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Troubleshooting

 

Guide

 

32|

 

Page

 

 

 

 

 

DESCALING

 

THE

 

UNIT

 

Hard

 

water

 

is

 

a

 

severe

 

problem

 

for

 

the

 

copper

 

coils

 

inside

 

heat

 

exchangers.

  

Heat

 

exchanger

 

failure

 

due

 

to

 

scale

 

buildup

 

from

 

hard

 

water

 

conditions

 

is

 

NOT

 

covered

 

by

 

warranty.

  

It

 

is

 

highly

 

suggested

 

that

 

a

 

scale

 

inhibitor

 

be

 

installed

 

before

 

the

 

cold

 

water

 

inlet

 

after

 

this

 

procedure

 

is

 

done.

 

1)

 

TOOLS

 ‐ 

Gather

 

the

 

following

 

materials

 

together:

 

a.

 

Pump:

  

The

 

pump

 

should

 

provide

 

a

 

minimum

 

of

 

1GPM

 

through

 

the

 

heater

 

b.

 

Cleaning

 

Solution:

 

Food

 

grade

 

citric

 

acid,

 

food

 

grade

 

phosphorus

 

acid.

 

c.

 

Water

 

hoses

 

d.

 

Bucket

 

 

2)

 

SETUP

 ‐ 

 

Disconnect

 

power

 

to

 

the

 

unit

 

 

3)

 

WATERLINES

 

 

Assumes

 

isolation

 

valves

 

with

 

drain

 

ports

 

are

 

installed

  

a.

 

Isolate

 

the

 

unit

 

by

 

closing

 

the

 

incoming/outgoing

 

water

 

isolation

 

valves

 

C

 

and

 

D.

 

b.

 

Connect

 

hoses/pump

 

to

 

the

 

drain

 

ports

 

of

 

the

 

isolation

 

valves:

  

Outlet

 

of

 

the

 

pump

 

to

 

valve

 

B,

 

and

 

another

 

hose

 

from

 

Valve

 

A

 

to

 

the

 

bucket.

  

 

4)

 

PUMP

 

  

a.

 

Fill

 

the

 

bucket

 

with

 

5

 

gallons

 

of

 

diluted

 

solution.

  

Dilution

 

ratio

 

depends

 

on

 

the

 

cleaning

 

solution

 

used.

 

b.

 

Place

 

the

 

pump

 

into

 

the

 

bucket

 

if

 

it

 

is

 

submersible,

 

or

 

use

 

an

 

inlet

 

hose

 

into

 

the

 

bucket

 

if

 

it

 

is

 

not

 

submersible.

 

 

5)

 

DESCALE

 

a.

 

Open

 

valves

 

A

 

and

 

B.

 

b.

 

Circulate

 

descaling

 

solution

 

through

 

the

 

unit

 

for

 

45

 

minutes.

 

 

6)

 

CLEANSE

 

THE

 

SYSTEM

 

 

Flush

 

the

 

chemicals

 

out

 

of

 

the

 

heat

 

exchanger

 

with

 

fresh

 

water.

 

a.

 

Close

 

valve

 

A

 

and

 

B.

   

b.

 

Open

 

valve

 

D

 

and

 

run

 

fresh

 

water

 

through

 

the

 

PRV

 

for

 

15

 

minutes.

 

c.

 

Clean

 

the

 

filter

 

after

 

flushing

 

the

 

unit

 

with

 

fresh

 

water.

 

d.

 

Once

 

the

 

unit

 

is

 

flushed

 

and

 

cleansed,

 

close

 

A

 

and

 

B,

 

open

 

C

 

and

 

D,

 

and

 

reconnect

 

power

 

to

 

the

 

unit.

 

 

 

321923

000

 

Figure

 

35

 

Summary of Contents for 110

Page 1: ...or T KJr2 OS 310 Indoor T K4 IN 310 Outdoor T K4 OS 510 Indoor T D2 IN 510 Outdoor T D2 OS 9 12 11 321923 000 A O Smith Water Products Company 500 Tennessee Waltz Parkway Ashland City TN 37015 Toll Fr...

Page 2: ...blems 8 Error Codes 12 Procedures 19 Verifying proper Dipswitch settings 19 Draining the unit 21 Cleaning the filter 21 Checking for a Cross Connection 21 Check for Reverse Connection 21 Check gas sup...

Page 3: ...Troubleshooting Guide 3 Page 1 SPECIFICATIONS Table 1...

Page 4: ...edures consult with the technical service department or service agent IMPORTANT Installation and service must be performed by a qualified installer for example a licensed plumber or gas fitter Otherwi...

Page 5: ...nts depending on the set temperature 2 OPERATION a The proportional gas valve will modulate based on the amount of hot water demanded and the temperature rise needed The fan speed will modulate as wel...

Page 6: ...e the functions of the rotating fan and cause improper burning of the gas Regularly ensure that the area around the unit is dust or debris free regular maintenance is recommended for these types of en...

Page 7: ...s or 70 140ppm one must be installed If there is no water softener installed existing installations will gradually accumulate scale buildup on the heat exchanger and cause a leak Heat exchanger failur...

