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T-M32 / T-M32 ASME Service Manual

Ver. 1.03

CONFIDENTIAL

Item #

Part #

Description

Common parts for other models

110

EX01Z

High voltage ignite cable

111

EM409

Damper

112

EX02C

Urethane tube

113

EKK2D

Pressure port

T-K3, T-K3-Pro, T-K3-SP, T-H2-DV/OS, T-K4-IN/OS,
T-D2-IN/OS, T-M50

114

EM379

Fan motor fixing plate

115

EKK25

Fan motor

T-K3, T-K3-Pro, T-K3-SP, T-H2-DV/OS, T-K4-IN/OS,
T-D2-IN/OS, T-M50

116

EM381

Fan damper

117

EKJ59

Freeze protection thermostat

T-K3, T-K3-Pro, T-K3-SP, T-KJr2-IN/OS,
T-K4-IN/OS, T-D2-IN/OS

118

EM435

Manifold gasket A

119

EX00F

Manifold gasket B

EM440

Manifold assembly with gas valve
assembly LP

120

EM441

Manifold assembly with gas valve
assembly NA

121

EM167

Wire cramp 60

T-K3, T-K3-Pro, T-K3-SP/OS, T-H2-DV/OS,
T-KJr2-IN/OS, T-K4-IN/OS, T-D2-IN/OS, T-M50

122

EX00D

Gas inlet ring

123

EM442

Gas inlet

124

EKK1B

Igniter plate

T-K3, T-K3-Pro, T-K3-SP/OS, T-H2-DV/OS,
T-KJr2-IN/OS, T-K4-IN/OS, T-D2-IN/OS, T-M50

125

EKN74

Igniter

T-K3, T-K3-Pro, T-K3-SP/OS, T-H2-DV/OS,
T-KJr2-IN/OS, T-K4-IN/OS, T-D2-IN/OS, T-M50

151

EW00D

Pan screw M4×8

152

EW003

Screw M4×10

153

EW00H

Pan screw M4×12 (W/Washer)

154

EW00B

Screw M3×6

155

EW008

Screw M3×10

156

EZP26

O-ring P26 NBR (Black)

157

EW006

Pan screw M4×10

Содержание T-M32 ASME

Страница 1: ...ASME Service manual Ver 1 03 1 CONFIDENTIAL T M32 T M32 ASME On demand Water Heater Service manual T M32 A O Smith Water Products Company 500 Tennessee Waltz Parkway Ashland City TN 37015 Toll Free 1...

Страница 2: ...ents in the interior view 6 5 Schematic diagram 8 6 Wiring diagram 9 7 Wiring diagram checkpoints for diagnosis 10 8 Resistance values of the temperature thermistors 12 9 Operational flow chart 13 10...

Страница 3: ...le set temp 100 F to 185 F default set 120 F Temperature dipswitch setting 100 F 115 F 120 F 135 F 145 F 155 F 165 F 185 F Bypass valve Yes Water control Thermistors 3 thermistors In Out Mixing Availa...

Страница 4: ...27 8mm COLD 3 1 8 80 8mm HOT 4 5 8 118 3mm GAS 6 1 4 159 mm 8 7 8 226mm 120 VAC 5 1 2 142mm 5 1 2 1 4 2m m 5 3 4 147mm COLD 1 5 8 4 0 9mm 120 VAC 1 5 8 42m m GAS 5 7 8 1 47 9 mm HOT 5 7 8 149mm G A S...

Страница 5: ...T M32 T M32 ASME Service manual Ver 1 03 5 CONFIDENTIAL 3 Interior view 16 20 1 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 21 2 22 23 24 25 26 27 28 29...

Страница 6: ...5 Transformer 702 EM454 6 Water inlet 411 EM404 T H2 DV OS 7 Water outlet 435 EKJ02 8 Mixing thermistor 418 EX00H T H2 DV OS 9 Inlet thermistor 422 EKK38 T K3 T K3 Pro T H2 DV OS T D2 IN OS T M50 10...

