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A.O . SMITH SER VICE HANDBOOK T he first por tion of this Ser vice Handbook addresses service issues associated with Residential Gas W ater Heaters that are atmospherically vented and use a thermocouple as their electrical source. The second por tion of this Handbook addresses ser vice issues of Residential Electric W ater Heaters having one or two ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 1 TABLE OF CONTENTS Page Introduction Terms ......................................................... 1 Tools .......................................................... 2 Residential Gas Water Heaters Gui ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 2 Qualifications Tools Required: For servicing gas models: • Cross top screw driver • 3/8, 7/16, ¾ inch open end wrenches • 3/16 inch Allen wrench • 11/16 inch – 6 point – socket – for anod ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 3 GENERAL SECTION SERVICE GUIDELINES MISCELLANEOUS INFORMATION Draw ef ficiency is the quantity of hot water available to the consumer before the outlet water temperature decreases 25 degrees F. A 40 gall ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 4 General Section – continued % Thermal Efficiency = (GPH X 8.25 X Temp. Rise X 1.0) divided by BTU/H Input BTU Output = GPH X 8.25 X Temp. Rise X 1.0 GPH = (BTU/H Input X % Eff.) divided by (Temp. Rise ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 5 INSTALLATION OF RESIDENTIAL GAS WATER HEATER Exhaust Vent to Outside of Building Union See Manual and Labels For Installation Clearances Temperature And Pressure Relief Valve – Do Not Reuse Old Valve. ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 6 RESIDENTAL GAS WATER HEATER SERVICE This portion of this manual applies to the Operations and Servicing of Residential Gas, Tank Type, Water Heaters, which are vented atmos pherically and use a thermoco ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 7 Residential Gas – continued Burner: The burner assembly consists of the main bur ner, main burner orifice, main burner gas supply tube, pilot burner, pilot burner orifice, pilot burner gas supply tube ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 8 Residential Gas – continued Temperature: Two metal probes mounted onto the back of the control are immersed inside the tank water. One probe (the shorter) acts as a temperature high limit. If water ge ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 9 Residential Gas - continued Water Flow: When a hot water faucet is opened, water pressure from the well tank or street main forces cold water into the water heater. This pushes hot water out of the tank ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 10 Residential Gas - continued Service: Air: A gas burning appliance requires the oxygen contained in 12.5 cubic feet of ai r (at sea level) for every 1000 BTU of heat that is generated. If your water hea ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 11 Residential Gas – continued The instruction manual gives guidelines under “Air Requirements” and “Unconfined “ or “Confined Space” sections. If you want to test for a lack of air: 1. Turn ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 12 Residential Gas - continued Sooting causes : If … … then the burner is clean but the chamber and/or flue are sooted check for lack of supply air. the main burner, chamber and flue are sooted check ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 13 Residential Gas - continued Electrical Testing– continued Millivolt dropout test through copper magnet winding and ECO (Emergency Cut Off) Procedure : Move meter probe to upper ECO solder joint and g ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 14 Residential Gas – continued Condensation is a mild acid – it will corrode steel Condensation is usually noted when: • water dripping is heard (only) while the main burner is on, • there is “w ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 15 Residential Gas – continued Exhaust Venting Notes Follow current National Fuel Gas Code requirements for proper installa tion. “D” – Typically, same or larger diameter as Draft Hood outlet “L ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 16 STANDARD RESIDENTIAL ELECTRIC WATER HEATERS INSTALLATION SOME MODELS MAY HAVE SIDE OR REAR CONNECTIONS TO †FUSED ELECTRICAL SUPPLY (BREAKER BOX) COLD WATER INLET LINE SHUTOFF VALVE INSTALL THERMAL EX ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 17 STANDARD RESIDENTIAL ELECTRIC WATER HEATERS This portion of this manual applies to the Operation and Servicing of Residential Electric, Tank Type, Water Heaters. The illustrations are for two element m ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 18 STANDARD RESIDENTIAL ELECTRIC WATER HEATER SERVICE GUIDELINES Construction See “General Section” for features co mmon to both gas and electric models. Miscellaneous : Amperage (Amps) (1 phase) = Wa ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 19 Residential Electric – continued Since the element (s) are - very nearly - totally immersed in the tank, thermal efficiency is assumed to be 100%. – all of the Btu (Watts) generated, enter the wate ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 