American Water Heater Power Flex 40-42K BTU, homeappliance

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Controller Gas Pressure Setting Error Codes In Use Indicator Indicates that hot water Ensure gas pressure check under Commissioning has been completed first! The regulator is electronically controlled and factory pre-set. Under normal circumstances it does not require 02 No burner operation during freeze protection mode • Service Call 16 Over Temperature Warning • Check for restrictions in air flow around unit and vent terminal. is being supplied. Temperature Display Indicates temperature Priority Indicator Indicates that this controller is setting the water temperature. adjustment during installation. Make adjustments only if the unit is 03 not operating correctly and all other possible causes for incorrect operation have been eliminated. 1. Turn OFF the gas supply. 2. Turn OFF the 120 V power supply. Power interruption during Bath fill (Water will not flow when power returns) • Turn off all hot water taps. Press ON/OFF twice. • Check for low water flow in a circulating system causing short cycling. • Check for foreign materials in combustion chamber and/or exhaust piping. • Check for clogged heat exchanger. setting or flashes error code. Thermostat Priority Button When no water is being supplied, pressing this button allows this controller to set the water temperature. ON/OFF Button 10 3. Remove the front panel from the appliance. 4. Check the gas type using the data plate on the side of the unit. If using a spare PC board, check that the gas type switches are in the correct position (dip switch 1 of SW2: ON for natural gas, NG, and OFF for propane, LPG). See dip switch settings section below. (ON is towards the right and OFF is towards the left.) 5. Attach the pressure gauge to the burner test point, located on the gas control (Fig. 2). Air Supply or Exhaust Blockage • Ensure approved venting materials are being used. • Check that nothing is blocking the flue inlet or exhaust. • Check all vent components for proper connections. • Ensure vent length is within limits. • Ensure condensation collar was installed correctly. • Verify dip switches are set properly. • Check fan for blockage. 32 Outgoing Water Temperature Sensor Fault • Check sensor wiring for damage. • Measure resistance of sensor. • Clean sensor of scale build up. • Replace sensor. 33 Heat Exchanger Outgoing Temperature Sensor Fault • Check sensor wiring for damage. Diagnostic Use of the Controller 1. To display error codes, press the ON/OFF button followed by the thermostat button to cycle through the error codes. 2. To display the water flow through the water heater, press the thermostat button (hold for 2 seconds) and then press the ON/OFF button while continuing to hold the thermostat button. 3. To display the outlet water temperature, press the thermostat button (hold for 2 seconds) and then press the ON/OFF button while continuing to hold the thermostat button. To Change the Temperature Scale (ºF / ºC) With the water heater turned off, press and hold the ON/OFF button until the display changes to the other temperature scale (about 5 seconds). To Turn Off the Controller Sound (Mute) 6. Turn ON the gas supply. 7. Turn ON the 120 V power supply. 8. If a controller is installed, turn the unit ON with the controller. Select the maximum delivery temperature and open all available hot water taps at full. 9. Set the unit to "Forced Low" combustion by setting No. 7 dip switch of the SW1 set to ON (Fig. 3). 