A.O. Smith ADM - 115 Installation & Service Manual Download Page 34

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Conversion to a different gas category

Instruction manual ADM

Exchanging orifices

4.1

Conversion to
different category
ADM 40 through 115

1. Isolate the appliance from the power supply

(10.3 "Isolating the appliance

from the mains")

2. Shut off the gas supply.

Caution

The burner can be hot.

3. Unscrew the cover plate (1) from the burner support.
4. Use a suitable tool to remove the retaining strips (2). Note that the retaining

strips have very sharp edges. Withdraw the retaining strips straight upwards.

Note

The radiation shield / condensation tray can be temporarily loosened to

simplify disassembly of the burner.

5. Remove the burners one by one from their brackets at the front. To do this,

you first move them away from you and then downwards. The orifices will
now be accessible

6. Remove the orifices.

Legend

1. cover plate
2. retaining strips
3. orifice with stamped figures

IMD-0126 R1

Summary of Contents for ADM - 115

Page 1: ......

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Page 3: ...ther than that stated in this manual and in accordance with the General Conditions registered at the Eindhoven Chamber of Commerce Refer further to the General Conditions These are available on request free of charge Although considerable care has been taken to ensure a correct and suitably comprehensive description of all relevant components the manual may nonetheless contain errors and inaccurac...

Page 4: ...4 Instruction manual ADM gis ...

Page 5: ...nstallation diagram 21 3 6 Water connections Vented 22 3 7 Water connections Unvented 23 3 8 Gas connection 24 3 9 Chimney flue 25 3 10 Electrical connection 26 3 11 Checking the supply pressure and burner pressure 28 4 Conversion to a different gas category 33 4 1 Conversion to different category ADM 40 through 115 34 4 2 Conversion to a different gas category ADM 135 36 5 Filling 41 5 1 Filling ...

Page 6: ...eshooting 55 11 1 Introduction 55 11 2 Error conditions 55 11 3 Troubleshooting table for general errors 56 11 4 ADM Troubleshooting table no hot water 57 11 5 Troubleshooting table insufficient hot water 59 12 Performing maintenance 61 12 1 Introduction 61 12 2 Preparation for maintenance 61 12 3 Water side maintenance 62 12 4 Gas side maintenance 63 12 5 Finalising maintenance 64 13 Warranty cer...

Page 7: ...ll gas Warning If there is a gas smell No naked flames No smoking Avoid causing sparks Do not use any electrical equipment or switch i e no telephones plugs or bells Open windows and doors Shut off the mains gas supply valve Warn occupants and leave the building After leaving the building alert the gas distribution company or your installation engineer 1 3 Regulations As the end user installation ...

Page 8: ... temperature Note To determine the correct maintenance frequency it is recommended to arrange for the service and maintenance engineer to check the appliance on both the water and gas side within three months following installation Based on this check the best maintenance frequency can be determined Note Regular maintenance extends the service life of the appliance Note Both the end user and the s...

Page 9: ...appliance This chapter describes the status mode or condition that the appliance may have and possible actions to take Starting and running This chapter describes how to start the appliance running The general heating cycle of the appliance is also described Shutting down This chapter describes how to shut the appliance down for a brief or long period of time Troubleshooting This chapter is mainly...

Page 10: ...Introduction 10 Instruction manual ADM 1 gis ...

Page 11: ...el 8 combustion chamber 9 anode 10 tank 11 heat exchanger 12 inspection and cleaning opening 14 cold water inlet 15 drain valve 16 gas control 20 spark igniter 21 flame probe 22 chimney pipe 24 insulation layer 33 draught diverter 34 flue gas sensor 35 radiation shield condensation tray 36 bar burners burner tray 37 flue gas thermostat 38 safety thermostat sensor 39 high limit thermostat sensor 40...

Page 12: ... tray This prevents overheating of the floor area below the appliance as well as serving as a collection tray for condensation water The insulation layer 24 prevents heat loss The inside of the tank is enamelled to protect against corrosion The anodes 9 offer extra protection 2 3 The appliance s heating cycle The entire appliance is controlled by the burner control 40 and the control thermostat 41...

