background image

A.O. Smith Water Products 

Company

500 Tennessee Waltz Parkway

Ashland City, TN 37015

Toll Free: 1-877-737-2840

    240 (T-H3J), 340 (T-H3S) 

    and 540 (T-H3) Models

On-Demand Water Heater 

Service Manual

Summary of Contents for T-H3J-DV

Page 1: ...A O Smith Water Products Company 500 Tennessee Waltz Parkway Ashland City TN 37015 Toll Free 1 877 737 2840 240 T H3J 340 T H3S and 540 T H3 Models On Demand Water Heater Service Manual...

Page 2: ...Schematic diagram 6 Wiring diagram 7 Wiring diagram checkpoints for diagnosis 8 A Resistance values of the temperature thermistors 8 B Resistance values of the temperature exhaust thermistors 9 Opera...

Page 3: ...e 0 6 Natural 0 7 Propane 0 7 Natural 0 7 Propane 0 6 Natural 0 7 Propane 0 7 Natural 0 7 Water control Flow rate GPM 0 5 to 6 6 0 5 to 8 0 0 5 to 10 0 Available set temperatures F C 100 to 140 38 to...

Page 4: ...0 VAC 3 77 mm 120 VAC 6 7 8 174 mm Drain port Female 10 3 4 272mm 22 1 22 570 mm Condensate drain port 4 102 mm 2 5 8 68 mm Exhaust Intake Female 7 7 8 199 mm 7 1 2 189 mm 7 180 mm 4 101 mm 17 3 4 450...

Page 5: ...6 3 4 172 mm 7 7 8 199 mm Drain port 7 1 2 189 mm 10 3 4 272 mm 22 1 2 570 mm 120 VAC Condensate drain port 7 7 8 199 mm Condensate drain port 11 281 mm 1 2 13 mm 120 VAC 3 77 mm GAS 131 mm HOT 140 m...

Page 6: ...els Service Manial Ver 1 00 CONFIDENTIAL 3 Interior view 240 Indoor T H3J DV 340 Indoor T H3S DV 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 18 19 20 21 22 23 24 26 28 27 29 30 31 31 33 33 17 33 37 38 34 39...

Page 7: ...0 T H3 models Service Manial Ver 1 00 CONFIDENTIAL 240 Outdoor T H3J OS 340 Outdoor T H3S OS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 23 24 25 26 28 27 29 35 30 31 31 33 33 17 34 39 32 32...

Page 8: ...and 540 T H3 models Service Manial Ver 1 00 CONFIDENTIAL 540 Indoor T H3 DV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 23 24 25 26 28 27 29 35 30 31 31 33 33 17 33 36 37 38 34 39 32 32 AC12...

Page 9: ...H3S and 540 T H3 models Service Manial Ver 1 00 CONFIDENTIAL 540 Outdoor T H3 OS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 23 24 25 26 28 27 29 35 30 31 31 33 33 17 36 34 39 32 32 REMOTE C...

Page 10: ...ls EK175 T H3S models 319143 545 540 models EK176 T H3 models 4 Igniter 711 319143 479 EK153 5 Gas valve assembly LP model Included in 102 319143 515 EK181 NA model 319143 516 EK182 6 Water inlet 404...

Page 11: ...dels Outdoor models 319143 526 240 340 models EK199 T H3J T H3S models 319143 528 540 models EK206 T H3 models 17 Secondary heat exchanger assembly Indoor models Included in 401 319143 525 240 340 mod...

Page 12: ...or models 319143 526 240 340 models EK199 T H3J T H3S models 319143 528 540 models EK206 T H3 models 30 Secondary heat exchanger drain plug 411 319143 096 EKK2T 31 Pipe heater 414 319143 531 EK209 32...

Page 13: ...ter modulates the gas and water valves to ensure proper output water temperatures 8 When the tap is closed the water heater shuts down The Direct Vent Indoor models detects the exhaust temperature by...

Page 14: ...t Switch BL Gas Propor tional Valve W R BL BL BL BL P BK BK W BK BK Outlet thermistor Inlet thermistor Surge box Hi limit switch for exhaust Exhaust thermistor W W W W BK W BL R BK Temperature control...

