A.O. Smith INTELLI-VENT Troubleshooting Manual Download Page 1

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INTELLI-VENT™ CONTROL INFORMATION

When Used On Gas, Residential, Power Vented

Water Heaters

Printed in the USA – 0605

Part No. GTC-070 R3

Revision 2 includes updated troubleshooting information for error codes 3, 4, and 6.

Revision 3 includes updated troubleshooting for error codes 4 and 6 and technical bulletins

http://waterheatertimer.org/How-to-troubleshoot-gas-water-heater.html#intellivent

Summary of Contents for INTELLI-VENT

Page 1: ...ted in the USA 0605 Part No GTC 070 R3 Revision 2 includes updated troubleshooting information for error codes 3 4 and 6 Revision 3 includes updated troubleshooting for error codes 4 and 6 and technic...

Page 2: ...standard residential controls Temperature Probe Thermistor The temperature probe houses the ECO and a temperature sensor which is a thermistor Thermistors are thermally sensitive variable resistors A...

Page 3: ...e Switch 5 Pin Molex Plug Hot Surface Ignitor Flame Sensor Resistor Wire Ignitor Assembly Flame Sensor Silicon Nitride Ignitor Hot Surface Ignitor Front Left Side View Temperature Probe ECO 6 LED indi...

Page 4: ...s are factory set at 120 F 2 Wake Up the control by holding down both of the temperature adjust buttons at the same time for about one second then release the buttons and the LED lights will indicate...

Page 5: ...commercial control all six LEDs are yellow The residential control has a vacation temperature setting 70 F and it is referenced on the display There is no vacation setting on a commercial control The...

Page 6: ...control must be replaced 195 F Commercial resettable reset temp 120 F OPERATING SEQUENCE Pre Purge Time 5 seconds Ignitor Warm up Time 20 seconds Trial for Ignition Period 4 seconds Inter Purge Time...

Page 7: ...are shown above notice the raised ridges identifying the 1 2 and 3 pins A black marker was used to highlight these ridges for the photograph Service Notes The Black Resistor Wire on the ignitor assem...

Page 8: ...INTELLI VENT TROUBLESHOOTING GUIDE Technical Training Department Ashland City Tennessee 2005 7 of 24 Wiring Harness Connection Diagram Models Equipped With Vent Temperature Limit Switch...

Page 9: ...INTELLI VENT TROUBLESHOOTING GUIDE Technical Training Department Ashland City Tennessee 2005 8 of 24 INTELLI VENT SEQUENCE OF OPERATION...

Page 10: ...s display error codes by flashing the LED lights on and off Important Service Installation Notes 1 Always turn power off for 10 to 20 seconds and then back on again to clear an error code before repla...

Page 11: ...tch circuit wiring is correct and the air pressure switch is not jumpered Turn off power and unplug the water heater from wall outlet Disconnect both wires from the air pressure switch terminals Check...

Page 12: ...pipe Defective air pressure switch Check pressure switch contacts with ohm meter during blower operation contacts should close show continuity after blower starts and comes up to speed If air pressur...

Page 13: ...cle the power to the water heater off and on to reset Check Repair Gas supply is off or too low of pressure to operate Insure manifold gas pressure is present and within requirement Insure the flame s...

Page 14: ...ff for 10 20 seconds then on again to clear these error codes If any of these error codes persist or cannot be cleared replace the Intelli Vent control ERROR CODE 10 FLAME SENSED OUT OF SEQUENCE Flame...

Page 15: ...iagnostic check detected a temperature adjust button stuck closed Check Repair Make sure no objects are leaning against the front of the control Lightly press and release each of the buttons once If t...

Page 16: ...resistor wire between pins 3 4 with an ohm meter A If the reading taken is less than 2000 or more than 1 7 million ohms replace the ignitor assembly B If the reading taken is between 2000 and 1 7 mil...

Page 17: ...m www statewaterheaters com If it is determined there is not a sufficient supply of combustion air or fuel gas resolve these problems first The test procedures outlined in this technical bulletin pres...

Page 18: ...INTELLI VENT TROUBLESHOOTING GUIDE Technical Training Department Ashland City Tennessee 2005 17 of 24 FLAME SENSOR ALIGNMENT CONT...

Page 19: ...nce test Check the ignitor resistance with an ohm meter set on a low scale Ignitor resistance should be between 11 5 and 18 8 ohms If the resistance of the ignitor is not within this range replace the...