Страница 7: ...ol valve 423 EKH32 T H2 DV OS T M50 21 GFI 712 EM207 T M50 22 Outlet drain plug 416 EK239 T H2 DV OS 23 Air fuel ratio rod AFR rod 106 EKK0E T K3 T K3 Pro T K3 SP OS T H2 DV OS T K4 IN OS T D2 IN OS T...

Страница 8: ...mber 6 Water circulates through the heat exchanger and is heated up to the set temperature 7 Using thermistors to measure temperatures the computer modulates the gas and water valves to ensure proper...

Страница 9: ...al Valve Flow Sensor W R B K W R WR BK R W BL BL BL L B G O R Parent W W BK BK BL BL R R Remote controller W BK Heater Thermostat Heater BK B K G W B K Trans former Ground B R B R 120 VAC G Ground B K...

Страница 10: ...k C Gas valves Red blue at COM SV3 78 to 100 VDC during operation 0 9 to 1 7k C1 Hi Limit switch Blue Blue Less than 1 VDC and less than 1 C2 Overheat cutoff fuse Blue Blue Less than 1 VDC and less th...

Страница 11: ...uel ratio rod Yellow AFR rod Between AFR rod and the computer board More than 0 5 A during operation I Flame rod Orange Flame rod Between flame rod and the computer board More than 1 A during operatio...

Страница 12: ...28 8 47 7 02 5 85 4 90 4 12 Temperature F 122 131 140 149 158 167 176 185 194 203 212 C 50 55 60 65 70 75 80 85 90 95 100 Resistance k 3 49 2 96 2 53 2 16 1 86 1 60 1 39 1 21 1 05 0 92 0 81 Temperatur...

Страница 13: ...FF Remove cause Opeartion lamp OFF Operation stop YES NO YES NO NO YES YES NO 20sec later YES NO NO YES YES NO YES NO 5sec later 3sec later YES YES NO YES NO 20sec later YES NO NO NO YES FM speed Abov...

Страница 14: ...sembly 18 10 5 Flame rod 19 10 6 AFR rod 20 10 7 Heat exchanger 21 10 8 Flow sensor 22 10 9 Water Control valve 23 10 10 Thermistors 25 10 11 Hi limit switch 26 10 12 Overheat cutoff fuse 27 10 13 Fre...

Страница 15: ...Unable to initialize sustain combustion 2 Dust or soot deposit on the burner surface 3 Cracks of the burners 4 Gas leakage from the burners Effects on the water heater if burners fails 1 Unexpected co...

Страница 16: ...flow from 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...

Страница 17: ...r 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 inspection connectio...

Страница 18: ...the valves fails 111 121 510 701 Diagnostic 1 Visual inspection connection breakage of wires 2 Listen for clunk sounds from the gas valves opening right after fan motor initiates 3 Check voltages and...

Страница 19: ...rror 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 Visual inspection conne...

Страница 20: ...heater will not initiate the ignition process The 721 error code will display 2 The fan motor speed cannot be modulated properly under abnormal flame conditions which can result in excessive CO emissi...

Страница 21: ...t this event 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...

Страница 22: ...sensor fails Ignition sequence does not start water heater will not initiate any operation Error codes when the flow sensor fails 441 only within Easy link and Multi unit systems Diagnostic 1 Visual i...

Страница 23: ...ion The function of the bypass valve 4 Prevents water from flowing through the heat exchanger when water heater is not in operation to protect the heat exchanger The function of the two way valve Fail...

Страница 24: ...and bypass valve Blue Brown 13 0 to 16 0 VDC Orange Brown ON 12 5 to 16 0 VDC OFF 0 to 1 VDC Color Number of wires Red Brown 0 position 1 VDC less The water control valve contains the flow adjustment...

Страница 25: ...er will have temperature fluctuations in hot water Error codes when thermistors fails 311 Output 321 Inlet 331 Mixing Diagnostic 1 Visual inspection connection breakage of wires and or debris on therm...

Страница 26: ...m the heat exchanger exceeds 194 F 90 C Note The mixing and output thermistors always act as backup hi limit detectors to detect excessively high water temperatures in the heat exchanger 2 The water h...

