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COMMERCIAL GAS WATER HEATERS

Service Handbook

PRINTED IN THE U.S.A. 1119 100274940_2000534998_Rev B

500 Tennessee Waltz Parkway

Ashland City, TN 37015

FOR MODELS:

XWH 150 THRU 800

INSTALLATION CONSIDERATIONS - PRE SERVICE CHECKS -

CONSTRUCTION - OPERATION & SERVICE - TROUBLESHOOTING

SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN

Содержание THRU 800

Страница 1: ...19 100274940_2000534998_Rev B 500 Tennessee Waltz Parkway Ashland City TN 37015 FOR MODELS XWH 150 THRU 800 INSTALLATION CONSIDERATIONS PRE SERVICE CHECKS CONSTRUCTION OPERATION SERVICE TROUBLESHOOTING SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN ...

Страница 2: ...f Operation 8 Access Modes 8 Saving Parameters 8 SEQUENCE OF OPERATION 9 TOUCH SCREEN DISPLAY MENU ACCESS 11 TOUCH SCREEN DISPLAY PARAMETER ACCESS 13 PARAMETER TABLE 14 VIEWABALE AND CHANGEABLE CONTROL PARAMETERS 16 Temperature 16 Service 16 Circulation Pumps 17 Building Management System BMS 17 Lead Lag 18 Economy Mode Clock 19 Short Cycling 20 MAINTENANCE 21 Maintenance Schedules 21 Maintenance ...

Страница 3: ...iction to perform a given task do not attempt to perform any of the 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 SERVICE REMINDER When performing any troubleshooting step outlined in this service handbook always consider the wiring and connectors betw...

Страница 4: ...lief Valve operation water discharged 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 thermal expansion A properly sized thermal expansion tank must be installed on all closed systems to control the harmful effects of thermal expansion Contact a local plumbing...

Страница 5: ...y be needed depending on the job site conditions Current NIOSH recommendations can be found on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lining to prevent airborne dust Remove the c...

Страница 6: ...ACE MODULE UIM TOUCH SCREEN DISPLAY Tank Temperature 71 F Operating Setpoint 184 F Status Ignition HELP DISABLE A O Smith XP MENU OFF GAS O N LCD Touch Screen Display Status Icons Main Menu Help Menu Enable Disable Reset Button Figure 1 User Interface Module UIM Touch Screen Display ...

Страница 7: ... BUILDING MANAGEMENT SYSTEM LOW VOLTAGE CONNECTION BOARD INLET TEMPERATURE SENSOR OUTLET TEMPERATURE SENSOR FLUE GAS SENSOR DAMPER PROVING SWITCH FLAME SENSOR LOW WATER CUTOFF BLOCKED CONDENSATE SWITCH TOUCH SCREEN DISPLAY CONTROL BOARD AIR PRESSURE SWITCH O TEMP HEAT EXCHANGER SWITCH DOOR TEMPERATURE SWITCH AIN ADAPTER CABLE Figure 2 UIM Control Inputs ...

Страница 8: ...NTROL OUTPUTS LOW VOLTAGE CONNECTION BOARD CONTROL BOARD ALARM BELL DAMPER RELAY RUN TIME CONTACTS SEQUENCER BUILDING MANAGEMENT SYSTEM WATER HEATER PUMP IGNITER BLOWER GAS VALVE TOUCH SCREEN DISPLAY BUILDING RECIRCULATION PUMP AIN ADAPTER CABLE Figure 3 UIM Control Outputs ...

Страница 9: ...of operation for water heating operation ACCESS MODES User The user can adjust tank target temperatures by accessing the Tank Temperature using the MENU option on the Touch Screen Display The date and time can also be changed Installer Most parameters are available only to the installer accessible by entering the installer password 5309 SAVING PARAMETERS Refer to the Parameter Table Table 4 on Pag...

Страница 10: ... switch and blocked drain switch must close The control starts the prepurge cycle The control starts the trial for ignition by energizing the spark electrode and opening the gas valve Tank Temperature 90 F Operating Setpoint 93 F Status Pre Purge HELP DISABLE A O Smith XP MENU Tank Temperature 92 F Operating Setpoint 93 F Status Standby HELP DISABLE A O Smith XP MENU Tank Temperature 92 F Operatin...

