A.O. Smith APW015DW Installation & Service Manual
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A.O. Smith APW015DW Installation & Service Manual

A.O. Smith APW015DW Installation & Service Manual

Indirect plate water heater
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100346577_2000604338_Rev B
Indirect Plate Water Heater
Installation & Service Manual
Double-Wall Models:
APW015DW - APW120DW
Series 100
This manual must only be used by
⚠WARNING
a qualified heating installer / service
technician. Read all instructions
before installing. Perform steps in
LOW LEAD CONTENT
the order given. Failure to comply
could result in severe personal
injury, death, or substantial property
damage.
Save this manual for future reference.

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Summary of Contents for A.O. Smith APW015DW

  • Page 1 100346577_2000604338_Rev B Indirect Plate Water Heater Installation & Service Manual Double-Wall Models: APW015DW - APW120DW Series 100 This manual must only be used by ⚠WARNING a qualified heating installer / service technician. Read all instructions before installing. Perform steps in LOW LEAD CONTENT the order given.

  • Page 2: Table Of Contents

    Contents HAZARD DEFINITIONS ..........2 8. START-UP PLEASE READ BEFORE PROCEEDING ..... 3 Introduction ............... 25 THE APW -- HOW IT WORKS ........4 Pre-operational checks and procedures ......25 1. DETERMINE APW LOCATION Initial start-up ..............25 Before locating the appliance, check: ........ 5 Checking mixed inlet temperature ........

  • Page 3: Please Read Before Proceeding

    Have this Indirect Plate Water Heater • Double-Wall Models (APW) serviced/inspected by a qualified service technician, at least annually. APW015DW, 030DW, 050DW, 070DW, 090DW, 105DW, and 120DW Failure to comply with the above could result in severe personal injury, death or A typical packaged APW water heater with a double-wall heat substantial property damage.

  • Page 4: The Apw - How It Works

    Indirect Plate Water Heater Installation & Service Manual The APW - How it works... 1. Control valve 6. DHW inlet The 3-way electronic control valve is powered by 24 VAC ANSI flanged connections (2" or 3" depending on model size) with which is received from the electronic control system control stainless steel piping that receives cold water from the DHW box.

  • Page 5: Determine Apw Location

    Indirect Plate Water Heater Installation & Service Manual Determine APW location Before locating the appliance, check: This appliance is certified as an indoor ⚠WARNING appliance. Do not install the appliance Check for nearby connection to: outdoors or locate where the appliance will •...

  • Page 6: Apw Water Heater Clearances

    Indirect Plate Water Heater Installation & Service Manual Determine water heater location Figure 1-1 APW Water Heater Clearances and Dimensions 24.00 24.00 24.00 24.00 DIR #2000577419 MODEL APW015DW 55" 44" 15" 35.5" 10.5" APW030DW 55" 52" 15" 35.5" 10.5" APW050DW 55"...

  • Page 7: Prepare Water Heater

    Indirect Plate Water Heater Installation & Service Manual Prepare water heater Receiving and unpacking the APW Setting the unit All of the APW water heaters are shipped fully assembled and APW water heaters contain two (2) round cutouts on the frame ready for installation;...

  • Page 8: Hydronic Piping

    Indirect Plate Water Heater Installation & Service Manual Hydronic piping APW piping assemblies Heating fluid and Domestic Hot Water (DHW) piping The diameter of the piping assemblies furnished with the water heater will depend on the size of the heat exchanger The diameter of the heating fluid (hot boiler water) and DHW installed in the model ordered.

