page 45 - TOP VIEW
45 Removing Old Burner : 11. After noting the position of the condensation drain hole on the top of the burner. Turn the inner door/ manifold/burner assembly upside. Using a phillips head screwdriver remove the 2 screws attaching the burner to the manifold pipe (saving screws for reinstallation late...
Page 46 - Do Not
46 16. After confirming no material of any type are between door gasket and combustion chamber shield, align the screws on the inner door with the screw holes on the combustion chamber and tighten with 1/4” nut driver or 1/4” socket & ratchet (Figure 97). After tightening the inner door screws, ...
Page 47 - BURNER ORIFICE REMOVAL / REPLACEMENT
47 BURNER ORIFICE REMOVAL / REPLACEMENT g COOLER HOTTER Electronic Control Display Figure 102. ON/OFF SWITCH ON OFF Figure 103. UNPLUGGED Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get h...
Page 50 - GAS CONTROL VALVE/THERMOSTAT REMOVAL / REPLACEMENT; Removing the Gas Control Valve/Thermostat:
50 GAS CONTROL VALVE/THERMOSTAT REMOVAL / REPLACEMENT Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualified service technician. Tools required: 3/4” Open-End Wrench or Cre...
Page 52 - Checking the Gas Supply Pressure; CHECKING THE GAS SUPPLY PRESSURE
52 23. Turn on the gas supply to the unit and test the gas supply line and union connections by brushing on an approved noncorrosive leak detection solution (Figure 116). 24. Turn on the electrical and the gas supplies to the water heater. Plug in the electric connection from the transformer to the ...
Page 53 - GAS WATER HEATER SIZING GUIDE; most cases, cancel all statements above concerning tank sizing.; LEAKAGE CHECKPOINTS
53 * To check where threaded portion enters tank, insert cotton swab between jacket opening and fi tting. If cotton is wet, follow draining instructions in the “Draining the Water Heater” section and then remove fi tting. Put pipe dope or Te fl on ® tape on the threads and replace. When you are fi n...
Page 54 - GENERAL INFORMATION
54 Draw efficiency is the quantity of hot water available to the consumer before the outlet water temperature decreases 25 degrees F. A 40 gallon water heater will typically provide 70% (28 gallons) of this “usable” hot water (60% is the minimum). The burner or elements are allowed to operate during...
