A.O. Smith 100 Series, Instruction Manual

Page 1: ...ND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE COMMERCIAL ELECTRIC WATER HEATERS OPTIONAL Thank you for buying this energy efficient water heater We appreciate your confidence in our products MODELS 52 80 120 SERIES 100 INSTALLATION OPERATION SERVICE MAINTENANCE LIMITED WARRANTY Printed on 2 8 2018 9 05 AM CT ...

Page 2: ...r death WARNING indicates a potentially hazardous situation which if not avoided could result in injury or death CAUTION indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided could result in property damage All safety messages will genera...

Page 3: ...ipe as the water begins to flow THERE SHOULD BE NO SMOKING OR OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting devices such as mixing valv...

Page 4: ...CONVERSION TO SINGLE PHASE 20 CONVERSION TO THREE PHASE 20 OPERATION 21 GENERAL 21 FILLING THE WATER HEATER 21 INITIAL START UP 21 Draining the Water Heater 21 TEMPERATURE REGULATION 22 High Temperature Limit Controls ECO 22 Thermostat Controls 22 Thermostat Settings Surface Mount Control 22 THERMOSTAT SETTINGS electronic Controls 23 ELECTRONIC CONTROL MODELS OPERATION 24 CONTROL SYSTEM FEATURES 2...

Page 5: ...the electrical system of the heater Never touch electrical components with wet hands or when standing in water When replacing fuses always use the correct size for the circuit see page 13 The principal components of the heater are identified on pages 7 8 The model and rating plate on page 6 interprets certain markings into useful information Both of these references should be used to identify the ...

Page 6: ... 390 410 307 246 205 176 154 137 123 112 102 95 88 36 122 868 492 369 295 246 211 184 164 148 134 123 113 105 40 5 138 226 554 418 3332 277 237 208 1185 166 151 138 128 119 45 153 585 615 461 369 307 263 230 205 184 168 154 142 132 54 184 302 738 553 443 369 316 277 246 221 201 184 170 158 Figured at 1 KW 3413 Btu 4 1 gallons at 100 F temperature rise To determine recovery rate per minute divide r...

Page 7: ...SE VOLTS AC ELEMENTS EACH RATED MEASURED WATTS COMMERCIAL STORAGE TANK WATER HEATER MODEL NUMBER SERIAL NUMBER ITEM ID PART NUMBER WATTS TOTAL CAPACITY US GAL STANDBY LOSS MAX WORKING PRESSURE Low Lead Content All models are listed b y U n d e r w r i t e r s Laboratories Inc Low Lead Content Printed on 2 8 2018 9 05 AM CT ...

Page 8: ...8 FEATURES AND COMPONENTS Figure 2 Electronic Control Modules Printed on 2 8 2018 9 05 AM CT ...

Page 9: ...9 FEATURES AND COMPONENTS Figure 3 Surface Mount Control Models Printed on 2 8 2018 9 05 AM CT ...

Page 10: ...tions will not result in damage to the area adjacent to the heater or to lower floors of the structure Close to the point of major hot water usage and the power supply Hot water piping and branch circuit wiring should be as short as possible Insulate hot and cold water piping where heat loss and condensation may be a problem Heater construction permits installation maintenance and service work to ...

Page 11: ...rature are available Consult a qualified installer or service agency Follow all manufacturer s Instructions for installation of these valves Before changing the factory setting on the thermostat read the Temperature Regulation section in this manual CONTAMINATED WATER This water heater shall not be connected to any heating system s or component s used with a non potable water heating appliance Tox...

Page 12: ...rature pressure relief valve discharge line and 2 the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions in this manual and replace the temperat...

Page 13: ... shall not exceed 15 amperes for 14 AWG 20 amperes for 12 AWG and 30 amperes for 10 AWG copper or 15 amperes for 12 AWG and 25 amperes for 10 AWG aluminum and copper clad aluminum For dry locations only See 75 C column for wet locations An electrical ground is required to reduce risk of electrical shock or possible electrocution The water heater should be connected to a separate grounded branch ci...

Page 14: ...des control circuit fusing using two 3 amp class G fuses with 600 volt rating Do not substitute fuses of a different rating SEQUENCE OF OPERATION 1 When the control is powered the UIM should display mode information water temperature Operating Set Point heating status and operating mode 2 If the control determines that the actual water temperature inside the tank is below the programmed Operating ...

Page 15: ...This table is to be used for 8 tap and 5 tap transformers Figure 4 Secondary Transformer Coil Table 5 Secondary Transformer Coil Configuration Volts Line On Load On 208 COMMON 208 SECONDARY 120V 240 COMMON 240 277 COMMON 277 480 COMMON 480 Printed on 2 8 2018 9 05 AM CT ...

