American Water Heater 160X3P Manual
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American Water Heater 160X3P Manual

On-demand water heater, condensing models
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Condensing Models
On-Demand Water Heater
Service Handbook
MODELS:
160X3P
180X3P
199X3P
(Indoor/Outdoor)
(Indoor/Outdoor)
(Indoor/Outdoor)
Series 100
Series 100
Series 100
THIS SERVICE HANDBOOK IS FOR USE BY QUALIFIED SERVICE PROFESSIONALS ONLY.
IF YOU NEED ASSISTANCE, CALL TECHNICAL SUPPORT.
IN USA, CALL AT 877 737 2840. IN CANADA, CALL 888 479 8324.
DIR 2000585401 Rev. B
March 2020

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Summary of Contents for American Water Heater 160X3P

  • Page 1 Condensing Models On-Demand Water Heater Service Handbook MODELS: 160X3P 180X3P 199X3P (Indoor/Outdoor) (Indoor/Outdoor) (Indoor/Outdoor) Series 100 Series 100 Series 100 THIS SERVICE HANDBOOK IS FOR USE BY QUALIFIED SERVICE PROFESSIONALS ONLY. IF YOU NEED ASSISTANCE, CALL TECHNICAL SUPPORT. IN USA, CALL AT 877 737 2840. IN CANADA, CALL 888 479 8324.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SPECIFICATIONS ......................................4 INTRODUCTION ......................................5 General Installation Guidelines ........................................5 NORMAL OPERATION ....................................6 Activation ........................................6 Operation ........................................6 Shutdown ........................................6 Preliminary Checklist ....................................6 Gas/Water/Electric: .................................. 6 TROUBLESHOOTING .....................................7 Remote Controller: ................................... 7 High Altitude: .................................... 7 Vent Length : ....................................7 Technology: ..................................
  • Page 3 DIP SWITCH SETTINGS ....................................25 WIRING DIAGRAM .....................................28 SERVICE PROCEDURES ....................................29 Filter/Drain Plugs Cleaning ..................................29 Checking for a Crossed Connection .................................30 Checking for a Reversed Connection ...............................30 Checking the Inlet Gas Pressure and Pressure Drop ..........................30 Adjusting the Manifold Gas Pressure and Firing Rate ..........................31 Checking the Manifold Gas Pressure ............................

  • Page 4: Specifications

    SPECIFICATIONS Table 1: 160X3P 160X3P 180X3P 180X3P 199X3P 199X3P Model Indoor Outdoor Indoor Outdoor Indoor Outdoor MIN: Natural Gas Input 9,000 9,000 9,000 BTU/h (Operating Range) 160,000 180,000 199,000 MAX: MIN: Propane Input 9,000 9,000 9,000 BTU/h (Operating Range) 160,000...

  • Page 5: Introduction

    160X3P, 180X3P and 199X3P tankless 1. Follow all local codes, or in the serious injury or death. Do not remove water heaters. It will be effective in...

  • Page 6: Normal Operation

    NORMAL OPERATION Becoming familiar with how a tankless delivery of water at the desired 10. When the flame sensor no longer temperature. This will result in a detects a flame, the green “In Use” water heater normally operates may loss of pressure at hot water fixtures LED will turn off.

  • Page 7: Troubleshooting

    NORMAL OPERATION / TROUBLESHOOTING rating plate. All four must be page 25. Also, see the installation missing check valve, or a the same in terms of gas type, manual for venting requirements. cartridge in a single-handle and your water heater model faucet that needs to be Incorrect vent length settings may must be converted for use with...

  • Page 8: Next Step

    • too high or low. The temperature The filter on the cold water inlet can be adjusted using the should be clean. See”Filter/Drain Plugs On-Demand temperature or remote controller. Cleaning” on page 29. Water Heater Solar installation can have higher •...

  • Page 9: Abnormal Sounds Come From The Unit

    • Make sure that a check valve Abnormal sounds come from is installed on the return line. the unit. A malfunctioning or missing • Check the fan for debris. check valve will cause a cross • connection, allowing cold water to Check for blockages in the exhaust back-feed into the system.
  • Page 10 THIS PAGE IS INTENTIONALLY BLANK • On-Demand Water Heater Service Handbook for X3P Models...