  • Page 9: Hydronic Piping Illustrations

    Indirect Plate Water Heater Installation & Service Manual Hydronic piping (continued) Figure 3-2 Water to Water Heat Exchanger Single Unit BUILDING RETURN COLD WATER SUPPLY BOILER WATER OUT HOT WATER SUPPLY BOILER WATER IN DIR #2000577498 Mixing valves are required for the protection of low temperature loops. CAUTION Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE...
  • Page 10 Indirect Plate Water Heater Installation & Service Manual Hydronic piping Figure 3-3 Water to Water Heat Exchanger Single Unit with Stratified Tank STRATIFIED HOT WATER STORAGE TANK RELIEF VALVE TANK HEIGHT TO DIAMETER RATIO 2:1 MIN., 3:1 PREFERRED TEMPERATURE GAUGE EXPANSION TANK HOT WATER SUPPLY PUMP...
  • Page 11 Indirect Plate Water Heater Installation & Service Manual Hydronic piping (continued) Figure 3-4 Water to Water Heat Exchanger Multiple Units BOILER WATER HOT WATER SUPPLY TEMPERATURE GAUGE DIR #2000577546 BOILER WATER OUT COLD WATER SUPPLY Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
  • Page 12 Indirect Plate Water Heater Installation & Service Manual Hydronic piping Figure 3-5 Water to Water Heat Exchanger Single Unit with Accumulator Tank RELIEF VALVE COLD WATER SUPPLY EXPANSION TANK ACCUMULATOR TANK BOILER WATER PUMP BOILER WATER BUILDING RETURN BALANCING VALVE FLOW INDICATOR TEMPERATURE GAUGE DIR #20005775360...
  • Page 13 Indirect Plate Water Heater Installation & Service Manual Hydronic piping (continued) Figure 3-6 Multiple Units with Boiler Side Buffer Tank as a Zone AUTOMATIC AIR VENT ZONE SUPPLY BUFFER TANK ZONE RETURN APW WATER HEATER ZONE PUMP DIR #2000577555 Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
  • Page 14 Indirect Plate Water Heater Installation & Service Manual Hydronic piping Figure 3-7 Multiple Units with Conventional Heating System as a Zone BOILER WATER IN HOT WATER SUPPLY BYPASS LINE BOILER WATER DIR #2000577549 COLD WATER SUPPLY Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.

  • Page 15: Adjustments

    Indirect Plate Water Heater Installation & Service Manual Adjustments Control valve calibration and status indications This section provides the adjustment procedures for the 3-way control valve (FIG. 4-1) and the APW electronic control system. The control valve actuators are self-calibrating for all valve sizes;...

  • Page 16: Manual Control Of 3-Way Valve

    Indirect Plate Water Heater Installation & Service Manual Adjustments Manual control of 3-way valve - removable handwheel 4. Set the control box POWER switch to the ON position to apply 24 VAC power to the control valve actuator (pins to hamper tampering 1 (G0) and 2 (G)).
  • Page 17 Indirect Plate Water Heater Installation & Service Manual Adjustments (continued) Ensure that the temperature controller is set to AUTO The control and the high limit are set at factory defaults. If (automatic) Mode and the AUTO indicator is lit. If the changes are required, the set point and high limit can be easily MAN indicator is lit, press the AUTO/MAN button to changed.

  • Page 18: Temperature Controller Operating Controls

    Indirect Plate Water Heater Installation & Service Manual Adjustments Table 4B Temperature Controller Operating Controls, Indicators and Displays CONTROL or INDICATOR MEANING FUNCTION Set Point SP for multiplier factory set at 0. Indicator Remote Set Illuminates when remote set point is active. Point Active Not used.

  • Page 19: Operating Information

    Indirect Plate Water Heater Installation & Service Manual Operating information Electronic control overview An electronic control system coupled with a control valve results in a highly responsive system which provides virtually The primary control mechanism for the electronic control constant hot water flow at the selected set point temperature. system is an electronic process controller which is installed in the control box.

  • Page 20: Wiring

    Indirect Plate Water Heater Installation & Service Manual Wiring Electrical wiring connections DO NOT route ModBus communication ⚠CAUTION wiring in the same conduit as power The control box and all other electronic control system wiring. Attempting to do so may result components are installed on the APW water heater prior to in excessive noise on the signal lines.

  • Page 21: Modbus

    Indirect Plate Water Heater Installation & Service Manual ModBus Installation Procedure Turn OFF the main electrical power to the appliance. Open the control box door by loosening the screws clamping the door closed. Connect wires to the control following the diagram in Figure 7-1.

  • Page 22: Modbus Eexception Codes

    Indirect Plate Water Heater Installation & Service Manual ModBus ModBus Exception Codes MODBUS Exception Codes Code Name Meaning The function code received in the query is not an allowable action for the server (or slave). This may be because the function code is only applicable to newer ILLEGAL FUNCTION devices, and was not implemented in the unit selected.

  • Page 23: Primary Data Tables

    Indirect Plate Water Heater Installation & Service Manual ModBus (continued) Primary Data Tables Table Data Type Read / Write Input Registers 16-Bit Word Read Only Holding Registers 16 Bit Word Read / Write Memory Map Input Registers Address Description Default Unit Min.

