A. O. Smith ATM5063V151, 910 ASME Service Manual

BL:BLUE

031:

Incorrect d

ipswitch setting

Maaiinntteennaannccee sshheeeett

Wiring Diag

ram and check point of th

Water heater

The

lower

bank

has settings for

391: Air

fuel Ratio Rod failure

The

upper

bank

has certain

Change the

dipswitch

settings when the power supply is turning off.

Single unit is the same as the child unit.

Temperature set

Upper

bank

Lower

bank

The Gas Type dipswitch

Easy-Link system

A B

D1 D2 E1

L G M

A A2

L L

I A B

E1 E2

E3 C1

C1 C2

Installation

type

MC50 Computer board

AATTMM5500

6633VV11551

A. Troubleshooting

If the error code is indicated on the 7-Seg-LED on the PCB (Part #702) of the water heater (and/or the remote controller), refer to Section B.

<< It takes long time to get hot water at the fixtures >>

・ The time it takes to deliver hot water from the water heater to your fixtures depends on

the length of piping between the two. The longer the distance or the bigger the pipes, the longer it will take to get hot water.

・ If you would like to receive hot water to your fixtures quicker, you may want to consider a

hot water recirculation system.

<< The water is not hot enough or turns cold and stays cold >>

・ Compare the flow and temperature. Refer to the “Output temperature chart” of the

installation manual.

・ Check cross plumbing between cold water lines and hot water lines. ・ Check if the gas supply valve fully open, the gas line sized properly and the gas supplies

pressure enough. Refer to the “Gas supply and gas pipe sizing” of the installation manual.

・ Check the set temperature, and change the dipswitch setting. Refer to Section D. ・ Refer to “Water circuit” in this section.

<<The water is too hot>>

・ Check the set temperature, lower setting temperature.

<<The hot water is not available when a fixture is opened>>

・ Refer to the “Power supply circuit” and “Water circuit” in this section.

<<Fluctuation in hot water temperature>>

・ Check if the filter on the cold water inlet cleaned. (Part #437) ・ Check if the gas line sized properly and the supply gas pressure sufficient. ・ Check for cross connection between cold water lines and hot water lines. ・ Refer to “Water circuit” in this section.

<<Unit does not ignite when water goes through the water heater>>

・ Refer to the “Power supply circuit” and “Water circuit” in this section. ・ If you use the remote controller, turn the power button on and then the green LED will

light up.

・ Check if the filter on the cold water inlet cleaned. (Part #437) ・ Refer to “Water circuit” in this section.

B. Error codes

・ Check the dipswitch settings on the PCB. Refer to Section D.

101: Warning for the “991” error code

・ Check the gas type of the water heater. If it’s wrong gas type model, replace the water

heater to correct one.

・ Check if there is any blockage (For example, Damper sticking, Vent Flaps installed on the

terminator, Snow build up around terminator, Installed in a closet (No ventilation or lack of combustion air)) in the intake air and/or exhaust. Refer to the “Vent termination clearances” of the installation manual.

・ If the water heater is installed as a direct-vent system, check whether there is enough

distance between the intake air terminal and the exhaust terminal. Refer to the “Vent termination clearances” of the installation manual.

・ Check if the total vent length doesn’t exceed 50 ft and the # of elbows is less than 5Ea. ・ Check the altitude/elevation of area of where the water heater installed. ・ Check if there is grease and/or dirt in the burner (Part #101) and the fan motor (Part

#416), especially if the water heater has been installed in a contaminated area.

・ Check if there is dust and lint in heat exchanger. ・ Check the manifold pressure of the water heater. Refer to installation manual.

111: Ignition failure

1. Check gas supply and inlet gas pressure.

2. Check if the Hi-limit switch (Part #403) is properly functioning.

3. Check for connection/breakage of wires (Part #111, 402, 705, 707), burn marks on the

computer board (Part #701), and/or soot on the flame rod (Part #103). And then if O.H.C.F (Part #402) is breakage, Consult the manu facturer.

4. Check if there is a buzzing spark ignition sound coming from the burner (Part #101) when

water heater prepares for combustion.

5. Listen for the double “clunk” sound coming from the gas valve assembly (Part #114)

when water heater goes into combustion.