  • Page 11: Error Codes

    ERROR CODES All units have self-diagnostics. If there is a problem with the unit, a numerical error code will display on the temperature controller of indoor models or on the TM-RE43 Remote Controller (if installed). Installation related problems can also produce an error code(s).
  • Page 12 ERROR CODE GREEN LED ON SYMPTOM OR ISSUE TROUBLESHOOTING PROCEDURE COMPUTER BOARD 111 or 121 Three Flashes Ignition failure / Loss of • Check for connection/breakage of wires, burn marks flame on the computer board (Part #701), and/or soot on the flame rod (Part #108).
  • Page 13 ERROR CODE GREEN LED ON SYMPTOM OR ISSUE TROUBLESHOOTING PROCEDURE COMPUTER BOARD Flame Rod Failure Check for connection/breakage of wires (Part #709) Two Flashes and/or soot on the Flame rod (Part #108). Flow Sensor Failure • Check for connection/breakage of wires (Part #402, 715).
  • Page 14 ERROR CODE GREEN LED ON SYMPTOM OR ISSUE TROUBLESHOOTING PROCEDURE COMPUTER BOARD • Inspect the flow adjustment valve (Part #402), for connection/breakage of wires Flow adjustment Four Flashes valve fault • Inspect the control valve for debris that may be blocking it.
  • Page 15 ERROR CODE GREEN LED ON SYMPTOM OR ISSUE TROUBLESHOOTING PROCEDURE COMPUTER BOARD Five Flashes Combustion Air and/or • Verify the gas type supplied to the water heater Exhaust Gas Blockage matches gas type orifice plate installed. DO NOT operate the water heater if they do not match; correct immediately.

  • Page 16: Code 031: Incorrect Dip Switch Settings

    Code 031: Incorrect DIP Switch in standby, and verify the gas pressure 2.3.1 Push the bu on in the does not drop below the minimum middle of it. The switch was Se ngs specified supply pressure when all reset if you heard and felt The system displays this code when an gas appliances are in operation.

  • Page 17: Code 201: Combustion Air And Gas Line Failure

    both the igniter and at the LED stayed off, then inspect the 1.65 kΩ. Normal resistance for SV2 computer board. Unplug and flame sensor. Clean it if necessary. and SV3 is 2.07-2.53 kΩ. If the reconnect them to clean the Replace it if any damage (chips or resistance is out of range, replace electrical connec ons.

  • Page 18: Code 311, 321, 331, 341 Or 351: Thermistor Failure

    Code 311, 321, 331, 341 or 351: Drain the unit of water. (See “Unit Draining and Filter Thermistor Failure Cleaning” on p. 29.) The system displays this code when it detects a thermistor failure. Remove the screw or clip that secures the thermistor, 1.

  • Page 19: Code 391: Flame Rod Failure

    Code 391: Flame Rod Failure 4. Check the flow sensor/control valve resistance of the valve. Normal wires to see if they are broken or resistance reading is 1.15-1.65 kΩ. 1. Ensure that the unit is plugged into disconnected. If the resistance is out of range, a socket that is properly grounded.

  • Page 20: Code 611: Abnormal Fan Motor

    and the gas valve had to be that are found. in the connections that can reduce the removed, make sure that each speed of the pump impeller. Clean out 3. Visually check for breakages in the gas valve wire is plugged into the the debris.

  • Page 21: Code 661: Bypass Valve Fault

    2. Check the resistance of the flow Unplug the bypass valve’s thermistor. The readings adjustment valve. To check it, harness. There is a connector in should be similar and it the middle of the harness which should be reading the you can access by removing temperature of the supply Turn off...