Page 16: ...16 Figure 5 CCB Control Circuit Diagram Electronic Control Models WIRING DIAGRAMS Printed on 2 8 2018 9 05 AM CT ...

Page 17: ...ring diagrams All heater circuits are designed for 60 50 hertz alternating current The water heater circuit wiring is 12 AWG AWM or TEW type rated 600 volts 105 C Fusing consists of three 30 amp fuses for each contactor Fusing is an optional feature for Canadian models Figure 6 Power Circuit Diagrams Electronic Control Models Printed on 2 8 2018 9 05 AM CT ...

Page 18: ...ellow wires to terminal L2 with red wires 4 Connect incoming power to terminals L1 and L2 CONVERSION TO THREE PHASE When heater is shipped for connection to a single phase electrical service it may be connected to a three phase electrical service of the same voltage by 1 Disconnect blue wires from terminal L1 2 Disconnect yellow wires from terminal L2 3 Reconnect all blue wires and yellow wires to...

Page 19: ...iring diagrams All heater circuits are designed for 60 50 hertz alternating current The water heater circuit wiring is 12 AWG AWM or TEW type rated 600 volts 105 C Fusing consists of two 30 amp fuses for each element Fusing is an optional feature for Canadian models Figure 8 Power Circuit Diagrams Surface Mount Control Models Printed on 2 8 2018 9 05 AM CT ...

Page 20: ...ires to terminal L2 with yellow wires 5 Connect incoming power to terminals L1 and L2 CONVERSION TO THREE PHASE When heater is shipped for connection to a single phase electrical service it may be connected to a three phase electrical service of the same voltage by 1 Disconnect blue wires from terminal L1 2 Disconnect red wires from terminal L2 3 Connect all blue wires to terminal L2 with yellow w...

Page 21: ...Turn on the electrical disconnect switch 5 Observe the operation of the electrical components during the first heating cycle Use care as the electrical circuits are energized 6 Close the front panel Temperature control and contactor operation should be checked by allowing heater to come up to temperature and shut off automatically Use care as the electrical circuits are energized DRAINING THE WATE...

Page 22: ... ECO activate the water temperature must drop below 140 F 60 C before the control system can be reset Once the water temperature has cooled below this point the power supply to the water heater must be turned off and on again to reset the control system THERMOSTAT CONTROLS The water heaters covered in this instruction manual are equipped with adjustable thermostat controls to control water tempera...

Page 23: ...int is adjusted to control water temperature This is an adjustable user setting in the control system s Temperatures Menu This and all control system menus are accessed through the UIM User Interface Module see Figure 12 UIM User Interface Module located on the front panel of the water heater Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Chi...

Page 24: ...ormation Screen below shows the control system Desktop Screen This is the default screen If there are no active Fault or Alert conditions and no user input for approximately 10 minutes the control system will return to this screen automatically MODEL INFORMATION Model information and menu titles are shown in the black bar at the top of the Desktop Screen TANK TEMPERATURE Current water temperature ...

Page 25: ...esent heating elements the control system has not energized and is not sensing electrical current from Heating elements icon for a water heater equipped with 3 Banks of heating elements Each circle represents one heating element Each diagonal row of 3 elements 1 Bank of elements Filled circles represent heating elements the control system has energized AND is sensing electrical current from Heatin...

Page 26: ...ermit tent operational problems or when the customer has reset the control system prior to a service agent s arrival Fault Occurrence Running total of all Fault and Alert Conditions that have occurred are displayed in this menu Can help determine poten tial root cause s of related operational problems Restore Factory Defaults This control system feature allows the user to restore control system us...

Page 27: ...h additional Bank of 3 heating elements OPERATING SEQUENCE With an Operating Set Point of 120 F and all Differential settings at 2 F the On Off sequencing of heating element Banks would be as follows BANK NUMBER DIFFERENTIAL SETTING TURN ON TEMP TURN OFF TEMP Bank 1 2 F 118 F 120 F Bank 2 2 F 116 F 118 F Bank 3 2 F 114 F 116 F TANK TEMPERATURE Non adjustable information display Current water tempe...

Page 28: ... current state of the ECO high temperature limit switch contacts The ECO switch is located inside the immersion Temperature Probe two red wires Enable Disable 1 2 Displays the current state open or closed of the two Enable Disable circuits J7 socket on the CCB Central Control Board see wiring diagrams provided for external supervisory controls such as building EMS Energy Management System Both of ...

Page 29: ...ter In Economy Mode Displays whether the control system is currently operating in Economy Mode or not Daily Operating Mode Sun Mon Tue Wed Thu Fri Sat Seven daily sub menus are listed at the bottom of the Economy Mode Setup menu There are 3 Operating Modes in each sub menu Normal Operation All Day Economy Mode All Day and Normal Operation Between Only one Operating Mode can be active the factory d...

