A.O. Smith Cyclone XL 100 Series Service Handbook Download Page 1

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SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN

PRINTED 0220

100314732 2000568400 Rev. A

Service Handbook

COMMERCIAL GAS WATER HEATERS

MODELS

BTHS 750A & 1000A

SERIES 100 & 101

INSTALLATION - OPERATION

- SERVICE - MAINTENANCE

Summary of Contents for Cyclone XL 100 Series

Page 1: ...ED BY A QUALIFIED SERVICE TECHNICIAN PRINTED 0220 100314732 2000568400 Rev A Service Handbook COMMERCIAL GAS WATER HEATERS COMMERCIAL GAS WATER HEATERS MODELS BTHS 750A 1000A SERIES 100 101 INSTALLATI...

Page 2: ...21 13 Flow Switch Stuck Closed 22 VENTING 24 General Venting Information 24 INTAKE AIR CONNECTION 25 ELECTRICAL CONNECTIONS ALL MODELS 26 Power Fluctuations and Electrical Noise 26 Dedicated Power Wir...

Page 3: ...procedures described in this service handbook If you do not understand the instructions given in this service handbook do not attempt to perform any procedures outlined in this service handbook SERVI...

Page 4: ...charged from the valve due to excessive pressure build up This condition is not covered under the limited warranty The Temperature Pressure Relief Valve is not intended for the constant relief of ther...

Page 5: ...e module The UIM includes the display circuit board and the control system s LCD Touch Display Used to adjust various user settings and view operational information 3 Central Control Board CCB enclosu...

Page 6: ...red non sacrificial anode rods at the top Protective current is fed by the control system to the titanium electrodes at the end of each anode rod This current flows through the water to the conductive...

Page 7: ...lation 35 Burner flange gasket 36 Observation sight glass 37 Burner 38 Flame rod 39 Flame rod gasket 40 Blower discharge gasket 41 Burner gasket 42 Spark rod 43 Spark rod gasket 44 Ignition cable 4 3...

Page 8: ...View 1 Burner Blower Assembly 2 Blocked Intake Air switch 3 Powered anode rods 4 Temperature Pressure Relief Valve 5 2 NPT hot water outlet connection 6 Temperature Probe 7 Spark Ignition Control 8 12...

Page 9: ...ivated Spark Ignition Transformer is energized 24 Volt 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...

Page 10: ...supply pressures meet the requirements described above and listed in the table Failure of the gas supply to meet these requirements is not covered under the warranty High Pressure building supply syst...

Page 11: ...he pressure port on the gas valve inlet flange See Figure 8 4 A digital manometer see Tools Recommended on Page 2 is needed to check supply gas pressure To monitor supply gas pressure attach a sensing...

Page 12: ...ble The unit will begin an ignition cycle When the Gas Control Valve icon appears on display screen immediately look through the sight glass for a brief blue flame if you are getting an Ignition Failu...

Page 13: ...e at the moment the gas control valve icon appears on the display follow these steps 1 Install a gas pressure gage at the gas valve s inlet pressure port and confirm that the gas supply pressure DOES...

Page 14: ...0 hrs 0 mins ago Error Code A7 1201 Restriction in air intake Check intake pipe and termination for blockage Press the Advanced button for CAUSES The Blocked Air Intake Switch has detected a possible...

Page 15: ...proper operation If flame is not present cycle the unit Off by turning the Enable Disable switch to Disable wait for 5 seconds and cycle the unit On by turning the Enable Disable switch to Enable to...

Page 16: ...ycle the flame sensing current is normally greater than 8 0 A with a clean Flame Sensor Over time the Flame Sensor can degrade and this will reduce flame sensing current With heavier use more heating...

Page 17: ...e replaced unless damaged The CCB monitors the current through the anodes and will declare a fault if there is a disconnected wire or if there is no water in the tank Side Mounted Power Anodes 2 Top M...

Page 18: ...Replace the Temperature Probe if shorted resistance is below 390 Ohms See Temperature Probe section below TEMPERATURE PROBE This section of the Service Handbook provides information on the Temperatur...

Page 19: ...n the UIM The electrical circuit breaker that serves the water heater must be turned off and on again to reset the Control System Note the Control System will not reset unless the condition has been c...

Page 20: ...ter when replacing the Temperature Probe If the Control System continues to lock out displaying Energy Cut Out ECO on the UIM and the water temperature inside the water heater is becoming excessive at...

