A.O. Smith 101 Series, Instruction Manual

Page 1: ...NTENANCE LIMITED WARRANTY 500 Tennessee Waltz Parkway Ashland City TN 37015 ANSI NSF 5 ASME CRN WARNING If the information in these instructions is not followed exactly a fire or explosion may result...

Page 2: ...ng Diagrams 66 Water Piping Diagrams 67 Limited Warranty 74 Table Of Contents Safe Installation Use and Service 3 General Safety Information 4 Precautions 4 Introduction 6 Qualifications 6 iCOMM BACne...

Page 3: ...ifornia to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances This product contains a chemical known to the State of Califor...

Page 4: ...as air escaping through the pipe as the water begins to flow There should be no smoking or open flame near the faucet at the time it is open General Safety Information Read and understand this instru...

Page 5: ...ment trap in accordance with NFPA 54 Use joint compound or Teflon tape compatible with propane gas Fire and Explosion Hazard Turn off gas lines during installation Contact a qualified installer or ser...

Page 6: ...Detailed installation diagrams are also found in this manual These diagrams will serve to provide the installer with a reference It is essential that all venting water piping gas piping and wiring be...

Page 7: ...ENSOR MAIN BURNER radial design BLOWER FLANGE INTAKE AIR combustion air CONNECTION 4 INCH PVC Figure 2 Hot Surface Igniter The control system energizes the Hot Surface Igniter with 120 VAC during the...

Page 8: ...2 14 15 17 1 18 16 10 8 FRONT Top View Components 1 Water Heater s 120 VAC on off switch 2 Powered anode rods The water heater s covered in this manual are equipped with two powered non sacrificial a...

Page 9: ...e 16 and Condensate Drain Installation on page 36 Side Views 1 Cleanout access panel covers water heater cleanout opening 2 CCB enclosure see Figure 3 on page 8 for description 3 120 VAC junction box...

Page 10: ...33 C 39 C 44 C 50 C 56 C 61 C 67 C 72 C 78 C BTH 300 Natural 300 000 88 GPH 1746 1164 873 699 582 499 436 388 349 318 291 269 250 Propane LPH 6610 4406 3304 2644 2203 1888 1652 1469 1322 1201 1102 101...

Page 11: ...page 21 Fire or Explosion Hazard Read instruction manual before installing using or servicing water heater Avoid all ignition sources if you smell gas Do not store or use gasoline or other flammable v...

Page 12: ...ulation Pump Wiring Diagrams on page 66 for electrical hookup information Install in accordance with the current edition of the National Electrical Code NFPA 70 or the Canadian Electrical Code CSA C22...

Page 13: ...upply gas pressure readings are taken while gas is not flowing static pressure AND while gas is flowing dynamic pressure Supply pressure must never fall below the minimum values Supply gas pressures s...

Page 14: ...rns 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 l...

Page 15: ...er heater is provided with a properly rated sized and certified combination Temperature Pressure Relief Valve T P valve by the manufacturer The valve is certified by a nationally recognized testing la...

Page 16: ...on See Condensate Drain Installation on page 36 Combustible Material Storage Fire or Explosion Hazard Read instruction manual before installing using or servicing water heater Avoid all ignition sourc...

Page 17: ...rea through a design of louver or grille or screen is known it shall be used in calculating the size of opening required to provide the free area specified Where the louver and grille design and free...

Page 18: ...egate input rating of all appliances installed in the enclosure When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum di...

Page 19: ...section of the manual are a reference for the openings that provide fresh air into confined spaces only Do not refer to these illustrations for the purpose of vent installation See Venting Installati...

Page 20: ...inal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size gas vent directly below Keep clear of all obstructio...

Page 21: ...tion the pipe may be stressed or high thermal stresses may be formed when the pipe heats up and expands Install accordingly to minimize such stresses 19 Carefully read the Venting Requirements on page...

Page 22: ...on the back cover of this manual to order 4 Concentric Termination Part 9006328005 6 Concentric Termination Part 9006144005 Venting Requirements Approved Materials Approved vent and intake air pipe ma...