Страница 11: ...is satisfied the control will de energize the gas valve The blower will continue to run for approximately 12 seconds during the postpurge The water heater pump will continue to run for its respective pump delay time before turning off A 60 second short cycle period will start which will delay any new call for heat until it times out In Standby ready to start a new cycle Table 1 Sequence Of Operati...

Страница 12: ...ition Press the MENU options to get access to Main Menu which includes Temperatures Heater Status Display Settings Heater Information etc Use the appropriate Menu option to change unit settings or for any other unit information Tank Temperature 92 F Operating Setpoint 93 F Status Standby HELP DISABLE A O Smith XP MENU Temperatures Heater Status Display Settings Heater Information Current Fault VIE...

Страница 13: ...ructions Status Icon Legend Operating States etc Table 2 Menus From The Display Panel Continued Operating Instructions Status Icon Legend Operating States Adjusting Operating Setpoint Change the Display Units Restore Defaults BACK Help Menu Status Icon Legend Operating States Adjusting Operating Setpoint Change the Display Units Restore Defaults Contact Information BACK Help Menu ...

Страница 14: ...een Adjust the Tank Setpoint using the buttons on the Touch Screen Display to the desired temperature Select Accept button to save the desired temperature settings The UIM will save the desired temperature settings and shows Complete on the screen before displaying back the Temperatures parameters screen Tank Temperature 92 F Operating Setpoint 93 F Status Standby HELP DISABLE A O Smith XP MENU Te...

Страница 15: ...EAR button YES NO YES YES Service Service Contact Info Contact Name YES NO YES YES Service Service Contact Info Contact Phone YES NO YES YES Circulation Pumps Circulation Pumps DHW Pump Delay YES NO YES YES Circulation Pumps DHW Anti Seize YES NO YES YES Building Management Building Management BMS Tstat Input YES NO YES YES Building Management BMS YES NO YES YES Building Management BMS Type YES NO...

Страница 16: ...Lead Lag DHW Size Slave X YES NO YES YES Economy Mode Clock Economy Mode Clock Current Time YES YES YES YES Economy Mode Clock Current Date YES YES YES YES Economy Mode Clock Setpoint Adjustment YES NO YES YES Economy Mode Clock Start Time X YES NO YES YES Economy Mode Clock Stop Time X YES NO YES YES Short Cycling Short Cycling Short Cycling Time YES NO YES YES Short Cycling Short Cycling Differe...

Страница 17: ...ler by accessing the Setpoint Offset parameter The temperature range of this parameter is 0 F 0 C to 10 F 30 C The default value is 4 F 6 C DISPLAY SETTINGS Backlight Delay This is the time in which the display remains illuminated The range is 30 seconds to 5 minutes The default is 3 minutes Temperature Units C F The control can be configured to display temperature in either C or F This parameter ...

Страница 18: ...ntrol or the 0 10V input value received through ModBus The default value is INACTIVE BMS Type When programmed for BMS control through the 0 10V BMS input or through ModBus the 0 10V signal can be interpreted as either a modulation command or a set point When the BMS Type parameter is set to POWER the 0 10V signal will control the modulation When set to SETPOINT the 0 10V signal will control the ta...

Страница 19: ... connected to the Leader water heater The default address is 1 Lead Lag Efficiency Enhancement Types There are two 2 options for the way a Lead Lag divides the load between its heaters The first is Lead Lag designated as L L in the menu This method is used when it is desired to have the least amount of total flow through the water heaters This method will modulate the last two 2 water heaters This...

Страница 20: ...hat Lead Lag The water heater size parameters allow the installer to program the sizes based on the Lead Lag address This screen shows the Lead Lag address and the size of the water heater with that address in BTU hr The UIM control automatically uses the Efficiency Enhancement Lead Lag type when controlling water heaters of different sizes ECONOMY MODE CLOCK Time and Date The control uses an inte...