Страница 27: ...wn the water heater instantly The 111 or 121 error code will display Failure event 1 Unable to detect the excessively high temperatures within the water heater Effects on the water heater if the overh...

Страница 28: ...Ceramic heaters do not activate allowing water contained in the heat exchanger to freeze up possibly causing the heat exchanger to burst Error codes when hears fails N A Diagnostic 1 Visual inspectio...

Страница 29: ...detect correct signals from any all water heater sensors 3 Unable to control water valves which may cause output temperature fluctuations 4 Errors in its self diagnostics In order to self diagnose pro...

Страница 30: ...r if transformer fails 1 The water heater does not operate due to lack of power from transformer 2 A failed transformer can cause electrical damage to other electrical components within the water heat...

Страница 31: ...ect electrical leakage within the water heater 2 OFF failure the water heater does not receive any power from the GFI which means the water heater cannot operate Error codes when the GFI fails N A Dia...

Страница 32: ...r 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 wears down Error codes when Igniter fails...

Страница 33: ...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 on even under f...

Страница 34: ...ilure 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 o...

Страница 35: ...No display on temperature remote controller even when remote is turned on 7 Fault of PCB of remote control 1 Check for normal voltage at terminal It takes long time to get hot water at the fixtures 1...

Страница 36: ...ter heater 1 Check the gas type of the water heater 2 Check how long the water heater has been installed and in use 3 Check the installation place 4 Check the altitude elevation of area of where the w...

Страница 37: ...d brown J Fluctuation of hot water temperature 7 Fault of Water control valve Normal 0 09 to 0 2 k between red black J Error Code Malfunction description Cancellation method Incorrect dipswitch settin...

Страница 38: ...between burner igniter rod Normal gap 0 16 4mm 3 PCB fault Normal 90 to 110 VAC at 7 purple purple during ignition B 3 PCB fault 1 No voltage to main gas solenoid valve MV Normal 78 to 100 VDC betwee...

Страница 39: ...ription Cancellation method Loss of flame Turn off the power or water supply Diagnosis Checkpoint 1 Check gas supply and pressure Refer to section 1 2 PCB fault 1 No voltage to gas main solenoid valve...

Страница 40: ...connection breakage of wires and or debris on thermistor Check voltage resistance between black black 12 Refer to Section 8 for proper range of values E2 Error Code Malfunction description Cancellatio...

Страница 41: ...10 8 Visual inspection connection breakage of wires andor debris on impeller Check voltage resistance between red black or white black H2 Error Code Malfunction description Cancellation method Fault...

Страница 42: ...connection breakage of wires and or burn marks on the computer board 2 Gas solenoid valve fault SV1 SV2 and or SV3 C Error Code Malfunction description Cancellation method Fan motor fault Turn off th...

Страница 43: ...le buildup and or water leakage Normal 13 0 to 16 VDC between blue brown Normal ON 12 5 to 16 0 VDC OFF 0 to 1 V Normal 1 V Less than 0 position Visual inspection PCB connection breakage of wires and...

Страница 44: ...ge of wires of the gas proportional valve Normal 20 to 40 between white red H1 Error Code Malfunction description Cancellation method False flame detection Turn off the power or water supply Diagnosis...

Страница 45: ...r or water supply Abnormal burning Refer to section 12 3 If not possible press and hold the INC and DEC buttons on the computer board simultaneously for more than 3 sec Diagnosis Checkpoint 991 1 Chec...

Страница 46: ...gle and Easy link system 58 12 8 B Pump control ON OFF Conditions BTU requirements for Re circulation mode 59 12 9 Multi unit system ON OFF conditions 60 12 10 Operation time for unit rotation 62 12 1...

Страница 47: ...HOT or COLD buttons Fig 1 shows mode 5 being selected When selecting information please refer to the table on p 49 for the proper mode 3 Press the INFO button to fix the mode and the information to w...

Страница 48: ...tem T M32 a maximum of twenty units can be linked together For the Easy link system a maximum of four units can be linked as well 4 Press the INFO button to fix the desired unit 5 When the desired uni...