10. Check the burner test point pressure. 11. Remove the rubber access plug and adjust the regulator screw on the modulating valve (Fig. 4) as required in Table 1. Replace the rubber access plug. 12. Set the unit to "Forced High" combustion by setting both No. 7 and No. 8 dip switches of the SW1 set to ON (Fig. 5). Ensure maximum water flow. 13. Check the burner test point pressure. 14. Adjust the high pressure potentiometer (POT) on the PC board as required to the pressure shown in Table 1. 15. Return the unit to normal operation by setting dip switches 7 11 No Ignition • Check that the gas is turned on at the water heater, gas meter, or cylinder. • Ensure gas type and pressure is correct. • Ensure gas line, meter, and/or regulator is sized properly. • Bleed all air from gas lines. • Verify dip switches are set properly. • Ensure appliance is properly grounded. • Disconnect EZConnect or MSA controls to isolate the problem. • Ensure igniter is operational. • Check igniter wiring harness for damage. • Check gas solenoid valves for open or short circuits. • Remove burner cover and ensure all burners are properly seated. • Remove burner plate and inspect burner surface for condensation or debris. • Measure resistance of sensor. • Clean sensor of scale build up. • Replace sensor. 34 Combustion Air Temperature Sensor Fault • Check for restrictions in air flow around unit and vent terminal. • Check sensor wiring for damage. • Measure resistance of sensor. • Clean sensor of scale build up. • Ensure fan blade is tight on motor shaft and is in good condition. • Replace sensor. 52 Modulating Solenoid Valve Signal Abnormal • Check modulating gas solenoid valve wiring harness for loose or damage terminals. • Measure resistance of valve coil. To turn the sound off (mute), press and hold both the and thermostat buttons until a "beep" is heard (about 5 seconds). Gas Pressure Setting NOTE: For additional installation and commissioning information refer to the Operation and Installation Manual. and 8 of the SW1 set back to OFF (Fig. 6). Close all water 12 taps. 16. Turn OFF the gas supply and 120 V power supply. 17. Remove the pressure gauge and install sealing screw. 18. Turn ON the gas supply and 120 V power supply. 19. Operate the unit and check for gas leaks at the test point. 20. Install the front panel. BURNER TEST POINT High Pressure Potentiometer Flame Failure • Check that the gas is turned on at the water heater and gas meter. Check for obstructions in the flue outlet. • Ensure gas line, meter, and/or regulator is sized properly. • Ensure gas type and pressure is correct. • Bleed all air from gas lines. • Ensure proper venting material was installed. • Ensure condensation collar was installed properly. • Ensure vent length is within limits. • Verify dip switches are set properly. • Ensure appliance is properly grounded. 61 Combustion Fan Failure • Ensure fan will turn freely. • Check wiring harness to motor for damaged and/or loose connections. • Measure resistance of motor winding. 65 Water Flow Servo Faulty (does not stop flow properly) If blank screen is present on remote control then the flow control has shorted out. Unplug flow control. If remote lights up and unit starts operating then replace flow control assembly. WARNING SW1 1 • Disconnect keypad. • Disconnect EZConnect or MSA controls to isolate the problem. • Check power supply for loose connections. 