Page 23: ...mponents 10 All vent exhaust pipes must be pitched a minimum of a 1 4 inch per foot back to the water heater to allow drainage of condensate 11 If installing 4 inch vent pipe connect the vent pipe to...

Page 24: ...e intake air and the vent terminations must be a minimum of 24 inches 60 cm above any parapet vertical wall or structure within 10 feet 3 m horizontally See Figure 20 on page 25 4 If installing only v...

Page 25: ...n page 25 The intake air and vent terminations must have a minimum separation of 24 61 cm measured on center line as shown in Figure 21 on page 25 In colder climates this separation should be increase...

Page 26: ...eter hole for 6 inch pipe where the pipe s will pass through the wall Note Beware of concealed wiring and piping when cutting through the wall 8 Cut a length s of pipe being installed 3 5 inches 8 9 c...

Page 27: ...structure as shown in Figure 24 and Figure 25 Note If this required distance to a parapet vertical wall or structure cannot be maintained standard terminations must be used See Vertical Termination In...

Page 28: ...assembly and secure it to the roof 5 Seal around the plumbing boot or roof flashing 6 Cement the vent cap onto the vent pipe Alternately a field supplied stainless steel screw may be used to secure th...

Page 29: ...IED LENGTH 25 3 8 INCHES 64 cm MAXIMUM ALLOWABLE LENGTH 45 3 8 INCHES 115 cm MINIMUM ALLOWABLE LENGTH 12 INCHES 30 cm VENT CAP STAINLESS STEEL VENT TERMINAL WITH SCREEN INTAKE AIR PIPE INTAKE AIR CONN...

Page 30: ...tions are maintained Ensure multiple terminations are arranged or grouped as required Note These clearances must be maintained to prevent the recirculation of vent exhaust gases to the intake air Clea...

Page 31: ...ALL ROOF Figure 39 Multiple Concentric Termination Arrangements The illustrations on this page show some of the installation arrangements for multiple concentric terminations that are allowed See Mult...

Page 32: ...32 Venting Arrangements Power Vent Vertical Figure 40 Direct Vent Vertical Figure 42 Power Vent Horizontal Figure 41 Direct Vent Horizontal Figure 43...

Page 33: ...g Arrangements Direct Vent Vertical Vent Horizontal Intake Figure 44 Direct Vent Vertical Concentric Figure 46 Direct Vent Horizontal Vent Vertical Intake Figure 45 Direct Vent Horizontal Concentric F...

Page 34: ...to building or combustion air inlet to any other appliance 6 inches 15 cm for appliances up to 10 000 Btu hr 3 kW 12 inches 30 cm for appliances between 10 000 Btu hr 3 kW and 100 000 Btu hr 30kW 36 i...

Page 35: ...into building or combustion air inlet to any other appliance 6 inches 15 cm for appliances up to 10 000 Btu hr 3 kW 12 inches 30 cm for appliances between 10 000 Btu hr 3 kW and 100 000 Btu hr 30 kW...

Page 36: ...PVC cement and PVC primer 1 2 inch PVC pipe minimum length to equal the distance between the water heater and a suitable building drain 1 2 inch PVC fittings elbows and couplings necessary to install...

Page 37: ...SHUTOFF VALVE TEE FITTING PIPE CAP SEDIMENT TRAP DIRT LEG Figure 52 Ensure all gas pipe is clean on the inside before installation To trap any dirt or foreign material in the gas supply line a sedime...

Page 38: ...o much torque when connecting the supply gas line to the water heater 7 Install a sediment trap dirt leg as shown in Figure 52 on page 37 8 Install a Main Gas Shutoff valve in the supply gas line as s...

Page 39: ...limited warranty Electrical Wiring All electrical work must be installed in accordance with the National Electrical Code ANSI NFPA 70 or the Canadian Electrical Code CSA C22 1 and local requirements...