Страница 49: ...12 Inlet temperature of the priority unit 0 to 999 F Error code history displays 2nd most recent error code 13 Mixing temperature of the priority unit 0 to 999 F Error code history displays 3rd most...

Страница 50: ...seg LED will light in a circular 0 pattern one segment at a time B Displaying error code history 1 Briefly press the Error call button do not hold down the button 2 If the T M32 has had prior error c...

Страница 51: ...Are there any obstructions in the intake air and or exhaust Damper sticking Vent Flaps installed on the Terminator Snow build up around Terminator Installed in a closet No Ventilation or lack of comb...

Страница 52: ...be confirmed in Diagnostic Mode Section 12 1 The relationship between the AFR stage and the 101 and 991 error codes 16 15 6 0 Gas type LPG Natural gas Installation Outdoor Indoor Direct vent Outdoor I...

Страница 53: ...gas input is reduced automatically See section 12 12 10 Maximum input Disable Default 4 Allow adjustments of fan motor speed Changing the FM speed is similar to changing the manifold pressure See sect...

Страница 54: ...in a T M32 Two priority units One priority unit 8 Parent Child setting on Easy link systems Parent Child Default MST DIRE OUT TMP3 TMP2 TMP1 1 2 3 4 5 6 7 8 MODE D PRT N O MST DIRE OUT TMP3 TMP2 TMP1...

Страница 55: ...ay button on the computer board of all child units for at least 5 seconds 2 The 7 seg LED on the computer board of all child units will display 0 to signify that the computer memory has been erased of...

Страница 56: ...Conditions For Every pump modes Conditions needed to turn ON The BTU requirement is more than 14 880 BTU h AND The water flow rate is more than 0 5 GPM Conditions needed to turn OFF The BTU requireme...

Страница 57: ...1 0 1 5 2 0 2 5 3 0 3 5 4 0 ON 40 5 70 2 80 2 85 1 88 1 90 1 91 5 92 6 100 OFF 52 4 76 2 84 1 88 1 90 5 92 1 93 2 94 1 ON 55 5 85 2 95 2 100 1 103 1 105 1 106 5 107 6 115 OFF 67 4 91 2 99 1 103 1 105...

Страница 58: ...ns enable the re circulation pump to be controlled by the following conditions ON OFF Conditions Re circulation mode Energy conserving re circulation mode Conditions that activate the pump The BTU req...

Страница 59: ...tion example Set temperature Tset 120 F Flow rate 2 5 GPM Condition needed to turn the pump ON 120 Tin 2 5 500 14 880 Tin 108 1 F Condition needed to turn the pump OFF 120 Tin 2 5 500 14 880 Tin 108 1...

Страница 60: ...T M32 Flow rate required to activate additional T M32 A n Where n number of currently activated T M32 s and A is dependent on the set temperature See table below Set temperature Factor A F C GPM L min...

Страница 61: ...26 No 18 OFF 55 208 No 4 ON 10 39 No 17 OFF 52 195 No 5 ON 14 52 No 16 OFF 48 182 No 6 ON 17 65 No 15 OFF 45 169 No 7 ON 21 78 No 14 OFF 41 156 No 8 ON 24 91 No 13 OFF 38 143 No 9 ON 27 104 No 12 OFF...

Страница 62: ...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 priority unit will switch bac...

Страница 63: ...lti unit system Under normal conditions 0 5GPM When the multi unit controller fails 0 5 5 2 5GPM Minimum flow rate of the multiple system depends on the number of the units installed in the multiple s...

Страница 64: ...sts even with a Level 3 setting please contact our Technical Service Department for advice Note that there are many high risks associated with manually changing the manifold pressures Level Function S...

Страница 65: ...l for the computer board and flow sensor diagnostic purposes Using the function 1 When in Standby mode right before ignition cannot be in combustion forced combustion or the FM adjustment modes press...

Страница 66: ...eed 1 amp For example To the right there is a sample of relay specifications from an arbitrary brochure You can select either the 120 VAC or 240 VAC relay because their current values are less than 1...

Страница 67: ...on otherwise proceed onto the next step 5 Press and hold down the MAX button on the computer board While holding down the MAX button press either the Increase or Decrease button to increase or decreas...