Page 15: ...lame rod AFR rod BK W W BL R BK Temperature controller BK BK W MAX button MIN button Increase button Decrease button Green LED Bank of Bypass Vavle R W BR Y BL Gas Propor tional Valve R Y O BL W FM IG...

Page 16: ...Light blue blue at COM MV 93 to 120 VDC during operation 1 35 to 1 65 k Green blue at COM SV1 93 to 120 VDC during operation 1 35 to 1 65 k Orange blue at COM SV2 93 to 120 VDC during operation 1 35...

Page 17: ...White Black 1 0 to 4 0 VDC pulse 1 080 pulse min more than 18 Hz I Air fuel ratio rod Yellow AFR rod Between the AFR rod and the computer board More than 1 A during operation Flame rod Orange Flame r...

Page 18: ...0 40 60 80 100 120 140 160 180 200 220 Resisitance k Temperature F 0 00 5 00 10 00 15 00 20 00 25 00 0 10 20 30 40 50 60 70 80 90 100 Resisitance k Temperature C Resisitance values at different temper...

Page 19: ...tor Temperature F vs Resisitance k Temperature C vs Resisitance k Resisitance values at different temperatures Temperature F 32 41 50 59 68 77 86 95 104 113 C 0 5 10 15 20 25 30 35 40 45 Resistance k...

Page 20: ...11 blink 121 blink 341 blink 311 blink OuTH failure 311 blink OuTH failure 331 blink Flame blows out OHCF melted above 430 F AFR rod failure Abnormal burning 121 blink 121 blink 991 blink 391 blink BV...

Page 21: ...Heat exchanger 10 8 Secondary heat exchanger 10 9 Flow adjustment valve 10 10 Flow sensor 10 11 Bypass valve 10 12 Thermistors 10 13 Exhaust thermistors 10 14 Hi limit switch 10 15 Hi limit switch for...

Page 22: ...t during the combustion reaction Failure events 1 Unable to initialize sustain combustion 2 Dust or soot deposit on the burner surface 3 Cracks on the burners 4 Gas leakage from the burners Effects on...

Page 23: ...om the manifold which can cause poor combustion in the combustion chamber In this case the AFR rod will detect an improper flame condition and computer will take safety measures 2 Gas leakage from the...

Page 24: ...1 The water heater does not function properly 2 Failure to ignite or abnormal ignition 3 Unstable combustion conditions Error codes when the fan motor fails 101 111 121 611 991 Diagnostic 1 Visual ins...

Page 25: ...akage of wires 2 Listen for clunk sounds from the gas valves opening right after fan motor initiates 3 Check voltages and resistance of coils proper range of values shown below Color Number of wires B...

Page 26: ...g The 111 and or 121 error code s will display 2 The water heater will not initiate the ignition process The 721 error code will display Error codes when the flame rod fails 111 121 721 Diagnostic 1 V...

Page 27: ...ting The 111 and or 121 error code s will display 2 The water heater will not initiate the ignition process The 721 error code will display 3 The fan motor speed cannot be modulated properly under abn...

Page 28: ...t and immediately stop the water heater from operating 3 Abnormal sounds during combustion Error codes when the heat exchanger fails N A Diagnostic 1 Visual inspection soot deposits cracks on the heat...

Page 29: ...T H3S models have the 77 mark and 540 T H3 models have the P77 mark as shown below 540 Indoor T H3 DV 15 461 mm 24 1 2 625 mm 11 282 mm P77 68A 240 340 Indoor T H3J T H3S DV 15 461 mm 24 1 2 625 mm 11...

Page 30: ...Water leakage from the secondary heat exchanger 2 Exhaust gas leakage 3 Abnormal sounds during combustion Error codes when the secondary heat exchanger fails N A Diagnostic 1 Visual inspection soot de...

Page 31: ...340 T H3S models have the 77 mark and 540 T H3 models have the P77 mark as shown below 540 Indoor T H3 DV 15 461 mm 24 1 2 625 mm 11 282 mm P77 68A 240 340 Indoor T H3J T H3S DV 15 461 mm 24 1 2 625...

Page 32: ...hot water output 3 Within an Easy Link system the 651 error code can occur Error codes when flow adjustment valve fails 651 only within Easy Link systems Diagnostic 1 Visual inspection connection bre...