Page 20: ...ts The outer and inner combustion chamber access covers and the fiberglass insulation between the outer jacket and the combustion chamber must also be installed correctly If not installed properly thi...

Page 21: ...cts on this air pressure switch will close in response to changes in vent system pressure At the beginning of a heating cycle the ignition control will check if the air pressure switch circuit is open...

Page 22: ...e term activate means to change state If the contacts are normally open activating the contacts will cause them to close If the contacts are normally closed activating the contacts will cause them to...

Page 23: ...tial products use the first type shown below SWITCH CONTACTS SWITCH ACTION Normally Open NO Close on a rise in pressure Close on a fall in pressure Normally Closed NC Open on a rise in pressure Open o...

Page 24: ...the blower comes up to speed record the pressure reading If the pressure reading does not reach the activation point for the pressure switch the vent system must be checked for restrictions too many...

Page 25: ...24 of 24 AIR PRESSURE SWITCH CIRCUITS 1 4 Blocked Exhaust Switch Normally Open Contacts Close on a Fall in Pressure Vent Temperature Limit Switch Normally Closed Contacts Open on a Rise in Temperatur...

Page 26: ...requiring the use of the restrictor was reduced to 20 feet or less with this change This means that if the vent distance is greater than 20 feet the restrictor is not needed The series numbers 100 101...

Page 27: ...ting distance requiring the use of the restrictor was reduced to 20 feet or less with this change This means that if the vent distance is greater than 20 feet the restrictor is not needed The model nu...

Page 28: ...Additional copies are available from the Ashland City Advertising Department Prepared by the A O Smith State Water Heater Technical Training Department Ashland City Tennessee...

Page 29: ...ing tube is properly connected not kinked or damaged 3 Check continuity of vent temperature limit switch replace switch if contacts remain open under 160 F 4 Ensure the correct size of vent pipe 2 3 4...

Page 30: ...ause excessive air turbulence in the combustion chamber 7 8 9 Self diagnostic tests have found a problem with the gas valve driver circuit internal microprocessor or other internal circuits 1 Turn the...

Page 31: ...eater back in operation and allow it to cycle several times to ensure the problem has been resolved If the error code persists continue to step 3 below 3 Turn off power to the water heater Remove the...

Page 32: ...that cannot be reset by cycling power to the water heater See the instructions below for the reset procedure 1 Turn off power to the water heater Carefully check the surrounding area for any substanc...

Page 33: ...ssembly and check the flue baffle ensure the flue baffle is in good condition and properly installed reinstall as necessary and or replace the flue baffle if worn or damaged 5 Ensure water heater is n...

Page 34: ......

Page 35: ...Vent Power Direct Vent Cyclone Master Fit BTN BTI models 1 At the beginning of a heating cycle the ignition control will verify the air pressure switch circuit is open before the control energizes th...

Page 36: ...tinuous conductive path through the switch contacts Open contacts will not allow electricity to flow there is no continuity through the switch contacts The state of the contacts open or closed can be...

Page 37: ...f switches Service Note Because one of the two air chambers is vented to the atmosphere the ambient in the surrounding area air pressure is critical Ambient air pressure can push or pull on the diaphr...

Page 38: ...A O Smith fan assisted water heaters This information can usually be found in the sequence of operation section of the owner s manual and or service manual for the product Contact the A O Smith techn...

Page 39: ...or wear leaks kinks or any kind of debris or condensate in the sensing tube repair replace as necessary Connect a digital manometer to the pressure switch end of the sensing tube as shown above Turn t...

Page 40: ...t equipped with normally closed air pressure switches Cyclone BTH 120 400 models are equipped with two normally closed air pressure switches a blocked inlet and blocked exhaust switch see pages 7 8 No...

Page 41: ...locked Intake Air Pressure Switch Cyclone BTH 120 400 Models Normally open contacts close on a rise in pressure Blower Prover Air Pressure Switch Cyclone BTH 120 400 Models Normally closed contacts op...

Page 42: ...Normally Closed Contacts Open on a Rise in Temperature Molex Plug 6 Pin Plug 4 6 Blocked Inlet Switch Normally Closed Contacts Open on a Fall in Pressure Blower Prover Switch Normally Open Contacts Cl...

Page 43: ...Intelli Vent Sequence of Operation...

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