Страница 68: ...IAL desired value 6 After gas pressure has been set deactivate the T M32 remove the manometer tube and replace the port screw Manifold port Figure 1 Tube To Manometer Figure 2 MAX button MIN button In...

Страница 69: ...utton on the computer board While holding down the MAX button press either the Increase or Decrease button to increase or decrease the fan motor speed respectively Figure 2 Refer to the remote control...

Страница 70: ...re met it is possible for both features to operate at the same time Ceramic heating blocks The blocks will only activate based on what the freeze protection thermostat senses The thermostat is located...

Страница 71: ...freeze protection the Automatic fan motor system will deactivate if Tout Tin 3 6 F OR Tin 50 F and Tout 50 F and TMIX 50 F OR Tin 39 F and Tout 39 F and TMIX 39 F and Flow sensor detects flow rate for...

Страница 72: ...hing on its screen In order to detect the temperature of the system accurately The computer makes the pump work every two minutes during the freeze protection operation A Activation conditions all 3 c...

Страница 73: ...for 5 seconds or longer to start a display of A at 7 seg LED on the computer board 2 While A is displayed press the Number display button The 7 seg LED will display o F F and then repeat the 3 letters...

Страница 74: ...en the all water flow has ceased close all hot water taps 6 Have a bucket or pan to catch the water from the drain plugs of the T M32 Unscrew the drain plugs to drain all the water out of the T M32 7...

Страница 75: ...709 0 52 708 115 703 707 719 712 706 705 For T M32 706 For T M32 ASME 13 Components diagrams Case assembly Computer board assembly Other than Part 706 the T M32 and the T M32 ASME share the same comp...

Страница 76: ...L Burner assembly The T M32 and theT M32 ASME share the same components 103 101 102 401 104 105 152 707 152 106 107 151 108 109 110 152 152 111 152 112 113 153 114 115 154 116 117 155 118 119 121 704...

Страница 77: ...408 409 410 052 052 417 416 418 427 415 435 420 430 421 428 429 436 420 431 414 420 423 420 405 426 425 401 402 403 411 412 413 427 419 422 419 150 424 432 437 434 419 433 414 414 414 414 414 414 414...

Страница 78: ...r 52 EW002 Screw M4 10 Coated 101 EM410 Burner assembly 102 EM411 Burner gasket 103 EM412 Guide plate gasket 104 EKK2V Burner window T K3 T K3 Pro T K3 SP OS T H2 DV OS T KJr2 IN OS T K4 IN OS T D2 IN...

Страница 79: ...2 IN OS 118 EM435 Manifold gasket A 119 EX00F Manifold gasket B EM440 Manifold assembly with gas valve assembly LP 120 EM441 Manifold assembly with gas valve assembly NA 121 EM167 Wire cramp 60 T K3 T...

Страница 80: ...ter fixing plate T K3 T K3 Pro T K3 SP OS T H2 DV OS T KJr2 IN OS T K4 IN OS T D2 IN OS T M50 406 EM222 Filter plug T H2 DV OS T M50 407 EZM25 O ring P25 EPDM Purple T H2 DV OS T M50 408 EX006 Water i...

Страница 81: ...e heater 212 427 EW00L Pan screw M4 6 W Washer 428 EZM15 O ring P15 EPDM Purple T K3 T K3 Pro T K3 SP OS T H2 DV OS T KJr2 IN OS T K4 IN OS T D2 IN OS T M50 429 EKH33 Flow sensor T H2 DV OS T M50 430...

Страница 82: ...708 EC00X Nylon clamp T K3 T K3 Pro T K3 SP OS T H2 DV OS T KJr2 IN OS T K4 IN OS T D2 IN OS 709 EM45T Igniter Freeze protection wire 710 EM393 AC100V wire 711 EM403 AC100V Transformer connecting wire...

Страница 83: ...DENTIAL 15 Records of revision of this manual Version Changes Date 1 00 Sample evaluation 06 27 08 1 01 Revised by the R D and Takagi Japan 12 09 08 1 02 Revised by the R D and Takagi Japan 02 12 09 1...

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