71 SV0, SV1, SV2, and SV3 Solenoid Valve Circuit Fault • Check wiring harness to all solenoids for damage and/or loose connections. This appliance must be installed, serviced and removed by a trained and qualified person. During pressure testing of the consumer piping, ensure gas valve is turned off before unit is shut off. Failure to do so may result in serious injury to yourself or damage to the unit. APPLIANCE OPERATING PRESSURES Table 1 Gas Inlet SW2 Spare Parts Only Fig. 1 Fig. 2 • Check power supply for proper voltage and voltage drops. • Ensure flame rod wire is connected. • Check flame rod for carbon build-up. • Disconnect and re-connect all wiring harnesses on unit and PC board. • Check all components for electrical short. • Measure resistance of each solenoid valve coil. 72 Flame Sensing Device Fault • Ensure flame rod is touching flame when unit fires. • Check all wiring to flame rod for damage. • Remove flame rod and check for carbon build-up; clean with sand paper. Water Inlet Max. Min./Max Forced Low Forced High • Check gas solenoid valves for open or short circuits. • Remove burner plate and inspect burner surface for • Check inside burner chamber for any foreign material blocking NAT.G LPG NAT.G LPG NAT.G LPG flame at flame rod. 305 5"W.C. 8"W.C. 2.9"W.C. 4.2"W.C. condensation or debris. • Measure micro amp output of sensor circuit with flame present. 150 PSI 0.56"W.C. 0.88"W.C. 505 Commissioning /10.5"W.C. /13.5"W.C. 3.3"W.C. 5.1"W.C. Regulator adjustment screw access plug Fig. 3 Fig. 4 14 Thermal Fuse • Check gas type of unit and ensure it matches gas type being LC used. • Replace flame rod. Scale Build-up in Heat Exchanger (when checking With all gas appliances in operation at maximum gas rate, the flowing inlet pressure at the incoming test point on the water heater should read 5" W.C. - 10.5" W.C. on natural gas and 8" W.C. - 13.5 W.C. on propane gas. If the pressure is lower, the gas supply is inadequate and the unit will not operate to specification. Check the gas meter regulator and pipework for correct operation/sizing and correct as required. Troubleshooting Important Safety Notes There are a number of (live) tests that are required when fault finding this product. Extreme care should be used at all times to avoid contact with energized components inside the water heater. Only trained and qualified service technicians should attempt to repair this product. Before checking for resistance readings, disconnect the power source to the unit and isolate the item from Fig. 5 Fig. 6 Heat Exchanger and Outgoing Water Temperature Thermistors: Check all thermistors by inserting meter leads into each end of the thermistor plug. Set your meter to the 20 K scale and read resistance. Applying heat to the thermistor bulb should decrease the resistance. Applying ice to the thermistor bulb should increase the resistance. See below for examples of typical temperatures and resistance readings. • Check for restrictions in air flow around unit and vent terminal. • Check for low water flow in a circulating system causing short cycling. • Ensure dip switches are set to the proper position. • Check for foreign materials in combustion chamber and/or exhaust piping. • Check heat exchanger for cracks and/or separations. • Check heat exchanger surface for hot spots which indicate blockage due to scale build up. Refer to instructions in manual for flushing heat exchanger. • Measure resistance of safety circuit. • Ensure high fire and low fire manifold pressure is correct. • Check for improper conversion of product. maintenance code history "00" is