Page 30: ...onal Button underneath CHANGE to activate the adjustment mode for the Setpoint Adjustment value Use the Up Down buttons to change the Setpoint Adjustment to the desired value The SetpointAdjustment value is adjustable from 2 F to 50 F The factory default is 20 F Notice how the text above the Operational Buttons on the display changes to UPDATE CANCEL when the adjustment mode is activated and how t...

Page 31: ...CANCEL when the adjustment mode is activated and how the current setting is outlined rather than highlighted in black Press the Operational Button underneath ACCEPT to enter and confirm the new setting Pressing the Operational Button underneath CANCEL would discard the new setting and retain the previous setting Use the Up Down and the CHANGE ACCEPT Operational Buttons to individually select and c...

Page 32: ...ANGE buttons to enter the Mon sub menu Use the Up Down buttons to select highlight in black the Normal Operation Between setting Press the Operational Button underneath SELECT to change the operating mode for Monday to Normal Operation Between Note that when this setting is selected Start and Stop time user settings appear on the display Use the Up Down buttons to navigate between the Start and St...

Page 33: ... current tank temperature drops below programmable Alarm SP Fault or Alert Used for external notification whenever a Fault or Alert condition is active Fault Used for notification whenever a Fault condition is active Disabled Disables the Alarm Relay Output Function Alarm SP Adjustable user setting 90 F to 190 F the control system uses for the Temp Alarm SP function described above This setting ha...

Page 34: ...istory Menu This menu displays non adjustable operational information The control system records and stores the last 9 Fault and Alert messages in chronological order in this menu The most recent will be at the top of the list A time stamp is displayed below each listed Fault and Alert message showing when the Fault or Alert condition occurred The Fault History is useful when dealing with intermit...

Page 35: ...ement The heater tank is equipped with an anode rod to aid in corrosion control and should be inspected periodically see Anode Rod Inspection ANODE ROD INSPECTION Each water heater contains at least one anode rod which will slowly deplete due to electrolysis prolonging the life of the water heater by protecting the glass lined tank from corrosion Adverse water quality hotter water temperatures hig...

Page 36: ... in operation Allow the water heater to complete several heating cycles to ensure it is operating properly SEDIMENT REMOVAL Water borne impurities consist of fine particles of soil and sand which settle out and form a layer of sediment on the bottom of the tank In time if not removed the level of sediment might reach the heating elements and cause their failure For convenience sediment removal and...

Page 37: ...hen the time required to heat water to the desired temperature 6 Look for hot water leakage 7 Sediment or pipe scale may be affecting water heater operation ABNORMAL SOUNDS 1 Sediment or lime scale accumulations on the elements causes sizzling and hissing noises when the heater is operating The sounds are normal however the tank bottom and elements should be cleaned See the Maintenance section o f...

Page 38: ...pening and valve to swab spud area Remove valve if leak is indicated and repair with pipe joint compound Water on the side of the tank may be condensation due to the panel or insulation not being in place Water leaks at the elements may be due to 1 Defective elements which leak at terminals or through flange Replace element 2 Loose element gasket leak Tighten element with element wrench If leak co...

Page 39: ...in the system 3 Service valves are shown for servicing unit However local codes shall govern their usage COMMERCIAL ELECTRIC 1 UNIT LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LO...

Page 40: ... be wired to and control the pump between the water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 1 UNIT WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATE...

Page 41: ...uld be wired to and control the pump between the water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 1 UNIT WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE...

Page 42: ...ervice valves are shown for servicing unit However local codes shall govern their usage COMMERCIAL ELECTRIC 2 UNITS LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND OR...

Page 43: ... the pump between the water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 2 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VAL...

Page 44: ...rol the pump between the water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 2 UNITS WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHEC...

Page 45: ... for servicing unit However local codes shall govern their usage COMMERCIAL ELECTRIC 3 UNITS LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL...

Page 46: ...ater heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 3 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING...

Page 47: ... water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 3 UNITS WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRA...

Page 48: ...ver local codes shall govern their usage COMMERCIAL ELECTRIC 4 UNITS LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS EXPANSION ...

Page 49: ...orage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 4 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING ...

Page 50: ... storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control COMMERCIAL ELECTRIC 4 UNITS WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PI...

Page 51: ...ifold Kits with Three Heaters Tank Capacity Gallons Part Number H W D A 52 100109232 66 1 4 91 3 4 27 1 4 13 1 4 80 100109232 70 1 2 95 1 4 31 1 4 9 3 4 120 100109232 73 1 4 99 1 2 35 3 4 5 1 2 Inlet and outlet size 2 1 2 Table 13 Manifold Kits with Four Heaters Tank Capacity Gallons Part Number H W D A 52 100109233 66 1 4 126 3 4 27 1 4 13 1 4 80 100109233 70 1 2 130 1 4 31 1 4 9 3 4 120 10010923...

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