Page 21: ...e exhaust temperature is normally around 100 F leaving the water heater If the heater is running during the standby mode the flue exhaust temperature tends moving up during the standby heating cycle T...

Page 22: ...side the pump s outlet is installed correctly if it s a new heater installation Confirm the flow switch is installed vertically with flow arrow pointed upward Confirm the flow switch s vane can swing...

Page 23: ...rm the flow switch is installed correctly with flow arrow vertically pointing upward 4 Remove inspect the flow switch s vane free from debris 5 Replace the flow switch if malfunction is detected with...

Page 24: ...mbustion air from the room where they are installed and discharge all flue gases to the outdoor atmosphere through a sealed vent exhaust pipe Power vent configurations have one vent pipe connected to...

Page 25: ...essure Port Figure 18 AIR INTAKE SCREEN Service Notes Plastic debris left on the edges of intake air pipe sections after cutting must be removed on Direct Vent installations This debris can collect in...

Page 26: ...of local codes with the National Electrical Code ANSI NFPA 70 or the Canadian Electrical Code CSA C22 1 If any of the original wire as supplied on the water heater must be replaced it must be replaced...

Page 27: ...still be energized and the display will read Water Heating Disabled The Enable Disable Switch can be used to disable operation and reset error codes To operate the water heater make sure the switch is...

Page 28: ...imum equivalent lengths required in the Instruction Manual that came with the water heater Exceeding the maximum length or number of elbows allowed will also lead to Blocked Exhaust and or Blocked Air...

Page 29: ...speeds during the Pre Post Purge operating states and runs at a lower speed during the Trial For Ignition operating state The Igniter Status icon is displayed on the UIM during the Trial For Ignition...

Page 30: ...eed RPM Low Fire Speed RPM Ignition Speed RPM BTHS 750 4475 2300 2000 BTHS 1000 6000 2300 2000 Note 10 High Heating Speed RPMs are based from the Nominal Certification Heating Speed RPMs Table 3 Blowe...

Page 31: ...e ignition cable from the spark igniter and the yellow wire from the Flame Sensor 9 Disconnect the 3 Pin and 5 Pin plugs from the Combustion Blower Assembly 10 Disconnect the 24 Volt power wires to th...

Page 32: ...e 21 Burner Assembly The Control System is programmed to start sparking a few seconds before the Gas Control Valve opens See the Sequence of Operation Flow Chart page 9 Service Notes The animated ligh...

Page 33: ...All instructions for ignition and temperature control originate from this circuit board Diagnostic and operational messages are generated by the CCB and sent to the UIM See Figure 24 page 40 Most of t...

Page 34: ...RE 1 Ensure power to the water heater is turned off 2 Remove the water heater s top cover UIM and the bottom plastic cover 3 Remove the temperature probe connectors 4 Unlock clips on both sides and re...

Page 35: ...J3 J13 J4 J17 J10 J9 J14 J15 J1 J6 J12 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 8 8 8 9 9 7 10 8 Figure 22 Central Contro...

Page 36: ...9 Neutral J3 Socket UIM Pin DESCRIPTION 1 5V 2 AIN Reset 3 Data 4 Data 5 D Grd J4 Socket Flue Probe Flow Switch Pin DESCRIPTION 1 Flue Probe 2 Flue Probe 3 Flow switch 4 Flow Switch J5 Socket Blower...

Page 37: ...t Used 6 Condensate 7 Gas Pressure Switch 8 Gas Pressure Switch 9 Gas Control Valve 10 Gas Control Valve 11 24V 12 24V Return J15 Socket Pressure Switches Table 14 Pin Table 15 Description 1 Blocked A...

Page 38: ...the UIM Table 18 CPAM Fault Warning Codes Corrective Action Code Description Corrective Action Cc Anode Shorted Check wiring for shorts clean anode Ce Hardware fail ADC error Reset power if still fai...

Page 39: ...s V 24V 24V Rtn Condensate Gas PS Gas V Switch 1 Red 2 Black CCB J6 120V Out Neutral 120 to Spark Red Black Red Black Upper Temperature Probe ECO 1 Red 2 Black CCB J9 Upper Probe ECO Thermistor 4 Red...

Page 40: ...ser Interface Module Tank Temperature 103 F Operating Set Point 120 F Status Heating MENU HELP GAS OFF O N Figure 24 UIM User Interface Module Screen ICOMM REMOTE MONITORING SYSTEM This water heater i...

Page 41: ...41 NOTES NOTES...

Page 42: ...42 NOTES NOTES...

Page 43: ...43 NOTES NOTES...

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