6. (Only no sparking a nd/or kick sound) Check voltage on each wire to gas valves assembly

(Part #114) and/or the igniter (Part #102). Refer to the “Appendix A” in Section C.

*No sparking sound >>>>> Refer to the #1 at “Appendix A” in Section C. *No kick sound >>>>> Refer to the #2 at “Appendix A” in Section C.

7. Check if there is leaking from heat exchanger (Part #401 or 444).

8. Check if there is dust and lint in nozzles of the manifold (Part #114).

9. Check current on the flame rod (Part #103). Refer to the #3 at “Appendix A” in Section C.

121: Loss of flame

1. Check gas supply and inlet gas pressure.

2. Check if the Hi-limit switch (Part #403) is properly functioning.

3. Check for connection/breakage of wires (Part #111, 402, 705, 707), burn marks on the

computer board (Part #701), and/or soot on the flame rod (Part #103). And then if O.H.C.F (Part #402) is breakage, Consult the manu facturer.

4. Check if there is leakage from heat exchanger (Part #401 or 444).

5. Check if there is dust and lint in nozzles of the manifold (Part #114).

6. Check current on the flame rod (Part #103). Refer to the #3 at “Appendix A” in Section C.

311,321,331: Disconnected/short-circuited thermistor

・

Check for conne ction/breakage of wires and/or debris on t hermistor (Part #405, 424, 430, 704).

・ Check thermistor resistance. Refer to the “Appendix D” in Section C.

<<The fan motor still spinning after operation has stopped>>

・ This is normal. After operation has stopped, the fan motor keeps running from 35

seconds in order to re-ignite quickly, as well as purge all the exhaust gas out of the flue.

<<Abnormal sound from water heater>>

・ An abnormal sound from the water heaters is caused by not enough air supply or wrong

installations. The water heater needs more combustion air. Refer to the “101” error code in the section B.

<<Power supply circuit>>

1. If the remote controller installed, press the “ON/OFF” button of the remote controller,

and make sure that the green LED on the “ON/O FF” button of the remote controller is lit. Restart the water heater.

2. Check if that the 7-Seg LED on the PCB (Part #702) of the water heater is lit. If so, the

power supply circuit of the water heater is under normal condition. Next, refer to the “Water circuit” in this section.

3. Check the fuse on the surge box (Part #722), and if it has a brown spot, need to replace it.

4. Check the power supply, and make sure that the water heater has 120 VAC.

5. If the 7-Seg LED on the PCB (Part #702) isn’t lit, some electrical parts can be broken.

Consult the manufacturer.

<<Water circuit>>

1. If you set the remote controller, turn the power button on and then the green LED will

light up.

2. Open all hot water faucets, and make sure that there is enough water flow. This water

heater needs at least 0.5 GPM water flow to operate.

3. Check for reverse connection and cross connection.

4. Check if the filter on the cold water inlet cleaned. (Part #437)

5. Check if there is no debris or obstruction on the fixtures.

6. Check if water ways in the water heater are frozen. If so, unfreeze them. And refer to

installation manual to protect your water heater from freeze.

7. Check if the inlet water pressure is higher than 40 psi. And if it’s lower than 40 psi, need

to increase the pressure.

8. Check for connections and breakage of wires (Part #418, 421).

9. Check if the motor drive of the water control valve (Part #418) is locked due to scale

buildup, and/or water leakage. Consult the manufacturer.

・

Check for connection /breakage of wires (Part #705) and/or soot on the AFR rod. (Part #103)

441: Flow Sensor failure (Only Easy-Link system)

・ Check for connection/breakage of wires and/or debris on the flow sensor impeller (Part

#421).

510,551: Abnormal Main and Gas Solenoid Valve

・ Check for connection/breakage of wires (Part #707) and/or burn marks on the computer

board (Part #701).

・ Reset power supply of the water heater. ・ Check voltage on the each valve on the gas valves assembly (Part #114). Refer to the

“Appendix C” in Section C.

611: Fan motor fault

・ Check for connection/breakage of wires, dust buildup in the fan motor (Part #416) and/or

burn marks on the computer board (Part #701).