Page 8: ...troller if one is installed Check for cross plumbing between cold water lines and hot water lines See the Procedures section p 21 for instructions Unit may be hard water scaled The scale acts as an in...

Page 9: ...d water may be back feeding into the system o Problems with a recirculation system Check that a check valve is installed between the pump discharge and the connection to the cold water supply Check to...

Page 10: ...ME TO GET HOT WATER AT THE FIXTURES The time it takes to deliver hot water to your fixtures depends on the length of piping between the two The longer the distance or the bigger the pipes the longer i...

Page 11: ...water cross connection o Open Pressure Relief Valve Water flow should stop If not unit is plumbed in backwards Clean the filter p 21 If the fan never initiates check for a fouled water flow sensor p 3...

Page 12: ...Incorrect Dipswitch Settings 101 10 5 Warning for 991 Error Code 111 11 3 Ignition Failure 121 12 3 Flame Loss 311 31 2 Output Thermistor 321 32 2 Inlet Thermistor 331 N A N A Mixing Thermistor 391 39...

Page 13: ...air is contaminated with dust lint laundry machine nearby grease kitchens or other contaminants clean the burner See p 26 on procedures for cleaning the burner rod assembly 4 Weather related issues hi...

Page 14: ...AME LOSS This error code appears if the flames disappear while the unit is still supposed to be in operation 1 Verify that the hi limit switch is not tripped Turn the power off to the unit Push the wh...

Page 15: ...temperature about 74 F 3 Clean the thermistor a Drain the unit of water See p 21 b Remove the computer board to access the inlet thermistor The computer is fixed in place by a single screw at the top...

Page 16: ...immediately shut off gas and power to the unit and contact the Technical Service Department 2 Check the wire connections to the gas valve assembly for burns or cuts 3 If the unit was recently rebuilt...

Page 17: ...supply 2 Check that all wire connections are secure and free of burns The flow adjustment valve is located behind the computer board and attached to the cold water inlet 3 Check for water leakage fro...

Page 18: ...e heater with the power supply on this error code will result Turn off power before disconnecting the remote from the heater 5 Check for any signs of power surges ERROR CODE 761 510 T D2 COMMUNICATION...

Page 19: ...ch settings can cause a 031 error code or a number of operational problems Table 3 310 T K4 110 T KJr2 Dipswitch Settings No Function ON position OFF position 1 Gas type Propane Disable 2 Natural Gas...

Page 20: ...position 0 6 ON position 12 18 Outdoor 510 T D2 OS No 4 OFF position ON position No 5 OFF position 0 4 ON position 8 12 5 6 N A N A N A Default Table 5 4 510 T D2 Dipswitch Settings LOWER BANK No Fun...

Page 21: ...ilter back into place Hand tighten only CHECKING FOR A CROSS CONNECTION 1 Turn off cold water supply 2 Turn on all hot water fixtures a The water should eventually completely drain b If water continue...

Page 22: ...ap mixture onto fittings No bubbles means there are no leaks CHECKING MANIFOLD GAS PRESSURE 1 Ensure the unit is not in operation 2 Remove the screw off the manifold port 3 Connect a manometer to the...

Page 23: ...pectively Figure 5 18 Refer to the manometer to verify that pressure has been set to desired value 3 Now press and hold down the MAX button on the computer board to change the maximum burn pressure 4...

Page 24: ...epartment for further assistance 5 If an ohmmeter is not available jump the plug connection on the opposite side of the OHCF with a wire paper clip or other metal material 6 Restore power and test uni...

Page 25: ...setup The 3 digit LED on the PCB should not be lit 3 FRONT COVER Remove the front cover It is held on by two screws on the top corners of the tankless unit 4 ROD ASSEMBLY a Locate the black yellow and...

Page 26: ...circuit breaker depending on the setup 3 GAS Shut off the gas supply 4 FRONT COVER Remove the front cover 5 MANIFOLD PLATE GAS VALVE ASSEMBLY a Remove the manifold plate screws They are wide pan head...

Page 27: ...compromised please contact the Technical Service Department for further assistance b Thoroughly saturate the burner with the cleaning solution from the top down through the slots as well as the openi...

Page 28: ...y solid buildup in the heat exchanger please contact the Technical Service Department for further instruction 11 SENSORS a Clean the flame sensor and AFR with sandpaper thoroughly to a bright finish I...

Page 29: ...t of 100 Grit Sandpaper c 2 Philips Screw Driver d Needle Nosed Pliers e Duct Tape f Flashlight g Air Compressor h Old Towels at Least Three 2 PREPARE THE UNIT a POWER Disconnect power to your unit b...

Page 30: ...exchanger assembly remove them so the heat exchanger is completely free 8 REPLACE THE HEAT EXCHANGER COMPONENTS a Remove and inspect the new heat exchanger making sure it is designed for the correct...

Page 31: ...w sensor is located behind the computer board b Remove the waterway clips on each side of the flow sensor by pushing on the tabs 6 CHECKING THE FLOW SENSOR a Check for functionality Flow rate is deter...

Page 32: ...closing the incoming outgoing water isolation valves C and D b Connect hoses pump to the drain ports of the isolation valves Outlet of the pump to valve B and another hose from Valve A to the bucket 4...

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