substituted for "LC") • Flush heat exchanger. Refer to instructions in manual. • Replace heat exchanger. No Code (Nothing happens when water flow is activated.) • Clean inlet water supply filter. • On new installations ensure hot and cold water lines are not reversed. • Check for bleed over. Isolate unit from building by turning off hot water line to building. Isolate the circulating system if present. Open your pressure relief valve; if unit fires, there is bleed over in your plumbing. • Ensure you have at least the minimum flow rate required to fire unit. • Ensure turbine spins freely. • Measure the resistance of the water flow control sensor. • Remote control does not light up but you have 12 VDC at the the circuit (unplug it). (SV1, SV2, SV3 and POV) Gas valve and Modulating solenoids: (Set meter above 2K) Wire color Voltage Resistance Connector # Pin #'s Example: 59°F = 11.4 ~ 14K 86°F = 6.4 ~ 7.8K 113°F = 3.6 ~ 4.5K 140°F = 2.2 ~ 2.7K 221°F = 0.6 ~ 0.8K terminals for controls. (Main) Pink - Black 11 ~ 13 VDC 36.8 ~ 44.8 ohms H5 6 - 7 Outgoing Water Thermistor: (SV1) Black - Yellow 11 ~ 13 VDC 36.8 ~ 44.8 ohms H6 5 - 6 (SV2) Black - Blue 11 ~ 13 VDC 36.8 ~ 44.8 ohms H7 4 - 6 (SV3) Black - Brown 11 ~ 13 VDC 36.8 ~ 44.8 ohms H8 3 - 6 (POV) Pink - Pink 2 ~ 15 VDC 67 ~ 81 ohms H3 9 - 10 (M) Water Flow Control Device Servo or Geared Motor: Red - Blue 11 ~ 13 VDC 22 ~ 28 ohms F7 9 - 10 Grey - Brown 4 ~ 6 VDC N / A F7 5 - 7 Grey - Yellow N / A N / A F7 5 - 8 NOTE: The grey wire listed above turns to black at F connector on the PCB. (QS) Water Flow Sensor: Black - Red 11 ~ 13 VDC 5.5 ~ 6.2 K ohms F2 1 - 3 Yellow - Black 4 ~ 7 VDC 1 ~ 1.4 Mega ohms F2 2 - 3 By-pass Flow Control (By-pass servo model ONLY): White - White N / A See example above F5 3 - 4 Heat Exchanger Temperature Thermistor: Pink - White N / A See example above F4 3 - 11 Intake Air Thermistor (Indoor model ONLY) Orange - White N / A See example above F3 3 - 12 Surge Protector: Black - White 108 ~ 132 VAC N / A D2 1 - 3 Blue - Brown 108 ~ 132 VAC N / A D1 1 - 3 With the power off you can check the continuity through the surge protector. Place a meter lead on the top pin #1 of the surge protector and pin #3 on the bottom of the surge protector. Check across the top pin #3 and bottom pin #1. If you read continuity BY-PASS SERVO MODEL ONLY BY-PASS FLOW CONTROL DEVICE FREEZE PROTECTION G OPTION R Wiring Diagram G1 BR O Y R W for 2-Unit Connection (Optional) COLOR CODING W :White BK:Black BR:Brown R :Red BL:Blue Y :Yellow P :Pink O :Orange Brown - White G1 1 - 5 Orange - White 2 ~ 6 VDC 15 ~ 35 ohms G1 2 - 5 across these two points then the surge protector is good. If you do not get continuity then replace the surge protector. WATER FLOW SENSOR F1 F2 R R 5 WY ORBR 1 G (CN7) G :Green GY:Gray Yellow - White (Unit in operating mode) G1 3 - 5 Red-White - Ground G1 4 - 5 Remote Controls: Y QS BK Y BK MAX MODULATING VALVE (IG) Ignition System: Grey - Grey 90 ~ 110 VAC N / A C1 1 - 2 Terminals B1 10 ~ 13 VDC 1.5 ~ 3.0 K ohms B 1 - 3 Frost Protection: INDOOR MODEL ONLY AIR TEMPERATURE F3 O RBK Y G F W RBK A MIN Dip SW1 1 O 2 CURRENT ADJUSTING (FM) Combustion Fan Motor: This unit has frost protection heaters mounted at different points to THERMISTOR W W 3 1 F 3 Red - Black 6 ~ 45 VDC N / A E1 1 - 2 White - Black 5 ~ 10 VDC 9.2 ~ 9.4 K ohms E1 2 - 4 O W F (CN9) 4 protect the water heater from freezing. The heaters located on the 13 1 5 6 Gas pressure F4 Yellow - Black 11 ~ 13 VDC 3.5 ~ 3.9 K ohms E1 2 - 3 hot water outlet