Page 33: ...ate any operation Error codes when flow sensor fails 441 only within Easy Link systems Diagnostic 1 Visual inspection connection breakage of wires and or debris on impeller 2 Check voltages proper ran...

Page 34: ...he valve cannot modulate properly Effects on the water heater if bypass valve fails 1 Water leakage from failed valve can damage other water heater components 2 Temperature fluctuations in the hot wat...

Page 35: ...tors fails 311 Outlet 321 Inlet 331 Heat exchanger Diagnostic 1 Visual inspection connection breakage of wires and or debris on thermistor 2 Check voltages and resistance proper range of values shown...

Page 36: ...80 100 120 140 160 180 200 220 Temperature F Resisitance k Resistance values of thermistors as a function of temperature Inlet thermistor 42 Outlet thermistor 113 Part 319143 214 EKK4J Part 319143 529...

Page 37: ...hort error code appears before starting operation If resistance values are just off the 341 error codes will display Error codes when exhaust thermistor fails 341 Direct Vent Indoor models only Diagno...

Page 38: ...always act as backup hi limit detectors to detect excessively high water temperatures in the heat exchanger 2 The water heater is always shut down immediately after the ignition process and either the...

Page 39: ...L 10 14 Hi limit switch Before pressing the button on the hi limit switch After the hi limit switch was working refer to the following procedure 1 Turn off the controller 2 Open a hot water tap and lo...

Page 40: ...t fails 1 Unable to shut down the water heater if the exhaust gas temperature in the exhaust chamber exceeds 151 F 66 C 2 The water heater is always shut down immediately after the ignition process an...

Page 41: ...instantly The 111 or 121 error code will display Failure events 1 Unable to detect the excessively high temperatures within the water heater Effects on the water heater if the overheat cutoff fuse fa...

Page 42: ...ter contained in the heat exchanger to freeze up possibly causing the heat exchanger to burst Error codes when heater fails N A Diagnostic 1 Visual inspection connection breakage of wires and the cond...

Page 43: ...n the water heater if the computer board fails A component s may not operate within the water heater In most cases of computer board failure the whole the water heater does not operate at all Error co...

Page 44: ...if the igniter fails 1 The water heater cannot ignite during the ignition process and the 111 or 121 error codes will display 2 No effects on the water heater however the durability of the igniter we...

Page 45: ...eze protection thermostat fails 1 The freeze protection heaters will always be ON causing heat damage to components inside the water heater 2 The freeze protection heaters will never be able to turn o...

Page 46: ...of the absorber Effects on the water heater if the surge box fails 1 Unable to protect the computer board if high voltage gets applied to the unit The computer board can short out stopping all operat...

Page 47: ...CB of the controller 1 Check for normal voltage at terminal It takes long time to get hot water at the fixtures 1 The time it takes to deliver hot water from the water heater to fixtures depends on th...

Page 48: ...r installed 5 Check the vent length when the water heater has been installed indoors 6 Check if there is any blockage in the intake air and or exhaust 7 Check if there is dust and lint in burner and h...

Page 49: ...tion method 101 Warning for the 991 error code Refer to section 12 3 On the PCB press the INC and DEC buttons simultaneously for 3 sec Then turn the power off Diagnosis Check point 1 Check the gas typ...

Page 50: ...valve VG0 Normal 1 0 to 15 VDC between white red during operation C H1 4 Gas solenoid valve fault 1 Main gas solenoid valve MV fault Normal 1 35 to 1 65 k between COM blue 3 light blue 2 Gas solenoid...

Page 51: ...ortional valve VG0 fault Normal 1 0 to 15 VDC between white red C H1 4 Check for soot on the flame rod 1 Clean the flame rod 2 PCB fault During operation more than 1 A through the flame rod wire orang...

Page 52: ...thermistor fault Refer to section 10 12 Visual inspection connection breakage of wires and or debris on thermistor Check voltage resistance between black black 12 Refer to Section 8 A for proper range...

Page 53: ...ual inspection of gas valves connection breakage of wires Normal 93 to 120 VDC between COM blue 9 green during operation Normal 93 to 120 VDC between COM blue 53 orange during operation Normal 93 to 1...