Страница 21: ...trol will abort short cycling and allow the water heater to fire This parameter can be changed by the installer by accessing the Short Cycling Differential parameter The temperature range of this parameter is 0 F 0 C to 54 F 30 C The default value is 10 F 6 C Ramp Delay Step X Time This parameter allows the installer to enable or disable the DHW ramp delay The default setting is disabled Ramp Dela...

Страница 22: ...heckout and performance verification per Section 10 of this service handbook Flame inspection stable uniform Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F above return water temperature Check Delta T Temperature Rise Refer to Table 7 in this Service Handbook If combustion or performance indicate need Clean heat exchanger Remove and c...

Страница 23: ...or system exhibit any unusual behavior 3 Remind the owner to follow the proper shutdown procedure and to schedule an annual maintenance 4 Inspect any problems reported by the owner and correct before proceeding Inspect water heater area 1 Verify that water heater area is free of any combustible materials gasoline and other flammable vapors and liquids 2 Verify that air intake area is free of any o...

Страница 24: ...ng any T P relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Please refer to the System Piping section of the XP Water Heater Instruction Manual before proceeding further Safety T P relief valves should be re inspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has...

Страница 25: ...ater wiring 1 Inspect all water heater wiring making sure wires are in good condition and securely attached Check control settings 1 Use the UIM control display to access MENU and check all parameter settings 2 Check settings of external limit controls if any and adjust if necessary Perform start up and checks Note The start up must only be performed by a qualified service technician 1 Start water...

Страница 26: ...m assembly The water heater contains ceramic fiber materials Use care when handling these materials per the instructions on Page 3 of this Service Handbook Failure to comply could result in severe personal injury 5 Remove the condensate hose from the heat exchanger end Connect a field supplied 3 4 diameter hose to a drain pan Using field supplied means cover the refractory in the back of the combu...

Страница 27: ...se the heat exchanger door must be replaced Consult factory for replacement heat exchanger door Kit 100173794 and 100173799 Check Delta T 1 Check the Delta T using Table 7 below as a reference Table 7 Water Heater Pump Applications Recommended Temperature Rises MODEL PIPE SIZE ARMSTRONG GRUNDFOS FLOW RATE GPM LOSS FT HD TEMP RISE 150 1 1 4 E8 16 16 6 18 F 200 1 1 4 E8 21 11 8 18 F 285 2 E17 30 17 ...

Страница 28: ...aximum 132 VAC to water heater 3 Make sure all external limit controls are installed and operating Check the following 1 Wire connectors to control module are securely plugged in at the module and originating control 2 Gas pressures Maximum 14 inches w c Natural and LP with no flow lockup or with water heater on Minimum 4 inches w c natural 8 inches w c LP with gas flowing verify during water heat...

Страница 29: ...eaker Check position of ON OFF switch Turn switch to the ON position Check 120 VAC through the ON OFF switch Check wiring harness connection between display board and main control board Connect harness at both points No voltage through the switch Replace switch Bad display board Replace board Bad main control board Replace the main control board Blown fuse Replace fuse F3 on the main control board...

Страница 30: ...mum listed in the General Venting section of the XP Water Heater Instruction Manual Dirty damaged burner Refer to Page 24 in this Service Handbook for the burner removal and inspection procedure Clean or replace the burner as necessary Low water flow through the heat exchanger Refer to System Piping section of the XP Water Heater Instruction Manual for minimum flow rates Air in the piping system P...

Страница 31: ...heck water heater pump operation on a call for heat Check for closed valves or obstructions in the water heater piping Verify system is full of water and all air has been purged from the system Check voltage to pump Check pump relay operation Check for disconnected wires to pump Check for disconnected wires to flow switch Blocked Condensate SW The blocked condensate switch has detected excessive c...

Страница 32: ...nd cleaning procedures Replace if necessary Inspect the heat exchanger Refer to the Instruction Manual for removal and cleaning procedures Replace if necessary Faulty air pressure switch Replace switch O TEMP HEX SWITCH Applies to 285 800 Models Only Inspect the back of the inner combustion chamber at burner level for refractory breakdown missing Replace heat exchanger if refractory is broken and ...