  • Page 24: Procedure To Change Modbus Address

    Indirect Plate Water Heater Installation & Service Manual ModBus Procedure to change ModBus address Troubleshooting Press and hold Page ( ) until "Access Go To Should you encounter problems communicating over Level 1" appears. ModBus, the following items should be checked in this order: Press the button twice to get to Level 3.

  • Page 25: Start-Up Introduction

    Indirect Plate Water Heater Installation & Service Manual Start-up Introduction Initial start-up In order to prevent a possible over-temperature condition This section provides the pre-optional checks, initial start-up during initial start-up, The manufacturer recommends that the and operating procedures for the APW water heater. following steps be performed in the order specified: 1.

  • Page 26: Checking Mixed Inlet Temperature

    Indirect Plate Water Heater Installation & Service Manual Start-up Checking mixed inlet temperature Shutting down the system To shut down the APW for a short period of time, simply turn If desired, the water heater mixed inlet temperature can be OFF power and close the isolation valves as described in Steps monitored using the controls and displays on the temperature 1 and 2 below.

  • Page 27: Maintenance Maintenance And Annual Startup

    Indirect Plate Water Heater Installation & Service Manual Maintenance Maintenance and annual startup The APW water heater requires regular routine maintenance to keep the unit operating at optimum efficiency. The manufacturer recommends that the tasks listed in Table 9A - Scheduled Maintenance Actions, be performed at the periodic intervals specified. Table 9A Scheduled Maintenance Actions Interval Maintenance...

  • Page 28: Periodic Cleaning Of Heat Exchanger

    Indirect Plate Water Heater Installation & Service Manual Maintenance Periodic cleaning of heat exchanger Check water heater relief valve For a detailed description of the following 1. Inspect the relief valve and lift the lever to verify flow. maintenance tasks, reference the CD provided with Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald the unit:...

  • Page 29: Troubleshooting

    Indirect Plate Water Heater Installation & Service Manual Troubleshooting Table 10A Troubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION - Check external line switch, fuse, or breaker. - Ensure On/Off switch is in the ON position. No 120 VAC supplied to the unit - Check 120 VAC through the On/Off switch.

  • Page 30: Checking Temperature Sensors

    Indirect Plate Water Heater Installation & Service Manual Troubleshooting Checking temperature sensors The temperature sensors (inlet and outlet water) are resistance type devices. The following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the sensor at a known temperature. If the resistance of the sensor does not closely match its corresponding table, replace the sensor.