Page 54: ...fault Refer to section 10 11 10 18 Visual inspection of bypass valve connection breakage of wires motor drive locked due to scale buildup and or water leakage Normal 3 0 to 11 VDC between brown red V...

Page 55: ...ler 741 error code will cease to display Diagnosis Check point 1 Temperature remote controller or PCB fault Normal 11 to 25 VDC between white black 2 Check for signs of power surges F Error Code Malfu...

Page 56: ...k point 1 Inspect cable connections between Parent and Child units Normal 15 VDC between black white during Easy link operation 2 Check for signs of power surges D1 and D2 Error Code Malfunction descr...

Page 57: ...re settings above 140 F can lead to this error code K1 K2 Error Code Malfunction description Cancellation method 991 Imperfect combustion Refer to section 12 3 Turn off the power or water supply If no...

Page 58: ...system Only 540 T H3 models 70 12 8 A ON OFF conditions Overview 71 12 8 B ON OFF conditions BTU requirements 72 12 9 Multi unit system ON OFF conditions Only 540 T H3 models 73 12 10 Operation time f...

Page 59: ...pressing any buttons the display will return to normal Mode Information Fig 1 Fig 2 For example the figures above show how to arrive at the outlet temperature information TEMPERATURE CONTROLLER and T...

Page 60: ...Press the INFO button to select the desired unit 5 When the desired unit is selected and fixed scroll up or down to the needed information mode of the unit by pressing the HOT or COLD buttons Fig 3 sh...

Page 61: ...ion 0 to 720 minutes After 720 the next rotation occurs Air Fuel ratio rod current 0 to 999 A 8 ON OFF cycles during current rotation 0 to 100 cycles After 100 the next rotation occurs Flow rate 0 to...

Page 62: ...or speed 26 Current value of proportional valve 0 to 999 mA 27 The number of combustion stages The water heater has 4 stages for combustion 1 means 1st stage 2 means 2nd stage 3 means 3rd stage 4 mean...

Page 63: ...rd Green LED 540 T H3 models computer board Green LED Power ON OFF switch Temperature controller Temperature remote controller OR 2 Turn on the ON OFF button of either the temperature controller or th...

Page 64: ...991 341 Blinking six times 510 391 551 441 721 Temperature controller Temperature remote controller The green LED will blink in the patterns shown below when the water heater has an error code When t...

Page 65: ...d up around Terminator Installed in a closet No Ventilation or lack of combustion air 6 If installed in laundry room check the burner and heat exchanger Dust and lint may deposit in burner and heat ex...

Page 66: ...ition 101 error code 991 error code Stage FM 15 13 5 0 9 AFR normal range of values If the detected AFR value is higher than the normal value the FM speed is increased If the AFR value is lower than t...

Page 67: ...ault 9 Output temperature settings Default 120 F 140 F 60 C 120 F 49 C Default 10 Deactivation of the exhaust temperature control This switch is for a specialized purposes only Enable Disable Default...

Page 68: ...or a specialized purposes only Enable Disable Default 7 Allow adjustments of fan motor speed Changing the FM speed is similar to changing the manifold pressure See section 12 15 Enable Disable Default...

Page 69: ...Parent Child setting for Easy Link systems Parent Child Default 2 3 4 FM FM and Input FM speed is increased automatically See section 12 13 5 Output temperature settings Default 120 F 140 F 60 C 120...

Page 70: ...hold the Increase button on the computer board of the parent unit for at least 5 seconds 2 The green LED on the computer board of the parent unit will be blinking for 10 seconds 3 The controller of th...

Page 71: ...ower 5 4 F than the set temperature and BTU requirement is more than 14 880 BTU h AND The water flow rate is more than 0 5 GPM OR The water flow rate is more than 0 8 GPM Only 135 F 57 C Conditions ne...

Page 72: ...3 5 4 0 100 ON 40 5 70 2 80 2 85 1 88 1 90 1 91 5 92 6 OFF 52 4 76 2 84 1 88 1 90 5 92 1 93 2 94 0 110 ON 50 5 80 2 90 2 95 1 98 1 100 1 101 5 102 6 OFF 62 4 86 2 94 1 98 1 100 5 102 1 103 2 104 0 12...

Page 73: ...below 2 Condition required to reduce the number of activated 540 T H3 models A In the case of reducing down from two units of 540 T H3 models to one unit of 540 T H3 models Flow rate A 1 7 B All other...

