A.O. Smith APW015DW, Installation & Service Manual

Page 1: ...eries 100 This manual must only be used by a qualified heating installer service technician Read all instructions before installing Perform steps in the order given Failure to comply could result in s...

Page 2: ...unit 7 3 HYDRONIC PIPING APW piping assemblies 8 General piping information 8 Heating fluid and Domestic Hot Water DHW piping 8 Scalding 8 Hydronic piping illustrations 9 14 4 ADJUSTMENTS 3 Way contro...

Page 3: ...formation This instruction manual provides detailed coverage for the Indirect Plate Water Heater APW Each APW is equipped with an electronic control system specifically designed for an electronic cont...

Page 4: ...electronic circuitry for the electronic control system In addition the electronic control system includes several sensors and safety devices which provide temperature and flow control information to...

Page 5: ...exceed 100 F Do not install the appliance where the relative humidity may exceed 95 Do not install the appliance where condensation may form on the inside or outside of the appliance or where condens...

Page 6: ...eater Clearances and Dimensions 6 Indirect Plate Water Heater Installation Service Manual MODEL A B C D E APW015DW 55 44 15 35 5 10 5 APW030DW 55 52 15 35 5 10 5 APW050DW 55 52 15 35 5 10 5 APW070DW 6...

Page 7: ...FIG 2 1 Use these tabs or cutouts to lift and move the unit as specified in the heat exchanger HEX manual supplied with the unit In multiple unit installations it is important to plan the position of...

Page 8: ...g Assemblies Model Piping Assembly Diameter APW015 APW050 2 APW070 APW090 3 APW105 APW120 4 Indirect Plate Water Heater Installation Service Manual Scalding This water heater can deliver scalding temp...

Page 9: ...to Water Heat Exchanger Single Unit Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local co...

Page 10: ...TANK TANK HEIGHT TO DIAMETER RATIO 2 1 MIN 3 1 PREFERRED HOT WATER SUPPLY TEMPERATURE GAUGE Figure 3 3 Water to Water Heat Exchanger Single Unit with Stratified Tank Please note that these illustratio...

Page 11: ...UPPLY BOILER WATER OUT Figure 3 4 Water to Water Heat Exchanger Multiple Units Please note that these illustrations are meant to show system piping concept only the installer is responsible for all eq...

Page 12: ...R SUPPLY BOILER WATER IN BOILER WATER OUT BUILDING RETURN Figure 3 5 Water to Water Heat Exchanger Single Unit with Accumulator Tank Please note that these illustrations are meant to show system pipin...

Page 13: ...Multiple Units with Boiler Side Buffer Tank as a Zone Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing req...

Page 14: ...ASS LINE Figure 3 7 Multiple Units with Conventional Heating System as a Zone Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equ...

Page 15: ...control valve Remove hand wheel ring CAUTION As a precaution ensure that all heating fluid hot boiler water shutoff valves are fully closed prior to performing any of the following adjustment procedur...

Page 16: ...from the temperature controller The valve can now be mechanically rotated The temperature control system is now disabled Be sure to return to the Auto Mode prior to returning the system to heating se...

Page 17: ...controller These controls and displays are illustrated and described in FIG 4 6 and Table 4B on page 18 If necessary set point temperature adjustment is accomplished as follows 1 Set the ON OFF POWER...

Page 18: ...al Button and Indicator Not used If MAN is lit in the top of the screen press AUTO MAN to put the control back into Auto Mode Run Hold Button and Indicators Not used for APW applications a Page Button...

Page 19: ...s position B AB It should be noted that the over temperature switch has a slightly slower response to temperature changes than the temperature controller The control valve actuator also incorporates a...

Page 20: ...ess into the junction box through one of the knockouts as shown in FIG 6 1 3 Connect 120V power supply to the wires in the junction box Black Live White Neutral Green Ground Use a minimum of 14 AWG wi...

Page 21: ...onnect wires to the control following the diagram in Figure 7 1 4 Close the control box door 5 Turn on the main electrical power 7 Configure the control per this manual and resume operation Figure 7 1...

Page 22: ...e outside the expectation of the application program since the MODBUS protocol is unaware of the significance of any particular value of any particular register 04 SLAVE DEVICE FAILURE An unrecoverabl...

Page 23: ...Maximum Load 32 units 32 nodes NOTE Cable must be terminated with 120 ohm impedance matching resistor on each end Physical Wiring Figure 7 2_Wiring Diagram Mixed Inlet Temperature Domestic Water Outl...

Page 24: ...n twice to return to Level 1 12 Press Page Should you encounter problems communicating over ModBus the following items should be checked in this order 1 Physical Layer 2 Communications Configuration a...