  • Page 31: Sizing Data

    DOMESTIC WATER INLET- BOILER WATER INLET TEMP DOMESTIC BOILER APW MODEL FLOW (GPM) PRESSURE LOSS (PSI) MAX. FLOW (GPM) MAX. PRESSURE LOSS (PSI) OUTLET (°F) (°F) OUTLET TEMP (°F) APW015DW APW030DW APW050DW APW070DW APW090DW APW105DW APW120DW APW015DW 13.5 APW030DW APW050DW 31.5...
  • Page 32 Indirect Plate Water Heater Installation & Service Manual Sizing data Table 11B Sizing Chart _ 60 - 140 DOMESTIC WATER INLET‐ BOILER WATER INLET TEMP  DOMESTIC  BOILER APW MODEL FLOW (GPM) PRESSURE LOSS (PSI) MAX. FLOW (GPM) MAX. PRESSURE LOSS (PSI) OUTLET (°F) (°F) OUTLET TEMP (°F) APW015DW APW030DW 15.5 APW050DW APW070DW APW090DW APW105DW APW120DW APW015DW 12.5 APW030DW APW050DW APW070DW 44.5 APW090DW...
  • Page 33 Indirect Plate Water Heater Installation & Service Manual Sizing data (continued) Table 11C Sizing Chart _ 60 - 160 DOMESTIC  BOILER DOMESTIC WATER INLET‐ BOILER WATER INLET TEMP  APW MODEL FLOW (GPM) PRESSURE LOSS (PSI) MAX. FLOW (GPM) MAX. PRESSURE LOSS (PSI) OUTLET (°F) (°F) OUTLET TEMP (°F) APW015DW APW030DW APW050DW 21.5 APW070DW APW090DW APW105DW APW120DW APW015DW APW030DW 19.5 APW050DW 27.5 APW070DW APW090DW APW105DW...
  • Page 34 Indirect Plate Water Heater Installation & Service Manual Sizing data Table 11D Sizing Chart _ 60 - 180 DOMESTIC WATER INLET‐ BOILER WATER INLET TEMP  DOMESTIC  BOILER APW MODEL FLOW (GPM) PRESSURE LOSS (PSI) MAX. FLOW (GPM) MAX. PRESSURE LOSS (PSI) OUTLET (°F) (°F) OUTLET TEMP (°F) APW015DW APW030DW APW050DW APW070DW APW090DW APW105DW APW120DW 60.5 APW015DW APW030DW 23.5 APW050DW APW070DW APW090DW 51.5...
  • Page 35 Indirect Plate Water Heater Installation & Service Manual Sizing data (continued) Table 11E Sizing Chart _ 40 - 120 DOMESTIC  BOILER DOMESTIC WATER INLET‐ BOILER WATER INLET TEMP  APW MODEL OUTLET (°F) (°F) FLOW (GPM) PRESSURE LOSS (PSI) MAX. FLOW (GPM) OUTLET TEMP (°F) MAX. PRESSURE LOSS (PSI) APW015DW APW030DW APW050DW APW070DW 32.5 APW090DW 41.5 APW105DW APW120DW APW015DW APW030DW 19.5 APW050DW 27.5 APW070DW APW090DW...
  • Page 36 Indirect Plate Water Heater Installation & Service Manual Sizing data Table 11F Sizing Chart _ 40 - 140 DOMESTIC  BOILER DOMESTIC WATER INLET‐ BOILER WATER INLET TEMP  APW MODEL OUTLET (°F) (°F) FLOW (GPM) PRESSURE LOSS (PSI) MAX. FLOW (GPM) OUTLET TEMP (°F) MAX. PRESSURE LOSS (PSI) APW015DW APW030DW APW050DW 20.5 APW070DW 31.5 APW090DW APW105DW APW120DW APW015DW APW030DW 18.5 APW050DW APW070DW APW090DW...
  • Page 37 Indirect Plate Water Heater Installation & Service Manual Sizing data (continued) Table 11G Sizing Chart _ 40 - 160 DOMESTIC  BOILER DOMESTIC WATER INLET‐ BOILER WATER INLET TEMP  APW MODEL FLOW (GPM) PRESSURE LOSS (PSI) MAX. FLOW (GPM) MAX. PRESSURE LOSS (PSI) OUTLET (°F) (°F) OUTLET TEMP (°F) APW015DW APW030DW APW050DW APW070DW 30.5 APW090DW APW105DW APW120DW APW015DW 10.5 APW030DW APW050DW APW070DW 38.5 APW090DW 49.5...
  • Page 38 Indirect Plate Water Heater Installation & Service Manual Sizing data Table 11H Sizing Chart _ 40 - 180 DOMESTIC WATER INLET‐ BOILER WATER INLET TEMP  DOMESTIC  BOILER APW MODEL OUTLET (°F) (°F) FLOW (GPM) PRESSURE LOSS (PSI) MAX. FLOW (GPM) OUTLET TEMP (°F) MAX. PRESSURE LOSS (PSI) APW015DW APW030DW APW050DW 19.5 APW070DW APW090DW APW105DW APW120DW APW015DW 10.5 APW030DW 17.5 APW050DW 24.5 APW070DW...

  • Page 39: Diagrams

    Indirect Plate Water Heater Installation & Service Manual Diagrams Figure 12-1 Wiring Diagram - Electrical Control System Control Box...

  • Page 40: Replacement Parts List

    When ordering replacement parts: When ordering replacement parts always give the following information: Model, serial, and part number Kit number Parts description Replacement Parts List Item Parts Description Kit # Model 100346661 APW015DW-070DW Pump 100346658 APW090DW-120DW Control 100346659 APW015DW-120DW Sensor 100346657 APW015DW-120DW 100112873 APW015DW-050DW T &...
  • Page 41 Indirect Plate Water Heater Installation & Service Manual Notes...
  • Page 42 Indirect Plate Water Heater Installation & Service Manual Notes...
  • Page 43 Indirect Plate Water Heater Installation & Service Manual Notes...

  • Page 44: Revision Notes

    Revision Notes: Revision A (Process #3000045653_Change #500033372) initial release. Revision B (Process #3000047064_Change #500034483) made changes to the Replacement Parts List kit numbers for T & P Valve and High Limit. 100346577_2000604338_Rev B 09/21...

This manual is also suitable for:

100 seriesApw120dw

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