  • Page 22: Code 721: False Flame Detection

    Code 721: False Flame 3. Make sure that all wiring is Code 761: Communica on Error connected to the remote controller Detec on in Easy-Link System properly. A false flame was detected by the A 761 error code means that the parent system during start up.
  • Page 23 appear if there are combustion se ngs. Each 90-degree air and/or exhaust vent issues elbow is equal to 5 feet of during the pre-purge sequence. straight pipe. Refer to the INCREASE DECREASE installa on manual for vent • Code 991: This error code will requirements.
  • Page 24 and obstructions in the venting or heater will affect manifold pressure readings. 9. Contact Technical Support regarding the manifold pressure. (See Table 1 on page 4.) With approval from Technical Support, adjust the manifold pressure to the correct values, if necessary. Reset Procedure 10.

  • Page 25: Dip Switch Settings

    DIP SWITCH SETTINGS Figure 6: DIP switch location. The computer board layout for all models is identical. See “Wiring Diagrams,” page 28. The DIP switches have certain special functions as shown on the following tables and generally should not need adjustment. Verify the functions of each DIP switch carefully before changing any settings.
  • Page 26 DIP SWITCH SETTINGS CONTINUED Table 4: Middle Bank of DIP Switches Parent se for Easy-Link System Parent unit (Def S ngle Parent talla (Default) 2,001 to 3,001 to 5,001 to 7,501 to 0 to 2,000 3,000 5,000 7,500 10,100 (0 to 610 m) (611 to (915 to (1,525 to...
  • Page 27 DIP SWITCH SETTINGS CONTINUED Table 5: Lower Bank of DIP Switches Gas type N tur (D f Vent se Vent Vent Vent Vent (Default) style type style type Intake Intake 2" DV 2" DV (3.1 to 18.3 m) (1.5 to 3.0 m) Intake Intake 2"...

  • Page 28: Wiring Diagram

    Ground Heater Figure 7:  Wiring Schematic for 160X3P, 180X3P, and 199X3P Models For instructions on how to use checkpoints during troubleshooting, refer to the water heater’s maintenance sheet. The maintenance sheet is stored in a pouch on the inside of the water heater’s front cover.

  • Page 29: Service Procedures

    SERVICE PROCEDURES 8. Replace all plugs and close all drain Filter/Drain Plugs valves. Cleaning NOTICE: Drain plugs must be hand tightened only. WARNING Water drained from the water heater may be hot and could cause severe burns. Failure to observe proper safety practices could lead to serious Figure 8: ...

  • Page 30: Checking For A Crossed Connection

    water faucet, the system has a rate, press and hold the “MAX” Checking for reversed connection. button on the computer board. (See Figure 11). a Crossed Checking the Inlet Connec on Gas Pressure and INCREASE Pressure Drop DECREASE 1. Turn off cold water supply valve to the water heater.

  • Page 31: Adjusting The Manifold Gas Pressure And Firing Rate

    4. Shut off the gas supply to the water Adjus ng the heater at the manual gas shutoff valve. Manifold Gas INCREASE DECREASE Pressure and port Manifold Firing Rate Port Figure 13:  Max button on computer board. WARNING Silicone 10. When you are finished, turn off Tube Complete the following procedures water flow and then turn off power...

  • Page 32: Checking The Overheat Cutoff Fuse (Ohcf)

    overheating during maximum 2. Locate the white OHCF which wraps Checking the Flow burn. If presence of a gas leak is around the heat exchanger (See Figure detected, immediately shut off the 14). Sensor unit and inspect the tube/manifold connection. Otherwise, proceed to the next step Tools and Materials: ●...

  • Page 33: Cleaning The Flame Sensor And Igniter Rod

    cover. Be sure to connect all 3 Cleaning the Flame wires on the front of the burner. Also, inspect all gaskets to make Sensor and Igniter sure that they are free of debris and are not ripped or torn. If the gaskets are ripped or torn, replace them BEFORE reassembly.

  • Page 34: Easy-Link Connections With Previous Models

    Note: The 199X3P may be installed in with an easy-link system of 540H heaters. The 180X3P and 160X3P are not compa ble Upper Bank with any other model as noted in Table 6 and the installa on manual.

  • Page 35: Easy-Link Unit Number Display And Renumbering Procedure (For 199X3P Models Only)

    Table 6: Parent Unit Child Unit (Acceptable Combinations) 199X3P 199X3P 199X3P 199X3P 199X3P 540H 540H 540H 540H 540H 540H 540H 540P 540H 540H 540H Parent Unit Child Unit (Unacceptable Combinations) 199X3P 199X3P 199X3P 540H 199X3P 199X3P 540H 540H 199X3P 199X3P 540H 540H 199X3P...

  • Page 36: Diagnostic Mode

    Individual Unit 3. Press the INFO button to select the Diagnos c Mode mode number. The information will 1. To enter diagnostic mode, press the display on the controller. HOT button and the COLD button simultaneously for at least five 4.

  • Page 37: Multiple Units In A Linked System

    Mul ple Units in a Linked System that are installed in the Easy-Link simultaneously for at least five seconds. system. See Table 6 for allowable 1. To enter diagnostic mode, complete NOTE: You may exit diagnostic mode by combina ons that can be linked this step on the parent heater or on pressing the ON/OFF button.
  • Page 38 Table 7: Diagnostic Modes Mode # Whole Easy-Link System informa on (#0) Unit informa (#1 to #4) Total system ow rate 0 to 999 (GPM) Total opera 0 to 999 (x 100 hours) BTU requireme t for 0 to 999 0 to 999 (×kBTU/h) ON/OFF cycles System...
  • Page 39 Mode # Unit informa 0 to 999 (x 10 steps) Bypass valve Closed = 10 Full = 164 Flow rate through 0 to 999 (%) bypass valve 32 to 212 (°F) temperature Over 212 °F = E5, 32 °F = E0 Pump speed 0 to 999 (×...

  • Page 40: Maintenance

    MAINTENANCE 34 35 36 37 38 39 40 Figure 21:  System component locations • On-Demand Water Heater Service Handbook for X3P Models...
  • Page 41 Table 8: LIST OF MAIN COMPONENT IN THE INTERIOR VIEW Item # diagram Case assembly Exhaust duct Pressure sensor Air damper assembly Flame Sensor Primary heat assembly assembly Secondary heat assembly Main Gas Valve Gas valve assembly 120 VAC Power ON-OFF switch Computer board Condensate drain port 120 VAC wire...

  • Page 42: Removing And Replacing The Exhaust Port Cap

    Removing and cover to the water heater. See Figure 22. exhaust port cap, ensure that it is good condi on. Set the front cover and screws aside Replacing the for re-installa on. WARNING! The exhaust port cap must be properly seated to prevent Exhaust Port Cap exhaust gases from leaking.
  • Page 43 • If you do not have the skills necessary complete this procedure Locate the plas c computer correctly, do not proceed. Seek board housing on the bo om assistance from a qualified service right side of the water heater. Remove Pressure technician.
  • Page 44 connected, slide the computer board and plas c housing back into the water heater. O-Ring P75, # 134 O-Ring P50, # 132 A ach the built in controller to the front of the water heater. Reconnect Venturi Body the wire from the built in controller to the computer board.

  • Page 45: Removing And Replacing The Copper Gas Pipe

    Turn on the gas supply to the Use a non-contact circuit tester to Carefully remove the old copper water heater at the manual gas confirm that power is off before gas pipe from the water heater. shutoff valve. working on or near any electrical parts. See Figure 30.

  • Page 46: Removing And Replacing The Venturi Assembly

    Turn on the gas supply to the water heater at the manual gas O-Ring P75, # 134 shutoff valve and check for leaks. If any leaks detected, re-seat O-Ring P50, # 132 appropriate connec on(s) and re-check. Venturi Assembly, # 126 Replace the front cover and O-Ring P40, # 125 secure with the four screws...

  • Page 47: Removing, Replacing, And Verifying The Gas Orifice Assembly

    Unscrew and keep the 4 screws immediately. Reference See Figure 31 Reconnect power to the water securing the venturi body to fan on page 46. for correct part placement heater by plugging it into the assembly. See Figure 31 on page 46. and orienta on.
  • Page 48 Use a non-contact circuit tester to WARNING! The gas orifi ce assembly Figure 35:  Fan Assembly Reinstall the copper gas pipe must be properly installed to prevent confirm that power is off before exhaust gases from leaking. Failure to using the 16-25A metal fasteners working on or near any electrical parts.

  • Page 49: Removing And Replacing The Main Gas Valve Mv Assembly

    Removing and Use a Phillips-head screwdriver to board, and wiring so that you have clear access to the gave valve assembly. remove the 4 screws securing the Replacing the cover to the water heater. Set the front Remove the 16-25A metal cover and screws aside for re-installa on.

  • Page 50: Removing And Replacing The Primary Heat Exchanger

    Secure the gas valve assembly to heater by plugging it into the wall physically disconnect power to the the gas inlet mount at using outlet or turning it on at the circuit water heater. the screw removed earlier. See Figure 38 breaker, as appropriate.
  • Page 51 mixing chamber assembly. See Figure 41. Figure 43:  Flame Rod Connector. Disconnect the Over Heat Cutoff 16-25A Fastener Fuse (O.H.C.F.) # 413 wires at the plas c connector and the Hi Limit Switch (# 721) wires at the plas c connector. Both connectors are located on the same blue cable.
  • Page 52 Disconnect the 6-15 metal fastener from the small copper drain pipe(# 465). Set the fastener aside for re- Compression Clamp Compressio n Clamp installa on. Figure 46. Exhaust Duct Exhaus Duct 6-15 Metal Screw Screw Drain Line Fastener Figure 48:  Drain line. Disconnect the ceramic block heater from the Primary Heat Exchanger inlet pipe.
  • Page 53 Once the burner plate has been to damage the various piping and wiring removed. Turn it over to view the connec ons that are s ll a ached. burner assembly and gaskets. Use a plas c scraper to remove the old burner assembly and gaskets.
  • Page 54 issues are present do not use the gasket, enclosure. on page 51. a new gasket must be used. Contact the Reconnect the copper pipe Reconnect igniter Service Center to order a new one. A ach (# 466) to the secondary heat connector (purple wires).

  • Page 55: Removing And Replacing Secondary Heat Exchanger

    correctly and seated securely. necessary to complete this installa on. procedure correctly, do not Before restoring power to the Remove the white plas c cable proceed. Seek assistance from a water heater, check the piping clips securing the various cables qualified service technician.
  • Page 56 Reference Figure 2 to iden fy cables. Disconnect the plas c connector 16-25A Metal joining the purple igniter rod wires. Fastener Disconnect fl ame connector (Yellow wire). No ce: Pressure Air Damper the fl ame rod connector uses a special Sensor Connector Gas Solenoid...
  • Page 57 Disconnect the rubber drain tube (# 416) from the bo om right of the secondary heat exchanger. The connec on Screws Screws uses a compression clamp and will require pliers to move the clamp. See Figure 64. Exhaust Duct Exhaus Screw Screw Compression Clamp...
  • Page 58 primary heat exchanger (# 401) to the a ached to the bo om of the primary already affi xed to it to secure the assembly. secondary heat exchanger (# 418). Note heat exchanger (# 401). Replace it if any Install the remaining screw to the side the loca on and orienta on of the two cuts or any other issues are present.

  • Page 59: Removing And Replacing The Igniter Flame Rod Assembly

    Reference Figure 59 for correct orienta on. reconnect the exhaust thermistor. See each step of these instructions. Figure 66 on page 57. Failure to do so could result in Reconnect the heat exchanger personal injury or death. thermistor connector. See Figure Before proceeding , take a moment 58 on page 56.

  • Page 60: Removing And Replacing The Thermistors

    screws removed earlier. Check to ensure NOTICE: DO NOT USE ELECTRIC the gasket is not pinched and is fully SCREWDRIVERS OR DRILLS, HAND sealed. TIGHTEN ALL SCREWS TO PREVENT OVER TIGHTENING. Before proceeding , take a moment to check all wiring connec ons and Disconnect power to the water pipe connec ons.

  • Page 61: Removing And Replacing The Water Piping System Components

    Remove the metal fastener or Removing and Built In Controller screw securing the thermistor. Replacing the No ce: keep the screw(s) or metal fasteners for re-installa on of the Water Piping thermistors. Connector Connecto Ensure all wires are routed correctly System and not pinched or under tension.
  • Page 62 water heater and open the plas c drain them. Reference Figure 75 & Figure 76 Built In Controller port located on the bo om le side of for correct type and placement. the water heater. Allow the system to A ach the built-in controller to completely drain before proceeding.
  • Page 63 Before restoring power to the Turn on the gas supply to the water water heater, check the piping heater at the manual gas shutoff connec ons by restoring water to the valve. system and check for any leaks. Allow a Reconnect power to the water few moments for the system to pressurize.

  • Page 64: Removing And Replacing The Recirculation Pump

    Removing and cover to the water heater. Set the front moval. cover and screws aside for re-installa on. Remove the plas c piping Joint Replacing the “E” and Joint “G”. Set these Locate the wire on the built-in sec ons aside for re-installa on. See controller and follow it to the Recircula on Figure 78.

  • Page 65: Removing And Replacing The Drain Port And Drain Tube

    Removing and Locate the wire on the built-in Connec ons use 12.7A metal controller and follow it to the fasteners. See Figure 78. Replacing the computer board. Carefully disconnect A ach the built-in controller to built-in controller from the front of the water heater. Drain Port and computer board.
  • Page 66 Remove the 6-15 metal fastener Remove the plas c piping Joint are present replace them immediately. securing the drain tube to the “E” and Joint “G”. Set these Reinstall the copper drain pipe base of the water heater enclosure. sec ons aside for re-installa on. See using the 6-15 metal fasteners Keep the fastener for re-installa on Figure 82.

  • Page 67: Removing And Replacing The Thermistor Inlet Plug

    Replace the front cover and NOTICE: DO NOT USE ELECTRIC Secure it in place with the M4 screw secure with the four screws SCREWDRIVERS OR DRILLS, HAND removed earlier. removed earlier. Note the placement of TIGHTEN ALL SCREWS TO PREVENT A ach the built-in controller to the built-in controller when se ng the OVER TIGHTENING.

  • Page 68: Component Diagrams

    COMPONENT DIAGRAMS Case assembly                                 Surge box assembly Built-in controller               • On-Demand Water Heater Service Handbook for X3P Models...
  • Page 69 Computer board assembly                                     Flow Flow Adjust Sensor Valve Pressure Sensor Valve Increase button MAX button MIN button Decrease button Air damper Exhaust thermistor DIP switches Pump Remote...
  • Page 70 Gas line Fan motor assembly 123 455 Gas inlet Burner assembly • On-Demand Water Heater Service Handbook for X3P Models...
  • Page 71 Water way 1 Hi-limit switch Heat exchangers                                                                    ...
  • Page 72 Water way 2 Bypass valve Pump & return inlet SCM c Water outlet Water inlet • On-Demand Water Heater Service Handbook for X3P Models...

  • Page 73: Component Diagrams/Item Numbers

    COMPONENT DIAGRAMS/ITEM NUMBERS Description Part # Description Part # Case assembly Pressure sensor 100320320 Front cover 100320351 Air Inlet Tube Intake/Exhaust port assembly 100320352 O-ring P40 EPDM 100320379 Bracket Venturi body 100320380 Top bracket Oval ring NBR 100320381 Hose clamp Orifice gasket 100320382 Rain protection tray...
  • Page 74 COMPONENT DIAGRAMS/ITEM NUMBERS CONT. Description Part # Description Part # Small heat exchanger fixing plate R Computer board 160X3P 100320425 Hose clamp 15 Computer board 180X3P 100320426 Exhaust duct Computer board 199X3P 100320427 Exhaust duct gasket 100320393 Rubber grommet 100076470...
  • Page 75 NOTES...

This manual is also suitable for:

180x3p199x3p

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