Page 25: ...e unit suddenly When unit is hot DO NOT shock with cold fluid WARNING CAUTION Initial start up In order to prevent a possible over temperature condition during initial start up The manufacturer recomm...

Page 26: ...in Steps 1 and 2 below However if the APW will shut down for an extended period of time it will be necessary to drain the unit using the appropriate steps listed below for the type of heat exchanger u...

Page 27: ...ners on both the boiler water and domestic water piping side Annually Once each year check the temperature sensors Once each year check the operation of the recirculation pump Periodic Periodic cleani...

Page 28: ...ection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to re inspect the water heater relief valve as directed could result in unsafe pressure...

Page 29: ...ts built in circuit breaker has not tripped Heat exchanger is improperly sized for load Reduce load on heat exchanger or re size heat exchanger Heat exchanger scaled on boiler side Clean and de scale...

Page 30: ...ce type devices The following tables show the correct values for the sensors at various temperatures Use an ohmmeter to read the resistance of the sensor at a known temperature If the resistance of th...

Page 31: ...1 160 108 9 105 8 APW070DW 80 3 130 122 14 APW120DW 160 2 225 116 15 APW105DW 160 2 225 116 15 8 APW030DW 59 2 75 121 8 170 APW015DW 38 1 75 138 APW050DW 78 3 75 APW090DW 155 2 160 110 9 105 8 APW070D...

Page 32: ...W 128 1 160 123 9 117 8 APW070DW 80 3 130 129 14 APW120DW 160 2 225 121 15 APW105DW 142 2 225 128 15 8 APW030DW 43 2 75 132 8 180 APW015DW 27 5 1 75 149 APW050DW 57 5 2 75 APW090DW 112 1 160 122 9 116...

Page 33: ...5 140 15 8 APW030DW 27 1 75 143 8 180 APW015DW 16 5 1 75 157 APW050DW 36 1 75 APW090DW 71 1 160 134 9 130 8 APW070DW 56 2 130 135 14 APW120DW 104 1 225 132 15 APW105DW 89 1 225 139 15 8 APW030DW 33 1...

Page 34: ...PW050DW APW070DW APW090DW APW105DW APW120DW 75 75 153 171 8 8 APW105DW APW120DW 19 8 5 1 1 21 1 41 1 APW120DW APW015DW APW030DW APW050DW APW070DW APW090DW APW015DW APW030DW 160 153 9 51 1 225 157 15 7...

Page 35: ...75 APW090DW 140 2 160 107 9 101 8 APW070DW 80 3 130 119 14 APW120DW 160 2 225 111 15 APW105DW 157 2 225 112 15 8 APW030DW 48 2 75 117 8 170 APW015DW 30 5 1 75 136 APW050DW 63 5 2 75 APW090DW 124 1 160...

Page 36: ...6 15 APW105DW 140 2 225 125 15 8 APW030DW 43 2 75 130 8 190 APW015DW 27 1 75 152 APW050DW 57 2 75 111 1 160 118 9 111 8 APW070DW 77 3 130 118 14 142 2 225 114 15 APW105DW 122 1 225 124 15 8 APW030DW 3...

Page 37: ...61 1 225 136 15 8 APW030DW 24 1 75 140 8 180 APW015DW 14 5 1 75 156 APW050DW 33 1 75 APW090DW 65 1 160 129 9 125 8 APW070DW 51 2 130 131 14 APW120DW 95 1 225 127 15 APW105DW 81 1 225 135 15 8 APW030D...

Page 38: ...169 APW050DW 24 5 1 75 APW090DW 48 1 160 146 9 142 8 APW070DW 38 1 130 147 14 APW120DW 71 1 225 144 15 APW105DW 60 1 225 151 15 APW030DW APW050DW APW070DW APW090DW APW105DW APW120DW 200 210 APW015DW...

Page 39: ...39 Indirect Plate Water Heater Installation Service Manual 12 Diagrams Figure 12 1 Wiring Diagram Electrical Control System Control Box...

Page 40: ...Parts Description Kit Model 1 Pump 100346661 APW015DW 070DW 100346658 APW090DW 120DW 2 Control 100346659 APW015DW 120DW 3 Sensor 100346657 APW015DW 120DW 4 T P Valve 100112873 APW015DW 050DW 100346652...

Page 41: ...41 Indirect Plate Water Heater Installation Service Manual Notes...

Page 42: ...42 Indirect Plate Water Heater Installation Service Manual Notes...

Page 43: ...43 Indirect Plate Water Heater Installation Service Manual Notes...

Page 44: ...on A Process 3000045653_Change 500033372 initial release Revision B Process 3000047064_Change 500034483 made changes to the Replacement Parts List kit numbers for T P Valve and High Limit 100346577_20...