Page 74: ...100 ON OFF cycles or after 12 hours of operation NOTE The priority unit is the unit that turns on first when there is a hot water demand When there is a black out and or cut off for over 50 minutes pr...

Page 75: ...units If this happens the minimum flow rate of the system changes from 0 5 GPM to 0 5 GPM multiplied by the number of the 540 T H3 models Refer to the following example Ex Minimum flow rate of a four...

Page 76: ...Previous models Previous models Previous models Case 1 Temperature remote controller 9007603005 TM RE30 Previous models Previous models 540 T H3 Previous models Case 2 Temperature remote controller 9...

Page 77: ...ure remote controller 9007603005 TM RE30 Although 520 T H2 can be connected with the temperature remote controller 9007603005 TM RE30 these cannot be connected with the temperature remote controller 9...

Page 78: ...FO button for at least 3 seconds 4 If the HI display on its screen you can set the high temperature mode If the Lo display on its screen you can set the default mode 5 After 5 seconds the display will...

Page 79: ...n Fan motor speed change DIPswitch settings No 3 No 4 No 5 0 0 DEFAULT N A N A OFF OFF OFF 1 Up to 2 500 ft N A 3 OFF ON OFF 2 Up to 5 000 ft 8 5 ON ON OFF 11 7 OFF OFF ON 3 Up to 7 500 ft 14 9 ON OFF...

Page 80: ...contact our Technical Service Department for advice Note that there are many high risks associated with manually changing manifold pressure Outdoor models of 240 T H3J 340 T H3S Natural gas Level Elev...

Page 81: ...No 2 No 3 No 4 0 0 DEFAULT N A N A OFF OFF OFF 1 Up to 2 500 ft N A 3 OFF ON OFF 2 Up to 5 000 ft 8 5 ON ON OFF 11 7 OFF OFF ON 3 Up to 7 500 ft 14 9 ON OFF ON 18 12 OFF ON ON 4 Up to 10 100 ft 22 15...

Page 82: ...contact our Technical Service Department for advice Note that there are many high risks associated with manually changing manifold pressure Outdoor models of 540 T H3 Natural gas Level Elevation Outpu...

Page 83: ...e the port screw Adjusting minimum manifold pressure 1 Ensure that water heater is not in operation 2 Remove the screw off the manifold port of the water heater Fig 1 3 Connect a manometer to the mani...

Page 84: ...r 1 00 CONFIDENTIAL Fig 3 240 T H3J 340 T H3S models computer board MAX button MIN button Increase button Decrease button 540 T H3 models computer board MIN button MAX button Increase button Decrease...

Page 85: ...minimum fan motor speed 1 While water heater is in operation set DIPswitch No 7 on the upper bank of the 540 T H3 computer boardto the ON position Fig 1 2 On the controller display mode 3 fan motor s...

Page 86: ...As long as each particular feature s activation requirements are met it is possible for both features to operate at the same time Automatic firing system Only 540 Direct Vent Indoor T H3 DV Activation...

Page 87: ...vate based on what the freeze protection thermostat senses The thermostat is located on the intake port for Direct Vent Indoor models close in vicinity to the inlet and outlet pipes for Outdoor models...

Page 88: ...ater heater Unscrew the drain plugs to drain all the water out of the water heater 7 Wait a few minutes to ensure all water has completely drained from unit 8 Clean the filter Inspect the water filter...

Page 89: ...er 1 00 CONFIDENTIAL 13 Components diagram Indoor models Outdoor models Case assembly 052 052 003 007 002 050 006 704 005 052 702 704 008 052 050 052 717 702 713 004 002 001 001 004 Temperature remote...

Page 90: ...1 00 CONFIDENTIAL Computer board assembly Surge box assembly 540 T H3 models 240 T H3J and 340 T H3S models 710 701 713 103 709 402 707 708 714 721 407 408 701 714 403 715 721 707 722 715 402 402 103...

Page 91: ...ial Ver 1 00 CONFIDENTIAL Burner assembly 101 104 115 106 107 108 110 109 111 712 112 062 053 053 709 053 401 103 105 065 054 113 114 102 708 119 151 118 055 051 150 057 055 120 711 712 063 117 053 11...