Page 40: ...ixing Valves on page 14 2 Dishwashing Machines on page 14 3 Temperature Pressure Relief Valve on page 15 4 Closed Systems and Thermal Expansion on page 14 5 For multiple water heater installations see...

Page 41: ...erature Probe two red wires see Figure 3 on page 8 for location The ECO switch contacts will open when the water temperature reaches approximately 202 F 94 C and close at approximately 140 F 49 C If t...

Page 42: ...ntrol system The Combustion Blower igniter 24 VAC Gas Valve and anode rods are all powered by the control system The main components of the control system are a UIM user interface module and a CCB cen...

Page 43: ...See Figure 3 on page 8 for Blower Prover Switch location The Hot Surface Igniter is being energized See Figure 2 on page 7 for Hot Surface Igniter location The igniter has been energized and the cont...

Page 44: ...from the combustion chamber at the end of a heating cycle Fault The control system has detected a Fault condition Heating operation is disabled until the Fault condition is corrected Power to the wat...

Page 45: ...ll control system menus from the Main Menu With Temperatures menu selected highlighted in black in the Main Menu screen press the Operational Button under SELECT to enter the Temperatures menu If the...

Page 46: ...obe Offset 0 F CHANGE BACK HELP Temperatures Bottom of Menu Differential 8 F Tank Temperature 120 F Upper Temperature 122 F Lower Temperature 118 F Heater Regulated to Tank Upper Probe Offset 0 F Lowe...

Page 47: ...ulated time the control system water heater has been energized Burner On Time Total accumulated time the control system has been in the heating operating state burner run time Cycle Count Total accumu...

Page 48: ...event will replace the oldest Press the Operational Button under VIEW to view details for each Fault or Alert message stored 1 Blocked Air Intake A7 51 mins ago 2 Blocked Exhaust A8 54 mins ago 3 Low...

Page 49: ...is menu item Show Contact Information Yes Change Contact Name Change Contact Phone Current Contact Info 000 000 0000 Access Code UPDATE CANCEL Service Contact Information Using the UP and DOWN buttons...

Page 50: ...on page 38 and repair any leaks found Initial Start Up Required Test Equipment Two U tube manometers recommended ranges 0 14 W C 0 3 5 kPa and 0 35 W C 0 8 7 kPa or pressure gauges Two digital manome...

Page 51: ...nifold gas pressure to stabilize for several minutes before making further adjustments 4 Replace the gas pressure regulator cover screw 5 Cycle the burner on and off several times to check operation 6...

Page 52: ...et Point to the lowest temperature setting see Operating Set Point And Differential Adjustment on page 45 2 When the water heater has completed its shut down sequence and enters the standby mode turn...

Page 53: ...lt in fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control syste...

Page 54: ...state of other system devices If the tank temperature drops below the Operating Set Point minus the Differential setting the control will automatically return to Step 2 and repeat the operating cycle...

Page 55: ...period 24 VAC Gas Valve is energized gas flows to Main Burner Is flame sensed at the Main Burner control system monitors the flame sensor Control System Locks Out Displays Fault Msg NO Control System...

Page 56: ...disable circuit disabling heating operation See Enable Disable Circuit on page 39 The heating capacity of the water heater has been exceeded the water heater is unable to meet demand Operational Probl...

Page 57: ...gthening the time required to heat water to desired temperature Hot water piping leaks open faucets water heater drain valve leaking or open Sediment or lime scale accumulation may be affecting water...

Page 58: ...ssure is below the required minimum pressure see Table 4 on page 13 Supply gas is turned off at the Main Shutoff Valve Supply gas pressure is dropping when other gas fired appliances on a common suppl...

Page 59: ...e 8 for switch location Excessive equivalent pipe length exceeded the maximum number of 90 elbows or wrong pipe size used in the intake air piping system see Venting Requirements on page 22 Balance pl...

Page 60: ...let the water run until the water is no longer hot Then close the hot water faucet 4 Connect a hose to the drain valve and terminate it to an adequate drain Maintenance General Keep appliance area cle...