20 Residential Electric – continued Surface Mounted Thermostat (s) and High Limit (s) The thermostats and high limits are held against the side of the tank. As the tank sur face heats or cools, a metal ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 21 Residential Electric – continued After having confirmed that the water heater has been installed per the installatio n manual instructions: C-2 Circuit • Single element • Single thermostat • Si ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 22 Residential Electric – continued Normal Sequence of Operation C-2 Circuit – Standard on most single element water heaters. • Single Element • Single Thermostat • Single High Limit Operation f ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 23 Residential Electric – continued A-6 Circuit • 2 Elements • 2 Thermostats • 1 High Limit Operation: From cold tank of water A- 6 CIRCUIT Power Interrupted to Upper Elemen t Upper Thermostat, 1, ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 24 Residential Electric – continued WIRING DIAGRAM A-6 Circuit • 2 Elements • 2 Thermostats • 1 High Limit A-6 Circuit - Standard on dual element water heaters non-simultaneous/interlocked operati ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 25 Residential Electric – continued A-7 Circuit • 2 Elements • 2 Thermostats • 2 High Limits • 4 wire *Some electrical utilities give discounts if electri city is used during “Off Peak” time ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 26 Residential Electric – continued Cold tank of water • Single Electrical Service • Single Phase A-7 Circuit Prior to 1996 Fused Disconnect Power Enters Terminal 1 Of Upper High Limit And Terminal ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 27 Residential Electric – continued A-7 Circuit • 2 Elements • 2 Thermostats • 2 High Limits • 4 Wire WIRING DIAGRAM A-7 – Post 1995 Four wire circuit for non-simultaneous element operation. T ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 28 Residential Electric – continued Cold tank of water • Single Electrical Service • Single Phase A-7 Circuit Post 1995 Fused Disconnect Power to Upper High Limit 1, and Upper Thermostat 3 Upper Hig ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 29 Residential Electric – continued CERTIFICATION AND APPROVALS UL – UL-174 applies to Residential Electric Water Heaters The following paragraph describes the relationship between ASHRAE, NAECA and t ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 30 Residential Electric – continued Three Phase – Unbalanced Circuit Note: Residential heaters may or may not offer the ability to wire elements for simultaneous operation. If they are wired for non-s ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 31 Residential Electric – continued SERVICE Testing C-2 type – single element, single controls type circuit Element Test OHMS Resistance Check ** Test Conditions: This test uses the multimeter's ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 32 Residential Electric – continued C-2 – service continued Complaint: No Hot Water Conditions: Tank water cold Power on Procedure: Multimeter set for AC voltage check Voltage Checks Test voltage betw ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 33 Residential Electric – continued C-2 service “No Hot Water” – continued Test between the two element terminals If … … then rated voltage is not present check wiring from control. rated volt ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 34 Residential Electric – continued C-2 – service “Water Too Hot” – continued Grounded Element Check – Amperage Method Grounded Element Test – using “clamp type” Amperage Meter. Many mul ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 35 Residential Electric – continued A-6 Circuit Servicing Testing A-6 - two element, two thermostat, one high lim it, two wire circuit type water heaters. Wired non-simultaneously – When the upper ele ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 36 Residential Electric – continued A-6 service – continued Testing with the Multimeter Probes installed to test for "voltage - (black test lead is “common".) Dial set to AC - Voltage scal ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 37 Residential Electric – continued A-6 service Voltage Check “No Hot Water” – continued Test between Thermostat 2 and High Limit 4 or T2 and L4 If … … then supply voltage is present: continue ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 38 Residential Electric – continued A-6 service – continued Grounded Element Test – Amperage Method - using “clamp type” Amperage Meter. Many multimeters could be used to co nduct this test but ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 39 Residential Electric – continued Testing The A-7 Wiring Circuit A-7 Circuit: Two elements Two thermostats Two high limits Four wires Non-simultaneous operation or simultaneous Supply wiring may be a: ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 40 Residential Electric – continued A-7 Service – continued Element Test OHMS Resistance Check ** Test Conditions: Element(s) not heating or water becoming excessively hot. This test uses the multimet ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 41 Residential Electric – continued A-7 Voltage Check Voltage Checks These tests are conducted on the heater, below the junction box. Complaint: No Hot Water Test Conditions: Tank is full of cold water ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 42 Residential Electric – continued A-7 Voltage Check - continued Complaint: Lack of Hot Water Test Conditions: Upper thermostat satisfied Test between upper high limit 4 and upper thermostat 4 If … ? ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 43 Residential Electric – continued A-7 service – Voltage Checks “Lack of Hot Water” – continued Test Condition Lower tank water is at least 15 ° F below lower thermostat setting Test between l ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 44 Residential Electric – continued A-7 – continued Grounded Element Test – Amperage Met hod – Using “clamp type” Amperage Meter. Many multimeters could be used to conduct this test but be cer ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 45 Miscellaneous Residential Electric Water Heater Service Items: • Watts divided by Volts = Amps Supply wire gauge and fuse (breaker) protection must be at least 12 5% of the expected Amperage draw of ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 46 A.O. SMITH TECHNICAL BULLETINS The following are bulletins designed to hel p service the standard, residential gas and electric model water heaters. These bulletins and more are available on the A. O. ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 47 WHY WATER HEATER TANKS LEAK WHAT WHY PREVENTION Water Pressure Water expands when it is heated (Thermal Expansion). Water cannot be compressed. Excessive Pressure in the tank causes failure of joints, ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 48 WHY WATER HEATER TANKS LE AK - Continued WATER CONDITIONS WHAT WHY PREVENTION “Hard” Water (Gas Water Heaters) “Hard” water contains minerals. As water is heated the minerals separate from the ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 49 TECHNICAL BULLETIN BULLETIN 11 WATER HAMMER GENERAL Water hammer is the destructive forces , poundi ng noises and vibration in a piping system when water flowing through a pi peline is stopped abruptly ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 50 TECHNICAL BULLETIN BULLETIN 13 MINERAL BUILD-UP SYMPTOMS • Rumbling • Crackling • Popping CAUSE With the advent of high input and larger storage tanks in both commercial an d residential heaters, ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 51 TECHNICAL BULLETIN BULLETIN 14 ALUMINUM HYDROXIDE SYMPTOMS “Crackling”, “gurgling”, or “poppi ng” noises from new water heaters (installed less than six months). CAUSE In a few isolated par ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 52 TECHNICAL BULLETIN BULLETIN 21 DISCOLORED WATER SYMPTOMS Rusty, brown, black, or yellow wa ter appearing in the hot water. CAUSE Complaints of discolored water are commonly blame d on water heaters and ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 53 TECHNICAL BULLETIN BULLETIN 22 SMELLY WATER CAUSE The most common cause of “smelly wa ter” is a non-toxic sulfate redu cing bacteria, scientifically termed Divibrio Sulfurcan s . This bacteria ofte ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 54 TECHNICAL BULLETIN BULLETIN 23 CHLORINATION PROCEDURE CAUSE The chlorination pro cedure is used to eliminate various bacteria that accumulate and grow in water heaters. These bacteria often cause odoro ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 55 TECHNICAL BULLETIN BULLETIN 35 NOT ENOUGH HOT WATER - GAS CAUSE Not enough hot water complaints a re becoming more frequent in the water heater industry. This increase was trigge red when changes requi ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 56 TECHNICAL BULLETIN BULLETIN 36 NOT ENOUGH HOT WATER - ELECTRIC CAUSE Not enough hot water complaints a re becoming more frequent in the water heater industry. This increase was trigge red when changes ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 57 TECHNICAL BULLETIN BULLETIN 45 THERMAL EXPANSION SYMPTOMS • Effects are o nly noticeable after hot wate r use followed by periods of no water use. • Relief valve d rips during any recovery cycle wh ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 58 THE FIX The ideal fix involves the use of a pressu re reducing valve if supply pressures are above 60 to 70 psi, and a properly sized expansion tank. The PRV reduces sup ply pressures to 40 to 60 psi a ...
RESIDENTIAL GAS AND ELECTRIC WATER HEAT ER SERVICE HANDBOOK A.O. Smith Water Products Company Training Department © 2002 Ashland City, Tennessee 59 TECHNICAL BULLETIN BULLETIN 52 LEAKING TEMPERATURE AND PRESSURE RELIEF VALVE SYMPTOMS • Wate r seeping around the relief valve tank connection • Lea kage at the threaded porti on of the relief valv ...
Handbook contents prepared by the T raining Department, Ashland City, Tennessee For additional information, contact A.O. Smith T echnical Information Department 1-800-527-1953 Website: www .hotwater .com For every technical pr oblem, ther e is a solution! A.O. Smith W ater Products Company proudly introduces our service handbooks and product traini ...
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