Страница 33: ... are no obstructions Check for 24 VAC to the gas valve at the 2 pin connection on the side of the main control board during the ignition attempt If no voltage is present replace the main control board If 24 VAC is present at the main control board check the wiring between the main control board and the gas valve Replace the wiring if necessary If 24 VAC is present check the outlet of the valve to ...

Страница 34: ...stalled correctly and there are no obstructions Check for 24 VAC to the gas valve at the 2 pin connection on the side of the main control board during the ignition attempt If no voltage is present replace the main control board If 24 VAC is present at the main control board check the wiring between the main control board and the gas valve Replace the wiring if necessary If 24 VAC is present check ...

Страница 35: ...em Verify that the water heater is piped properly into the system Refer to the Instruction Manual for proper piping methods Check 120 vac to water heater pump motor on a call for heat If voltage is not present check wiring back to the main control board Replace the main control board if necessary If 120 vac is present on a call for heat and the water heater pump is not operating replace the pump I...

Страница 36: ... 30 lower or higher than what is being called for Vent air intake lengths exceed the maximum allowed lengths Check for proper lengths Check for obstruction or blockage in the vent air intake pipes or at terminations Check the wiring connections at the blower fan and at the main control board Replace the blower fan BLOWN FUSE Replace fuse F4 on the control board Refer to Page 27 for additional info...

Страница 37: ...e sensor Replace flue sensor if necessary Measure the resistance of the sensor and compare the resistance to Table 11 2 on Page 38 Outlet Temp Drift The outlet temp thermistor has exceeded the 10 degree drift limit Check wiring connections to the thermistor Check wiring connections to the main control board Measure the resistance of the sensor and compare the resistance to Table 11 1 on Page 38 Ta...

Страница 38: ...r is properly connected Replace sensor if necessary Measure the resistance of the sensor and compare the resistance to Table 11 2 on Page 38 Memory Error Control Board Internal Error Cycle Power Replace the control board if reoccurs Table 10 Troubleshooting Chart Fault Messages Displayed on UIM Continued Tank Temperature 118 F Operating Setpoint 185 F Status Flue Sensor HELP RESET A O Smith XP MEN...

Страница 39: ... Inlet System Sensor Resistance vs Temperature TEMPERATURE F RESISTANCE TEMPERATURE F RESISTANCE 50 18 780 158 1 990 68 12 263 176 1 458 86 8 194 194 1 084 104 5 592 212 817 122 3 893 140 2 760 Table 11 1 Outlet Water Sensor Resistance vs Temperature S1A WIRE COLOR R BK AND Y S1B WIRE COLOR G AND Y TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE 50 19 55...

Страница 40: ...5 9 0 11 4 1 6 9 7 Once the combustion analysis is complete test the safety shutoff device by turning the manual shutoff valve to the OFF position and ensuring that the water heater shuts down and registers an alarm Open the manual shutoff valve reset the control 8 Turn the main power off to the water heater and replace the flue temperature sensor into the flue pipe connection 9 Place the water he...

Страница 41: ...four 4 times If after four 4 adjustments and the combustion is still not within the specified range revisit the possible causes in Table 13 on Page 39 or replace the gas valve Model 400 Locate the throttle adjustment screw on the top of the gas valve see Figure 10 Using a screwdriver turn the screw 1 8 turn counterclockwise to increase CO2 levels or 1 8 turn clockwise to decrease CO2 levels After ...

Страница 42: ... the possible causes in Table 13 on Page 39 or replace the gas valve Models 600 800 Locate the throttle adjustment screw on top of the gas valve see Figure 12 Using an Allen wrench turn the screw a 1 4 turn counterclockwise to increase CO2 levels or a 1 4 turn clockwise to decrease CO2 levels After one adjustment on the valve follow the Combustion Analysis Procedure on Page 39 of this Service Hand...

Страница 43: ...42 Servicing should only be performed by a Qualified Service Technician NOTES ...

Страница 44: ...r additional information contact A O Smith Corporation 500 Tennessee Waltz Parkway Ashland City TN 37015 Tech Support 800 527 1953 Parts 800 433 2545 www hotwater com Copyright 2019 A O Smith Water Heater Company All rights reserved ...

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