Page 92: ...052 059 052 409 417 Water outlet section Water inlet section 403 456 460 458 462 B A Bypass section 540 T H3 models D A B E E 459 454 411 F 412 058 F 413 452 450 414 451 414 451 414 401 416 009 464 C...

Page 93: ...uply code assembly 007 319143 512 EK161 Back guard panel 008 319143 513 EK160 Chamber fixing plate 009 319143 018 EKH23 Condensate drain port 520 320 T H2 DV OS T H2S DV OS 050 319143 025 EW000 Screw...

Page 94: ...10 310 Indoor 510 Indoor 110UOutdoor 310UOutdoor 510UOutdoor T K3 T K3 Pro T K3 SP T M50 T M32 T H2 DV OS T H2S DV OS T K4 IN T D2 IN T KJr2U OS T K4U OS T D2U OS 104 319143 031 EKK2X Burner gasket 52...

Page 95: ...DV OS T H2S DV OS T K4 IN OS T D2 IN OS 111 319143 038 EKN61 Rod cap 910 710 520 320 110 310 510 T K3 T K3 Pro T K3 SP OS T M50 T M32 T H2 DV OS T H2S DV OS T KJr2 IN OS T K4 IN OS T D2 IN OS 112 319...

Page 96: ...T K4U IN OS T D2U IN OS 117 319143 520 EX019 Combustion chamber tube 910 310 510 T M50 T K4 OS T D2 OS 118 319143 455 EK117 Gas inlet 110U 310U 510U T KJr2U IN OS T K4U IN OS T D2U IN OS 119 319143 3...

Page 97: ...64 EKD58 Bypass valve for 540 T H3 models 510U T D2U IN OS 404 319143 193 EKK1U Water inlet 110 310 510 110U 310U 510U T K3 T K3 Pro T K3 SP OS T KJr2 IN OS T K4 IN OS T D2 IN OS T KJr2U IN OS T K4U I...

Page 98: ...V OS T H2S DV OS T D2 IN OS T D2U IN OS 412 319143 228 EM212 Hi Limit switch for 240 T H3J and 340 T H3S models 110 310 110U 310U T KJr2 IN OS T K4 IN OS T KJr2U IN OS T K4U IN OS 319143 095 EKN34 Hi...

Page 99: ...10 510 110U 310U 510U T M50 T M32 T H2 DV OS T H2S DV OS T KJr2 IN OS T K4 IN OS T D2 IN OS T KJr2U IN OS T K4U IN OS T D2U IN OS 452 319143 066 EKK26 Fuse fixing plate 18 910 710 520 320 110 310 510...

Page 100: ...K4U IN OS T D2U IN OS 456 319143 100 EZM14 O ring P14 FKM 520 320 110 310 510 110U 310U 510U T K3 T K3 Pro T K3 SP OS T H2 DV OS T H2S DV OS T KJr2 IN OS T K4 IN OS T D2 IN OS T KJr2U IN OS T K4U IN...

Page 101: ...K3 T K3 Pro T K3 SP OS T KJr2 IN OS T K4 IN OS T D2 IN OS T KJr2U IN OS T K4U IN OS T D2U IN OS 462 319143 205 EKK39 Fastener 16 25A 510 510U T K3 T K3 Pro T D2 IN OS T D2U IN OS 463 319143 112 EX12K...

Page 102: ...ire for Outdoor models 706 319143 141 EKK4V 120 VAC Power ON OFF switch 520 320 110 310 510 110U 310U 510U T K3 SP OS T H2 DV OS T H2S DV OS T KJr2 IN OS T K4 IN OS T D2 IN OS T KJr2U IN OS T K4U IN O...

Page 103: ...0 EX13C Cable clamp for Indoor models 718 319143 131 EKH6E Exhaust thermistor assembly 520 Indoor 320 Indoor T H2 DV T H2S DV 719 319143 484 EK152 Remote fixing plate for 540 T H3 models 510U T D2U IN...

Page 104: ...104 Page 240 T H3J 340 T H3S and 540 T H3 models Service Manial Ver 1 00 CONFIDENTIAL 15 Revisions Version Description of changes Date 1 00 First edition 12 07 18...

Reviews: