Table of Contents
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Table of Contents
Related Manuals for A.O. Smith Cyclone XL 100 Series
Summary of Contents for A.O. Smith Cyclone XL 100 Series
- Page 1 Service Handbook COMMERCIAL GAS WATER HEATERS COMMERCIAL GAS WATER HEATERS MODELS BTHS 750A & 1000A SERIES 100 & 101 INSTALLATION - OPERATION - SERVICE - MAINTENANCE SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN PRINTED 0220 100314732 2000568400 Rev. A...
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Page 2: Table Of Contents
CONTENTS CONTENTS INTRODUCTION ..............3 INTAKE AIR CONNECTION ........... 25 Qualifications ................ 3 ELECTRICAL CONNECTIONS – ALL MODELS ....26 Service Warning ..............3 Power Fluctuations and Electrical Noise ......26 Service Reminder ..............3 Dedicated Power Wiring and Breakers ......26 Tools Recommended ............ -
Page 3: Introduction
INTRODUCTION INTRODUCTION This Service Handbook covers the water heater model and series numbers listed on the front cover only. The instructions and illustrations contained in this service handbook will provide you with troubleshooting procedures to verify proper operation and diagnose and repair common service problems. -
Page 4: Installation Considerations
INSTALLATION CONSIDERATIONS INSTALLATION CONSIDERATIONS This section of the Service Handbook covers some of the critical installation requirements that, when overlooked, often result in operational problems, down time and needless parts replacement. Costs to correct installation errors are not covered under the limited warranty. -
Page 5: Features And Components
FEATURES AND COMPONENTS FEATURES AND COMPONENTS (Behind UIM) Blower Berner Assembly Firere 2 Front View Firere 1 )Top View )withoet plastic cover Firere 3 Important: The Enable/Disable switch listed in this manual is NOT an “on/off” switch and does not disconnect 120 volt power to the CCB and other heater components. - Page 6 Temperature-Pressure Relief Valve. See Temperature-Pressure Relief Valve (page 14). 1” Honeywell modulating 24 VAC gas valve. 6” PVC air intake connection. Honeywell Venturi Mixing Unit. 10. Combustion blower. 11. Combustion sight glass. 12. Flame Sensor: The control system also monitors the flame sensor to confirm a flame is present at the Main Burner. If a flame is not verified during the ignition trial period (3-5 seconds) the control system will immediately de-energize the 24 VAC Gas Valve.
- Page 7 Firere 4. Combestion Blower & Berner Assembly 34. Heat shield & insulation 40. Blower discharge gasket 35. Burner flange gasket 41. Burner gasket 36. Observation sight glass 42. Spark rod 37. Burner 43. Spark rod gasket 38. Flame rod 44. Ignition cable 39.
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Page 8: Top View
TOP VIEW Firere 6. Top View Burner/Blower Assembly Temperature Probe Blocked Intake Air switch Spark Ignition Control Powered anode rods 120 VAC junction box Temperature-Pressure Relief Valve Exhaust/Condensate Elbow 2” NPT hot water outlet connection... -
Page 9: Sequence Of Operation Flow Chart
SEQUENCE OF OPERATION FLOW CHART SEQUENCE OF OPERATION FLOW CHART Seqeence is shown with Enable/Disable Switch in the Enable position If tank temperature drops below Operating Set Point minus Differential setting a heating cycle is activated Control System performs diagnostic checks. Control System Locks Out Normal state of all pressure switches, the flow switch, and Displays Fault Msg... -
Page 10: Fault And Alert Codes
FAULT AND ALERT CODES FAULT AND ALERT CODES 1. LOW GAS PRESSURE The minimum gas supply pressure is measured while gas is flowing (dynamic pressure) along with all additional gas appliances operating on the same gas supply system. Cyclone XL water heater can operate smoothly when gas supply pressure is as low as 3.5” WC dynamic for natural gas and 8.0”... - Page 11 Service notes: • The manifold gas pressure is non-adjustable as these are zero-governing gas systems. • There is usually a drop in supply gas pressure noticed when the water heater’s 24 Volt Gas Control Valve opens during ignition. The manifold pressure will go from a negative value (during pre-purge) to near zero when gas is flowing. •...
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Page 12: Ignition Failure
Pettinr The Water Heater Back In Service 1. Lower the Operating Set Point to end the heating cycle. Use the Enable/Disable Switch located on the front of the water heater and put the unit in disabled mode. 2. Close the main gas shutoff valve serving the water heater. 3. - Page 13 BURNER IGNITES )BRIEFLY) • If the burner ignites briefly then shuts off with an “Ignition Failure” error message, follow these steps: • Remove the connector from flame sense rod [picture of connector showing location on unit]. Inspect the connector for corrosion. Replace if corroded or damaged.
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Page 14: Blocked Air Intake
THROTTLE ADJUSTMENT UINDER BLUE COVER OFF-SET ADJUSTMENT UNDER SCREW COVER GAS PRESSURE TEST PORT 2" GAS INLET PORT #2: SUPPLY-GAS PRESSURE TEST PORT Firere 10. Gas Control Valve Assembly 3. BLOCKED AIR INTAKE CAUSES: locked ntake • The Blocked Air Intake Switch has detected a possible 0 days 0 hrs 0 mins ago restriction in the air intake pipe. -
Page 15: Blocked Exhaust
4. BLOCKED EXHAUST CAUSES: locked xhaust • The Blocked Exhaust Switch has detected a possible 0 days 0 hrs 0 mins ago restriction in the exhaust pipe. Error Code: 8-1201 • Restriction in exhaust pipe. Check exhaust pipe and termination for blockage. Press the Advanced button for BACK ADVANCED... - Page 16 • The current flowing between the Flame Sensor and Burner is DC micro amp current expressed as: µA (micro Amps). Flame sensing current can be measured with a DC micro amp test meter, see “Tools Recommended” on Page 3. CONTROL SYSTEM APPLIES AC CURRENT TO FLAME SENSOR SPARK...
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Page 17: No Water
6. NO WATER CAUSES: No Water • The controller has not detected a voltage potential of 0 days 0 hrs 0 mins ago water in the tank. Error Code: D6-8 • No water or low water in tank. No water detected by Powered •... -
Page 18: Anode Shorted
7. ANODE SHORTED CAUSES: Anode horted • The controller has detected a low resistance or short to 0 days 0 hrs 0 mins ago earth ground or the tank. Error Code: CC-B The Powered Anode is shorted to earth ground or the tank. The control indicates a problem with the anode ADVANCED... - Page 19 Should the ECO activate, the water temperature must drop below 140°F (60°C) before the Control System can be reset. Once the water temperature has cooled below this point the electrical circuit breaker that serves the water heater must be turned off and on again to reset the Control System.
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Page 20: Temperature Probe Open
5. Using an ohm meter set the range for continuity testing. 6. Check continuity between the two outside pins (red wires/Pins 2 & 3) of the plug end from the Temperature Probe, see Figure on Page 20 pin layout. Reselts/Actions •... -
Page 21: Flue Gas Temperature Probe Short/Open
10. FLUE GAS TEMPERATURE PROBE SHORT/OPEN The flue gas temperature is mounted near the exhaust connection to monitor the flue gas temperature leaving the water heater. Flue gas temperature probe short, fault code 0x4B, indicates that the probe’s resistance measured between the two connectors of the probe is below 394 ohms. -
Page 22: Flow Switch Stuck Closed
Flow Not Detected 0 days 0 hr 0 min ago Error Code: 175-0 Flow was not detected when in heating state. Press the Advanced button for more information BACK ADVANCED Firere 16. Flow Faelt Detected Warninr Messare Firere 17. Pemp Terminal Wirinr Whenever the water flow is not detected during the heating cycle, the water heater is turned off with “Flow Not Detected”... - Page 23 3. Confirm the flow switch is installed correctly with flow arrow vertically pointing upward; 4. Remove & inspect the flow switch’s vane free from debris; 5. Replace the flow switch if malfunction is detected with multimeter.
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Page 24: Venting
VENTING VENTING This section of the Service Handbook is not a complete venting installation instruction. Refer to the Instruction Manual that came with the water heater; ensure the venting has been installed per all Instruction Manual requirements. Costs to correct installation errors are not covered under the limited warranty. -
Page 25: Intake Air Connection
INTAKE AIR CONNECTION INTAKE AIR CONNECTION The intake air connection has a screen and a hose barb installed at the factory, see Figure below. The intake air connection screen is installed to prevent debris from entering the Combustion Blower and/or Burner. This screen is left in place when the water heater is installed in a Power Vent configuration but must be removed before connecting the intake air piping on Direct Vent installations. -
Page 26: Electrical Connections - All Models
ELECTRICAL CONNECTIONS – ALL MODELS ELECTRICAL CONNECTIONS – ALL MODELS The water heaters covered in this Service Handbook require a 120 VAC, 1Ø (single phase), 60Hz, 15 amp power supply and must also be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70 or the Canadian Electrical Code, CSA C22.1. -
Page 27: Enable/ Disable Switch
Ground Terminal Heater Wiring (Factory Installed) Lead Wire Ground L1 (Black Wire) Neutral (White Wire) Firere 19. Jenction Box Assembly ENABLE/ DISABLE SWITCH The Enable/Disable Switch is NOT an “on/off” switch and does not disconnect 120 volt power to the CCB and other heater components. When in the “Disabled”... -
Page 28: Installation Check List