line should have a resistance reading of 180-207 HEAT EXCHANGER THERMISTOR W P W BL BR WW (CN5) 7 8 Set your meter to the hertz scale. Reading across the white and black wires at terminals 2 and 4 you should read between 60 and 420 hertz. ohms through each of these heaters. The heater located on the P W Dip SW2 1 2 O 3 F 4 F 5 6 R Y heat exchanger piping should have a resistance reading of 156-180 Gas type F5 ohms and the one located in the water flow sensor valve should W OUTGOING WATER Spare Parts Only Thermal Fuse / Overheat Switch: Red - Red 11 ~ 13 VDC Below 1 ohms F6 F6 - H12 H1 Flame Rod: have a resistance reading 24-28 ohms. Amp Fuses: THERMISTOR F7 W W W E RBLBRYGY GY 4 1 BLR B1 H 12 1 B Place one lead of your meter to the flame rod and the other to ground. With the unit running you should read between 5-150 VAC. Set your This unit has one inline (3) amp glass fuses. Remove the fuse and check continuity through it. If you have continuity through the fuse then it is good. Otherwise the fuse is blown and must be replaced. WATER FLOW BRY RBKY E W 1 (CN12) W YBK R P (CN2) P Y BR Y (CN1) 1 3 BK BK REMOTE CONTROLLER meter to the ∝ amp scale and series your meter in line with the flame rod. You should read 1 ∝ amp or greater for proper flame circuit. In the event of low flame circuit remove the flame rod and check for CONTROL DEVICE FM COMBUSTION FAN R P BK BL C C1 SPARK ELECTRODE carbon or damage. THERMAL FUSES F6 R R R R GY GY (CN4) IG GY GY IGNITER GND The original PC boards on the water heaters do not have the bank of 6 dip switches. Only spare PC boards have this bank. 505 305 H2 H1 OVERHEAT SWITCH H3 MODULATING (CN3) D D3 PP 1 SOLENOID VALVE POV FROST SENSING BL Models 305 and 505 have a default maximum temperature SWITCH of 120°F (49°C) and an option to increase the maximum temperature to 140°F (60°C). Temperature settings from FLAME ROD Y H4 MAIN SOLENOID VALVE H5 SV0 BR 3 P BL BL (W) (W) D5 125-140°F (52-60°C) are available by setting dip switch 6 to ON in the SW1 bank of 8 dip switches. Adjust switches 2 and 3 in the bank of 8 depending on SOLENOID VALVE 1 SV1 BK H6 Y BK H7 SURGE PROTECTOR W W D2 BK ANTI-FROST HEATER BLBL D4 your altitude according to the table below. WARNING SOLENOID VALVE 2 SOLENOID VALVE 3 BL BK SV2 H8 BR BK SV3 BL BR G/Y D1 1 3 G/Y 3 1 W FUSE (3A) ANTI-FROST HEATER AC120V W BK GND GND HOT DO NOT adjust the other dip switches unless specifically instructed NEUTRAL to do so. Incorrect Dip Switch Settings can cause the water heater GROUND to operate in an unsafe condition and may damage the water heater and void the warranty. SW NOTES No. 505 2 High Altitude Off Level 0 0-2000ft Off Level 1 2001-5200ft On Level 2 5201-7700ft On Level 3 7701-10200ft 305 Outdoor 3 Off (0-610m) On (610-1585m) Off (1585-2347m) On (2347-3109m) 070 00012 39526 5 U287-1185 (02) EXPLODED VIEW - CABINET EXPLODED VIEW - INTERNALS 015 017 801 802 807 001 005 007 806 002 808 002 808 137 135 143 717 711 716 710 709 810 011 012 004 008 006 REMOTE CONTROLLER 013 014 016 003 114 118 116 119117 708 707 812 113 803110 138 103 718 132 706 125 EXPLODED VIEW - INTERNALS EXPLODED VIEW - ELECTRICAL 725729 100 721 818 727 403 815 804 814 409 805 408 404 101 813 805 413 401 713 724 723 726 722 730 810410 822 816411 702 700 807 819 821 102 712 817 701 703 814 Quantity 101 405 412 402 813 400 820 820 PARTS LIST 715 Quantity Quantity Number 001 002 003 004 005 006 007 008 011 012 013 014 015 016 017 100 101 102 103 103 110 110 113 114 116 117 118 119 125 132 135 137 138 