Page 13: ...s present 2 5 Safety of the installation In addition to the appliance s standard built in safety monitoring the appliance must also be protected by an expansion vessel expansion valve pressure reducing valve non return valve and a T P valve The use of an expansion vessel expansion valve and or pressure reducing valve depends on the type of installation unvented or vented 2 5 1 Inlet combination an...

Page 14: ...e open cold water head tank The head height of the tank determines the working pressure in the water heater which may not exceed 8 bar The installation must also be fitted with a vent pipe from the hot water pipe 3 6 3 Hot water side which opens into the cold water tank 2 5 4 T P valve A T P valve is only mandatory in an unvented installation However A O Smith also recommends the use of a T P valv...

Page 15: ...nt gas category 3 2 Packaging To avoid damaging the appliance remove the packaging carefully We recommend unpacking the appliance at or near its intended location Caution The appliance may only be manoeuvred in an upright position Take care that the appliance is not damaged after unpacking 3 3 Ambient conditions Caution The appliance may not be used in rooms where chemical substances are stored or...

Page 16: ...o replace the anodes 100 cm if using fixed anodes or 50 cm if using flexible anodes If the available clearance is less than 100 cm flexible magnesium anodes may be ordered Note When installing the appliance be aware that any leakage from the tank and or connections can cause damage to the immediate environment or floors below the level of the boiler room If this is the case the appliance should be...

Page 17: ...cifications The appliance is supplied without accessories Check the dimensions 3 4 1 Dimensions of the appliance gas data 3 4 3 Gas data and other specifications 3 4 2 General and electrical specifications of any accessories you plan to use B B A A A A AA IMD 0262 R2 ...

Page 18: ...Installation 18 Instruction manual ADM 3 is 3 4 1 Dimensions of the appliance Plan and elevation of the appliance Legend See the table 10º 37º 45º F E A D H G B M R K P S N J 6 1 3 4 6 2 5 IMD 0135 R2 ...

Page 19: ...0 515 500 515 525 600 595 S Height of T P valve connection 1550 1760 1550 1760 1595 1660 1660 1 Cold water supply connection male R11 2 R11 2 R11 2 R11 2 R11 2 R11 2 R11 2 2 Hot water outlet connection female Rp11 2 Rp11 2 Rp11 2 Rp11 2 Rp11 2 Rp11 2 Rp11 2 3 Gas control connection female Rp3 4 Rp3 4 Rp3 4 Rp3 4 Rp3 4 Rp3 4 Rp1 4 Drain valve connection female Rp11 2 Rp11 2 Rp11 2 Rp11 2 Rp11 2 Rp1...

Page 20: ...1 70 1 50 1 70 1 70 2 25 1 Blank plate 2 Burner pressure regulator 3 High low control 1 2 or 3 1 1 1 1 1 1 3 Gas category G30 30 mbar Nominal load gross calorific value kW 41 6 55 3 68 2 80 7 96 1 123 5 138 4 Nominal output kW 32 6 42 8 52 8 62 6 74 5 95 8 108 5 Supply pressure mbar 30 30 30 30 30 30 30 Burner pressure mbar Gas consumption kg h 3 0 4 0 5 0 5 9 7 0 9 0 10 1 Gas category G31 37 mbar...

Page 21: ...6 circulation pump optional 7 top to bottom circulation pump optional 9 drain valve 10 manual gas valve mandatory 11 service stop valve mandatory 12 temperature gauge recommended 14 hot water draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeration valve recommended 18 water tank 19 float valve A cold water supply B hot water supply C circulation pipe D gas supp...

Page 22: ...rculation pipe Ø 22 mm a stop valve 11 and a top to bottom circulation pump 7 2 Fit a non return valve 5 3 Fit a stop valve 11 3 6 3 Hot water side See B in the installation diagram 3 5 Installation diagram Note Insulating long hot water pipes prevents unnecessary energy loss 1 Fit the T P valve 3 2 Optional fit a temperature gauge 12 so you can check the temperature of the tap water 3 Fit a stop ...