INSTALLATION CHECK LIST INSTALLATION CHECK LIST The list below represents some of the most critical installation requirements that, when overlooked, often result in operational problems, down time and needless parts replacement. Before performing any troubleshooting procedures use the list below to check for installation errors. -
Page 29: Operation And Service
OPERATION AND SERVICE OPERATION AND SERVICE HOW IT WORKS This section of the Service Handbook will cover operation, common service procedures and water heater construction. The water heater covered in this Service Handbook has a helical shaped coil heat exchanger that is submerged in the storage tank. These water heaters use a top mounted down fired radial design Burner. -
Page 30: Blower Speed Control
BLOWER SPEED CONTROL BLOWER SPEED CONTROL The CCB monitors a feedback signal from a sensor that is installed on the blower. The CCB interprets the pulse signal from the sensor and then sends a signal to the blower to produce the proper blower speed and input. These models are capable of modulating their input rate. -
Page 31: Combustion Blower And Burner Removal/ Installation
COMBUSTION BLOWER AND BURNER REMOVAL/ INSTALLATION COMBUSTION BLOWER AND BURNER REMOVAL/ INSTALLATION Refer to the Combustion Blower & Burner Assembly, Heater Top View images in this Service Handbook and the Instruction Manual supplied with the heater for heater component locations. COMBUSTION BLOWER/ BURNER REMOVAL 1. -
Page 32: Spark Igniter
SPARK IGNITER SPARK IGNITER The water heaters covered in this Service Handbook use a Spark Igniter. The Spark Igniter has two rods: the sparking rod that has ceramic insulation and the grounding rod. See Figure 21. During trial for ignition, the Control System powers a high voltage transformer (Ignition Control) from J6, and the Ignition Control supplies high voltage to the sparking rod via the ignition cable. -
Page 33: Ccb (Central Control Board)
CCB )CENTRAL CONTROL BOARD) CCB )CENTRAL CONTROL BOARD) The CCB is a printed circuit board mounted inside a protective plastic enclosure, see Figures below and on next page. The CCB circuit board is the main control. All instructions for ignition and temperature control originate from this circuit board. Diagnostic and operational messages are generated by the CCB and sent to the UIM. -
Page 34: Ccb Cover Removal And Replacement
CCB COVER REMOVAL AND REPLACEMENT The cover on the CCB enclosure must be removed for various service procedures outlined in this Service Handbook. Refer to the instructions below when removing and replacing the CCB cover. Wiring to and from the CCB and other water heater components enters the CCB enclosure on the bottom. Removing the enclosure cover is a simple procedure. -
Page 35: Ccb Circuit Board Layout
CCB CIRCUIT BOARD LAYOUT Firere 22. Central Control Board )CCB) Firere 23. Power Board Assembly... -
Page 36: Ccb Connection Identification
CCB CONNECTION IDENTIFICATION J1 Socket - Hirh Voltare In Table 4. Pin # Table 5. Description Ground AUX NC Heater Pump AUX Common Not Used AUX NO AUX Common Line Voltage Neutral J3 Socket - UIM Pin # DESCRIPTION AIN Reset Data + Data - D Grd... - Page 37 J9 Socket - Temperatere Probe Table 10. Pin # Table 11. Description Thermistor Thermistor J12 Socket - Configuration Key J13 Socket - CPAM 14 Socket - Limit Strinr Table 12. Pin # Table 13. Description Anode Grounding Flame Sensor Condensate Not Used Condensate Gas Pressure Switch...
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Page 38: Cpam - Commercial Power Anode Module
CPAM – COMMERCIAL POWER ANODE MODULE The CPAM, which is mounted on the control panel backplate behind the UIM, provides catholic protection to the water heater tank through the two front-side mounted power anodes. The CPAM module will communicate with the CCB for its current, voltages. CPAM faults will be monitored by the CCB which will issue a fault for the powered anode circuit and will be displayed on the UIM. -
Page 39: Wiring Diagram
WIRING DIAGRAM WIRING DIAGRAM Blower Spark 24Vureg 1 White / Brown Module Speed f-back 2 White / Orange 1 Red 120V 24Vureg 4 White / Blue 1 White/Brown 2 Black PWM Signal Neutral PWM Signal 2 White/Blue 3 Green Ground 5 White / Green Dgnd Neutral... -
Page 40: Control Overview
CONTROL OVERVIEW CONTROL OVERVIEW Interaction with the water heater controller is through an UIM Touch Display called the User Interface Modele )UIM). This screen is also referred to as the “desktop” or “desktop mene”. While the water heater is operating, the user interface will display the UIM screen (if there are no active faults or warnings). An example of this screen is shown below. - Page 41 NOTES NOTES...
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- Page 44 Tech Support: 800-527-1953 Parts: 800-433-2545 www.hotwater.com Copyright © 2020. All rights reserved.