Page 61: ...water heater drain valve to flush the storage tank 7 Flush the water heater storage tank to remove sediment and allow the water to flow until it runs clean 8 Close the water heater drain valve when fl...

Page 62: ...pped with a powered anode system The anode rods 2 are of a permanent design and do not need replacing unless damaged Inspection and cleaning should be performed once a year Note Follow the instruction...

Page 63: ...numbers 1 4 On the other side of the dipswitch is the word OPEN The dipswitches are rocker type switches if one side of the rocker is down the other side will be up Pressing a rocker down on the side...

Page 64: ...VE B CENTRAL CONTROL BOARD C C 6 J 5 J 4 J 7 J 5 1 J 6 1 J 0 1 J 3 1 J 2 J 3 J 1 J TRANSFORMER INSIDE CCB ENCLOSURE 50VA GROUND STRIP BURNER GROUND BURNER BOLT ON OFF SWITCH GROUND 120 VAC NEUTRAL 120...

Page 65: ...WER PROVER 24 VAC GAS VALVE B C C 6 J 5 J 4 J 7 J 5 1 J 6 1 J 0 1 J 3 1 J 2 J 3 J 1 J TRANSFORMER 50VA GROUND STRIP BURNER GROUND BURNER BOLT LOW GAS PRESSURE SWITCH 1 BLACK RED 2 WHITE 1 BLACK 2 BLAC...

Page 66: ...IRCUIT DO NOT SHARE POWER WITH APPLIANCE AS THIS MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION CIRCULATING PUMP WIRING DIAGRAM DISHWASHER LOOP WITH TOGGLE SWITCH FIELD S...

Page 67: ...eview the following 1 See Mixing Valves on page 14 2 See Dishwashing Machines on page 14 3 See Temperature Pressure Relief Valve on page 15 ONE WATER HEATER SINGLE TEMPERATURE WITH BUILDING RECIRCULAT...

Page 68: ...es on page 14 3 See Temperature Pressure Relief Valve on page 15 ONE WATER HEATER TWO TEMPERATURE WITH HIGH TEMPERAURE LOOP RECIRCULATION WITH BUILDING RECIRCULATION LEGEND TEMPERATURE PRESSURE RELIEF...

Page 69: ...alve on page 15 ONE WATER HEATER SINGLE TEMPERATURE WITH VERTICAL STORAGE TANK FORCED RECIRCULATION WITH BUILDING RECIRCULATION LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATI...

Page 70: ...ONE WATER HEATER SINGLE TEMPERATURE WITH HORIZONTAL STORAGE TANK FORCED RECIRCULATION WITH BUILDING RECIRCULATION LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP DRAIN...

Page 71: ...llowing 1 See Mixing Valves on page 14 2 See Dishwashing Machines on page 14 3 See Temperature Pressure Relief Valve on page 15 TWO WATER HEATERS SINGLE TEMPERATURE WITH BUILDING RECIRCULATION LEGEND...

Page 72: ...Mixing Valves on page 14 2 See Dishwashing Machines on page 14 3 See Temperature Pressure Relief Valve on page 15 THREE WATER HEATERS SINGLE TEMPERATURE WITH BUILDING RECIRCULATION LEGEND TEMPERATURE...

Page 73: ...ves on page 14 2 See Dishwashing Machines on page 14 3 See Temperature Pressure Relief Valve on page 15 FOUR WATER HEATERS SINGLE TEMPERATURE WITH BUILDING RECIRCULATION LEGEND TEMPERATURE PRESSURE RE...

Page 74: ...stalled at the heater s and operational at all times The temperature and pressure relief valve installed on the heater is not an acceptable method 4 SERVICE AND REPAIR EXPENSES Under the limited warra...

Page 75: ...75...

Page 76: ...500 Tennessee Waltz Parkway Ashland City TN 37015 Technical Support 800 527 1953 Parts 800 433 2545 Fax 800 644 9306 www hotwater com...