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Troubleshooting

 

Guide

 

5|

 

Page

 

 

 

3.

 

NORMAL

 

OPERATION

 

Becoming

 

familiar

 

with

 

how

 

a

 

tankless

 

water

 

heater

 

normally

 

operates

 

may

 

help

 

to

 

figure

 

out

 

what

 

is

 

wrong

 

with

 

it.

  

Assuming

 

it

 

is

 

properly

 

installed

 

with

 

appropriate

 

gas,

 

water,

 

and

 

electric

 

connections,

 

the

 

following

 

is

 

how

 

it

 

should

 

operate:

 

1)

 

ACTIVATION

 

a.

 

A

 

hot

 

water

 

tap

 

is

 

opened

 

enough

 

that

 

the

 

flow

 

sensor

 

detects

 

a

 

flow

 

rate

 

through

 

the

 

heater

 

greater

 

than

 

the

 

activation

 

point

 

of

 

0.75

 

gpm.

 

b.

 

The

 

fan

 

activates

 

after

 

flow

 

is

 

detected.

 

c.

 

The

 

computer

 

checks

 

for

 

any

 

problems

 

with

 

the

 

unit

 

before

 

startup.

 

d.

 

Igniter

 

activates.

  

You

 

can

 

hear

 

the

 

buzzing

 

of

 

the

 

spark

 

igniter.

 

e.

 

Main

 

gas

 

valve,

 

proportional

 

valve,

 

and

 

solenoid

 

gas

 

valves

 

will

 

open.

  

You

 

will

 

hear

 

a

 

deep

 

“clunk

 

clunk”

 

noise.

 

f.

 

Once

 

a

 

flame

 

is

 

detected,

 

the

 

red

 

LED

 

located

 

on

 

the

 

computer

 

board

 

will

 

activate.

 

g.

 

In

 

a

 

multi

heater

 

setup,

 

the

 

controller

 

will

 

activate

 

the

 

next

 

heater

 

in

 

2

4

 

gpm

 

increments,

 

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

 

well

 

to

 

create

 

an

 

efficient

 

burn.

 

b.

 

You

 

will

 

notice

 

that

 

only

 

partial

 

sections

 

of

 

the

 

burner

 

will

 

be

 

lit.

  

This

 

is

 

normal

 

operation;

 

there

 

are

 

three

 

sections

 

on

 

the

 

burner

 

assembly,

 

and

 

the

 

computer

 

controls

 

the

 

amount

 

of

 

sections

 

needed

 

based

 

on

 

the

 

flow

 

rate

 

and

 

temperature

 

rise

 

required.

 

 

3)

 

SHUTDOWN

 

a.

 

The

 

heater

 

will

 

shut

 

down

 

when

 

the

 

water

 

flow

 

rate

 

drops

 

below

 

the

 

deactivation

 

point

 

of

      

0.4

 

gpm.

   

b.

 

The

 

heater

 

will

 

close

 

the

 

main

 

gas

 

valve

 

and

 

solenoid

 

gas

 

valves,

 

extinguishing

 

the

 

flame.

 

c.

 

When

 

the

 

flame

 

disappears

 

the

 

red

 

LED

 

will

 

turn

 

off.

 

d.

 

The

 

fan

 

will

 

increase

 

in

 

speed

 

to

 

purge

 

the

 

venting

 

of

 

any

 

remaining

 

exhaust

 

gases.

  

The

 

length

 

of

 

post

purge

 

can

 

last

 

up

 

to

 

1

 

½

 

minutes.

 

e.

 

The

 

heater

 

goes

 

into

 

standby

 

waiting

 

for

 

the

 

process

 

to

 

begin

 

again

 
 
 
 
 
 
 

*The

 

purpose

 

of

 

this

 

diagram

 

is

 

to

 

illustrate

 

the

tankless

 

water

 

heater

 

design

 

concepts,

 

and

 

may

 

not

 

be

 

accurate

 

to

 

your

 

models

 

physical

 

description

.

 

Figure

 

2

 

Содержание 110

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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