Page 23: ...Regulations 2 The maximum working pressure of the appliance is 8 bar Because the pressure in the water pipe at times can exceed 8 bar you must fit an approved pressure reducing valve 1 3 Fit a non return valve 5 and an expansion vessel 16 4 Fit an expansion valve 15 and connect the overflow side to an open wastewater pipe 3 7 2 Recirculation pipe You can install a top to bottom circulation pump to...

Page 24: ...ice purposes 4 4 Connect the circulation pipe to the T piece at the drain valve 9 as shown in the drain valve figure 3 6 4 Drain valve 3 8 Gas connection Warning The installation should be carried out by an authorised installation engineer in compliance with general and local regulations 1 3 Regulations Caution Make sure that the diameter and length of the gas supply pipe are large enough to suppl...

Page 25: ...bracket parts can be found in the plastic bag attached behind the control column The assembly procedure is as follows Installing the draught diverter 1 Take the mounting bracket out of the bag 2 Fit the mounting bracket 1 in such a way that it properly supports the draught diverter 3 Drill two holes 2 3 2 mm bit for the mounting bracket screws 4 Screw the mounting bracket tightly to the appliance ...

Page 26: ...he thermostat bracket and sensor have yet to be fitted inside the draught diverter Warning If the flue gas thermostat is not or is incorrectly fitted connected the flue gas discharge will not be protected An incorrectly fitted chimney can cause flue gases to backflow into the boiler room Flue gas safety 1 Fit the flue gas thermostat as follows 2 Take the bracket 1 and flue gas sensor 2 from the pa...

Page 27: ...ase then an isolating transformer must be applied in the supply circuit For more information or to order an isolating transformer please contact A O Smith Water Products Company The figure shows a view of the electrical connector block and the table shows the appropriate connections Connector block 1 In preparation first remove the protective cover from the control column 2 Undo the 4 screws A 3 R...

Page 28: ... 1 Feed the power cable through the metric strain relief to the top side of the control column 2 Connect the earth live L1 and neutral N of the power cable to terminals 1 through 3 in the connector block as stated in the table 3 Turn the strain relief tight to clamp the lead 4 If you do not need to make any more connections fit the protective cover onto the control column 5 Connect the power cable...

Page 29: ...nly applicable numbers are mentioned 1 burner pressure regulator 2 burner pressure regulator cap 3 burner pressure regulator adjustment screw 4 gas control connector 5 blank plate 6 supply pressure test nipple 7 gas control 8 manifold test nipple 1 4 5 6 7 2 8 3 IMD 0127 R1 ...

Page 30: ...e gas supply and bleed the air from the mains gas supply via test nipple 6 5 Connect a pressure gauge to the manifold test nipple 6 when gas starts to flow from this nipple 6 Switch on the power to the appliance using the isolator on the appliance 7 Set the control thermostat to the maximum temperature and start the appliance running by setting the ON OFF switch to position I 8 The heating cycle w...

Page 31: ...rrection required correct the burner pressure by turning adjustment screw 3 Adjustment screw anticlockwise burner pressure decreases Adjustment screw clockwise burner pressure increases 3 Cover the opening of the adjusting screw and check the burner pressure against the value given in thegas data table 3 4 3 Gas data 4 If the pressure reading is not correct repeat the burner pressure adjustment un...

Page 32: ...Installation 32 Instruction manual ADM 3 is ...

Page 33: ...of gases LP gas or natural gas or other gas category than that for which the appliance has been set at the factory the appliance will have be adapted using a special conversion kit Caution You must check the supply pressure and burner pressure once the conversion is complete This chapter covers the following Conversion to different category ADM 40 through 115 Conversion from natural gas to LP gas ...

Page 34: ...rt 4 Use a suitable tool to remove the retaining strips 2 Note that the retaining strips have very sharp edges Withdraw the retaining strips straight upwards Note The radiation shield condensation tray can be temporarily loosened to simplify disassembly of the burner 5 Remove the burners one by one from their brackets at the front To do this you first move them away from you and then downwards The...

Page 35: ...Gas data then the gas control must be fitted with a blank plate with cork gasket A burner pressure that deviates in comparison to the supply pressure requires the use of a burner pressure regulator with rubber gasket Each conversion kit contains all the necessary components 12 If the blank plate or burner pressure regulator need to be replaced Unscrew the connector 4 of the gas control If necessar...

Page 36: ...ting plate This clearly indicates that the appliance may no longer be run on the gas for which it was originally supplied 15 Start the appliance 9 Starting and running 4 2 Conversion to a different gas category ADM 135 4 2 1 Introduction This paragraph describes Conversion from LP gas to natural gas Conversion from natural gas to LP gas Conversion of gas control Legend Only applicable numbers are ...

Page 37: ...natural gas Installing and removing add on components Legend Only applicable numbers are mentioned 4 timers 5 bracket 6 6 contact terminal strip 7 strain relief 8 9 contact terminal strip 9 metric strain relief 10 high low control lead 4 9 7 5 10 6 8 IMD 0130 R1 ...

Page 38: ...he sticker showing the new gas category from the conversion kit and attach it below the appliance s rating plate This clearly indicates that the appliance may no longer be run on the gas for which it was originally supplied 12 Start the appliance 9 Starting and running 4 2 3 Conversion from natural gas to LP gas 1 Carry out steps 1 through 10 4 1 Conversion to different category ADM 40 through 115...

Page 39: ...wing the new gas category from the conversion kit and attach it below the appliance s rating plate This clearly indicates that the appliance may no longer be run on the gas for which it was originally supplied 12 Start the appliance 9 Starting and running ...

Page 40: ...Conversion to a different gas category 40 Instruction manual ADM 4 is ...

Page 41: ... 10 manual gas valve mandatory 11 service stop valve mandatory 12 temperature gauge recommended 14 hot water draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeration valve recommended 18 water tank 19 float valve A cold water supply B hot water supply C circulation pipe D gas supply E overflow pipe H overflow pipe IMD 0466 R0 UNVENTED VENTED 10 D 4 5 7 4 3 B A 4...

Page 42: ... cause might be The water supply pressure is greater than the specified 8 bar Rectify this by fitting a pressure reducing valve 1 The expansion valve in the protected cold supply setup is defective or incorrectly fitted 5 2 Filling vented installations To fill the appliance proceed as follows 1 Open the stop valve 11 in the hot water pipe and if present the stop valves 4 for the circulation pump 6...

Page 43: ...e 10 manual gas valve mandatory 11 service stop valve mandatory 12 temperature gauge recommended 14 hot water draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeration valve recommended 18 water tank 19 float valve A cold water supply B hot water supply C circulation pipe D gas supply E overflow pipe H overflow pipe IMD 0466 R0 UNVENTED VENTED 10 D 4 5 7 4 3 B A ...

Page 44: ... ON OFF switch on the control panel to position 0 2 Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0 3 Shut off the gas supply 10 4 Close the stop valve 11 in the hot water pipe 5 Close the supply valve of the cold water supply A 6 Open the drain valve 9 7 Bleed the appliance or installation so that it drains comp...

Page 45: ...control panel to position 0 2 Isolate the water heater from the power supply by putting the isolator between the appliance and the mains power supply to position 0 3 Shut off the gas supply 10 4 Close the stop valve 11 in the hot water pipe 5 Close the stop valve 4 between the cold water head tank and the cold water inlet 6 Open the drain valve 9 7 Bleed the appliance or installation so that it dr...

Page 46: ...Draining 46 Instruction manual ADM 6 gis ...

Page 47: ...e in ON mode or OFF mode In OFF mode the appliance is still electrically live This ensures that the frost protection is active Note To electrically isolate the appliance you must use the isolator between the appliance and the mains power supply 7 5 Control thermostat Use the rotary knob of the control thermostat to set the desired water temperature between 40 C and 70 C The range is continuous and...

Page 48: ...thermostat reset button A malfunction in the flue gas discharge e g a blockage in the chimney can lead to the flue gas thermostat locking out This state is evident when the push button on the flue gas thermostat has been activated refer to the figure Once the cause has been removed and the sensor has cooled down sufficiently press this push button to reset if the sensor is not sufficiently cooled ...

Page 49: ...r from the flue gas thermostat The safety pushbutton on the flue gas thermostat in the draught diverter has been activated After removing the cause the pushbutton 7 6 Burner control reset button must be pressed to restart the appliance Lockout error from the flue gas thermostat When this happens the red LED on the control panel will be illuminated The burner control is locked out After eliminating...

Page 50: ...Status of the appliance 50 Instruction manual ADM 8 gis ...

Page 51: ... C The heating cycle runs successively through the following states 1 HEAT DEMAND 2 WAIT 3 PRE GLOW 4 IGNITION 5 RUNNING 6 WAIT The entire cycle is explained in the example below Note The cycle has the same steps when frost protection is activated 1 The control thermostat sensor measures the temperature The water temperature falls below the set temperature of for example 60 C causing the control t...

Page 52: ...Starting and running 52 Instruction manual ADM 9 gis ...

Page 53: ...the frost protection you can prevent water freezing in the appliance Frost protection is activated by setting the ON OFF switch on the control panel to position 0 10 3 Isolating the appliance from the mains The appliance should only be isolated from mains power in the correct way The correct procedure is as follows 1 Shut down the appliance by setting the ON OFF switch to position 0 2 Isolate the ...

Page 54: ...Shutting down 54 Instruction manual ADM 10 gis ...

Page 55: ...essed to restart the appliance Lockout error from the flue gas thermostat When this happens the red LED on the control panel will be illuminated The burner control is locked out After eliminating the cause the appliance must be returned to service by pressing the reset button 7 6 Burner control reset button Blocking errors You can recognise this condition from the fact that the appliance does not ...

Page 56: ...our installation engineer Leakage from another nearby water appliance or pipe segment Trace the leak Leakage from the appliance s tank Consult the supplier and or manufacturer Condensation Before drawing too much tap water wait until the water in the boiler has reached the set temperature Explosive ignition Poor flame profile Incorrect supply pressure and or burner pressure Set the correct supply ...

Page 57: ...kage in the flue gas discharge the flue gas thermostat has cut out 1 Trace the blockage 2 Remove the blockage 3 Reset flue gas thermostat 7 7 Flue gas thermostat reset button When a demand is detected the appliance will restart Symptom Cause Precautions Comment Green LED ON and Red LED ON There are three possible causes for this error In order to determine the cause you must cause the error to app...

Page 58: ...ance Check whether the flame probe is defective Check that the flame probe leads are properly connected If the error cannot be resolved or is persistent contact your installation engineer Symptom Cause Precautions Comment b The safety thermostat has cut out 1 The safety thermostat has cut out correctly Reset the appliance Check whether the control thermostat is working Check whether the high limit...

Page 59: ...ontrol thermostat to a higher value Hot water supply is used up 1 Reduce hot water consumption and give the appliance time to heat up 2 If this error persists check whether the high limit thermostat is switching If this is the case check that the circulation and or top to bottom circulation pump are working If the error has not been rectified and no other cause can be found isolate the appliance f...

Page 60: ...is Instruction manual ADM 60 ...

Page 61: ...control panel to position 0 2 Set the control thermostat to the highest value note the original setting and set the ON OFF switch back again to position I 3 If there is no heat demand draw off some water to create a heat demand 4 Check whether the heating cycle 9 3 The appliance s heating cycle runs correctly 5 Set the control thermostat back to the original setting and set the ON OFF switch back ...

Page 62: ...Check the anodes and replace them if necessary 12 Now also check the flue baffles 12 4 4 Checking the flue baffles If necessary replace them 13 Place a new sealing ring on the rim of the tank and re fit the lid 14 Fit the draught diverter 3 9 2 Fitting the draught diverter 15 Feed the cable of the flue gas thermostat through the strain relief and attach the wiring to the connector block 14 2 Elect...

Page 63: ...ve the loose scale deposits and contamination 6 If the scale cannot be removed by hand descale the appliance with a descaling agent Contact the supplier manufacturer for advice on what descaling agent to use 7 Close the cleaning opening To avoid damage to the tank tighten the bolts that fasten the lid with a torque no greater than 50 Nm Use suitable tools for this For the best possible watertight ...