Description Main Body (W) Wall Mounting Bracket (W) Rubber Bushing Connection Reinforcement Panel Heat Protection Plate Front Panel Front Panel Packing Front Panel Packing Side Screw Cover Screw Cover Lid Cable Access Assy Rubber Bushing Rain Hood Packing Screw Cover Assy Gas Control Assembly Test Port Set Screw Gas Connection (3/4" NPT) Burner Unit Assy (LPG) Burner Unit Assy (NG) Manifold Assembly (LPG) Manifold Assembly (W-NG) Pressure Point Sealing Screw Combustion Chamber Sightglass Plate Electrode Flame Rod Electrode Packing Electrode Holder Fan Assembly Combustion Chamber Fan Bracket Flue Outlet Flue Outlet Gasket Seal Packing Parts Number 701022-005 701022-007 701022-008 701022-009 701022-010 701022-012 701022-013 701022-014 701022-017 701022-018 701022-019 701022-021 701022-022 701022-023 701022-024 701022-025 701022-026 701022-027 701022-028 701022-029 701022-031 701022-033 701022-034 701022-035 701022-036 701022-037 701022-038 701022-039 701022-044 701022-047 701022-049 701022-052 701022-054 505 1 2 1 1 1 1 1 2 2 4 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 305 1 2 1 1 1 1 1 2 2 4 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Number 143 143 400 401 401 402 403 404 404 405 408 409 410 411 412 413 700 700 701 701 702 703 706 707 708 709 710 711 712 713 715 716 717 Description Heat Exchanger Assembly Heat Exchanger Assembly Water Inlet (3/4" NPT) Water Flow Servo & Sensor Assembly Water Flow Servo & Sensor Assembly Rectifier By-pass Servo Assembly Stop Bracket Stop Bracket Plug Band Hot Water Outlet (3/4" NPT) Stop Bracket Plug Band (small) Drain Valve Water Filter Assy Cover PCB PCB Surge Protector Surge Protector with terminal (optional) PCB cover - side PCB cover - front Ignitor High Tension Cord Electrode Sleeve Thermistor - Heat Exchanger Thermistor Clip Large Temperature Fuse Clip Frost Sensing Switch Anti Frost Heater (120V) Valve Heater (120V) Assembly Antifrost Heater Clip B Antifrost Heater Clip A Parts Number 701022-061 701022-062 701022-070 701022-071 701022-072 701022-073 701022-074 701022-075 701022-076 701022-077 701022-078 701022-079 701022-080 701022-081 701022-082 701022-083 701022-281 701022-280 701022-086 701022-087 701022-089 701022-090 701022-091 701022-092 701022-093 701022-094 701022-095 701022-096 701022-097 701022-099 701022-100 701022-102 701022-103 505 1 - 1 1 - 1 1 2 - 1 1 1 1 1 1 1 1 - 1 1 1 1 1 1 1 1 1 5 1 1 1 2 1 305 - 1 1 - 1 1 - - 1 1 1 1 1 1 1 1 - 1 1 1 1 1 1 1 1 1 1 5 1 1 1 2 1 Number 718 721 722 723 724 724 725 726 727 729 730 801 802 803 804 805 806 807 808 810 812 813 814 815 816 817 818 819 820 821 822 888 889 Description Antifrost Heater Clip C Fuse Harness (W) Power Harness Solenoid Valve Harness Sensor Harness Sensor Harness Thermal Fuse Harness Assy Ignitor Harness Flow Sensor Remote Controller Harness Thermistor Screw Resin Washer O-ring Thermistor Stop Screw Screw Screw Resin Washer Screw O-ring O-ring O-ring O-ring O-ring O-ring O-ring Packing Screw Screw Screw Screw Manual Tech Sheet Parts Number 701022-105 701022-109 701022-110 701022-111 701022-114 701022-115 701022-116 701022-117 701022-118 701022-119 701022-120 701022-122 701022-123 701022-124 701022-125 701022-126 701022-127 701022-128 701022-129 701022-130 701022-132 701022-133 701022-134 701022-135 701022-136 701022-137 701022-138 701022-139 701022-140 701022-141 701022-142 315898-000 315896-000 505 1 1 1 1 1 - 1 1 1 1 1 4 4 3 1 3 2 2 4 2 1 2 2 2 1 1 2 2 4 2 3 1 1 305 1 1 1 1 - 1 1 1 1 1 1 4 4 3 1 2 2 2 4 2 1 1 2 1 1 1 2 2 4 2 3 1 1