Page 64: ...he flue baffles from the appliance 2 Check the flue baffles for the presence of corrosion removing this if necessary 3 Check the flue baffles for wear and replace the flue baffles if necessary 4 Place a new sealing ring on the rim of the tank and re fit the lid 5 Fit the draught diverter 3 9 2 Fitting the draught diverter 6 Feed the cable of the flue gas thermostat through the strain relief and at...

Page 65: ...r heater the warranty shall be reduced to one year from the original installation date 13 3 Conditions for Installation and use The warranty set out in article 1 and 2 will apply solely under the following conditions a The water heater is installed under strict adherence to A O Smith installation instructions for the specific model and the relevant government and local authority installation and b...

Page 66: ...e water heater other than by an approved service engineer 13 5 Scope of the warranty The obligations of A O Smith pursuant to the specified warranty do not extend beyond free delivery from the Veldhoven warehouse of the replacement sections parts or water heater respectively Shipping labour installation and any other costs associated with the replacement will not be accepted by A O Smith 13 6 Clai...

Page 67: ...nstruction manual ADM 67 is 14 Appendices 14 1 Introduction This section gives the electrical diagrams for Electrical diagram for ADM 40 to 135 natural gas and 40 to 115 LPG Electrical diagram 135 LP gas ...

Page 68: ... yellow green 4 black 5 white flat cable I 0 L 24V N N L M 4 2 1 3 4 12 12 1 4 1 2 3 1 4 2 1 2 1 4 4 4 3 3 3 4 3 4 4 11 H 1 G 4 3 12 4 3 11 12 4 N T V L L N H N 1 G HOT L A G N X FACE SUR M I FUSE F1 B 4 3 1 4 4 11 L K 4 11 1 J 3 3 2 4 4 230V AC L 50Hz N N N O C P F O N P A 4 L L I N N C D E R1 6 5 4 3 2 1 L N 2 L 3 L 12 9 7 8 10 11 1 4 1 3 2 1 4 4 4 0305471 R1 ...

Page 69: ...itch K Safety thermostat L High limit thermostat M Extra error signal connection N Gas control O Hot surface igniter P Flame probe CONTROLLER CONNECTIONS N1 Neutral Earth L Phase input of controller L Phase output to safety circuit and thermostat circuit TH Phase input of thermostat circuit GV1 Phase output to gas control MAX Phase input to safety thermostat LG Phase output to hot surface igniter ...

Page 70: ...5 4 3 2 1 4 1 4 2 3 C D E N L B L 1 3 2 1 N 2 1 1 3 2 3 4 4 2 L L 4 4 5 4 A 50Hz 230V AC 4 2 3 1 HOT FACE I F F1 FUSE 1 4 4 4 G 12 11 12 11 H 3 3 J 0 I 1 4 11 12 1 SUR R1 P C O N N L L N H N X 1 N N G T M A G V L 1 1 2 4 1 2 4 4 4 3 3 3 3 4 L N M L N 24V K 4 L 4 11 12 4 3 2 2 4 2 4 O N P Q 3 1 4 4 4 2 3 4 T 16 R 18 L2 16 18 2 A L N 3 R 2 A N T 1 2 L 15 1 1 L1 1 A 4 4 2 15 0304481 R1 ...

Page 71: ... thermostat L High limit thermostat M Extra error signal connection N Gas control O Hot surface igniter P Flame probe Q High low control R Timer CONTROLLER CONNECTIONS N1 Neutral Earth L Phase input of controller L Phase output to safety circuit and thermostat circuit TH Phase input of thermostat circuit GV1 Phase output to gas control MAX Phase input to safety thermostat LG Phase output to hot su...

Page 72: ...Appendices 72 Instruction manual ADM 14 is ...

Page 73: ...fferent 33 gas connection 24 general specifications 3 H heating cycle 12 humidity 15 I icons explanation 47 installation engineer 8 9 isolator 28 L liability 3 M mains power 28 maintenance burner 64 finalising 64 gas side 63 orifice 64 perform 61 preparation 61 water side 62 O operating modes 49 P packaging 15 protection 12 R running 51 S scale 62 service check 8 service engineer 8 shunt pump 22 2...

Page 74: ...0306 132 4 0 UK Index Instruction manual ADM ...

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