・ Check for frozen/corrosion of connectors of the fan motor (Part #416). ・ Check voltage between blue wire and each wire of the fan motor (Part #416), and check

resistance between white wire and red wire. Refer to the “Appendix B” in Section C.

631: External pump failure

・ Check whether the pump connected to MC50 PCB works properly.

651,661: Water control valve fault (Only Easy-Link system)

・ Check the water control valve (Part #418), connection/breakage of wires (Part #418),

motor drive locked due to scale buildup, and/or water leakage.

・ Check voltage between black wire and red wire. Refer to the “Appendix F” i n Section C.

681: External fan motor failure

・ Check whether the external fan motor connected to MC50 PCB works properly.

701: Computer board fault

・ Check for connection/breakage of wires (Part #707) and/or burn marks on the computer

board (Part #701).

721: False flame detection

1. Clean the flame rod (Part #103).

2. For indoor models, check if condensate drain is installed on the vent collar of the water heater.

3. Check if there is leaking from heat exchanger (Part #401 or 444).

741: Miscommunication between water heater and remote controller

1. Check the model type of the remote controller. Model No. 9007603005 is the correct one.

2. Inspect the connections between the water heater and remote controller. Refer to the

“Remote controller connections” of the Installation manual.

3. Check the power supply of the water heater.

4. If this error code appears only the 7-Seg LED on the PCB (Part #702), check the voltage on

the remote controller terminal on the PCB. Refer to the “Appendix E” in Section C.

5. If this error code appears only remote controller, replace the PCB (Part #702).

6. If this error code appears both the PCB (Part #702) and the remote controller, replace t he

remote controller.

761:

Miscommunication between Parent unit and Child units for Easy-link system

・ Check if the connections between the parent unit and the child units are correct. Refer to

“Easy-Link system” section in the Installation manual.

991: Imperfect combustion

・ Refer to the “101” error code in this section.

Rig ht si de unit

Burning lamp

Mixing thermistor

Inlet thermistor

Output thermistor

SV3

SV2

SV1

O.H.C.F

Hilimi t

Ground

W W

G;GREEN

Y:YELLOW

Water Control valve

BL BL BL

GFI

Surge box

10A

AC120V

Parent

Remo te cont roller

BK:BLACK

P:PURPLE

Lef t sid e u nit

Water Control valve

Mixing thermistor

Inlet thermistor

Output thermistor

SV3

SV2

SV1

BL BL BL

Ground

Draft switch

Priority SW

Button to check unit number

Error call button

Pump test run

Ground

7 Seg LED

OFF

Burning lamp

O.H.C.F

Hilimit

Appendix A (For error code 111)

Check these points during ignition stage.

# 1. Refer to check point “B” on the wiring diagram above.

12345 6

BK BK BK

Dipswitches

MAX button

MIN button Increase button

Decrease button

Alarm contact

Dipswitches

234 56

OFF

234 56

OFF

LB:LIGHT BLUE

Porpor-

Flow

tional

Sensor

Valve

Air-fuel ratio rod

Flame rod

Elect rod

Pump port

FM port

Communication lamp (right)

778

Communication lamp (left) Multi-system

on line lamp

Dipswitches

BKWR

BK R

Ground

Check voltage between purple wires.

(Normal: AC 90 to 110 V)

This Check point is normal? Yes >> Replace the igniter (Part #102) No >> Go to Next

O:ORANGE

BR:BROWN

Porpor-

Flow

tional

Sensor

Valve

Air-fuel ratio rod

Flame rod

Elect rod

BK BK

Thermostat

BKWR

BK R

Ground

Heater

OFF

12345 6

Dipswitches

MAX button

MIN button Increase button

Decrease button

BK BK BK

PPPPPPPP

Tra nsfor mer

Appendix B (For error code 611)

Refer to check point “G” in the diagram to the left and followings.

・ Check voltage between red wire and blue wire.

(Normal: DC 110 to 160 V)

・ Check voltage between yellow wire and blue wire.

(Normal: DC 13 to 17 V)

・ Check voltage between orange wire and blue wire

(Normal: DC 2.0 to 6.5 V)

All check points are normal? Yes >> Replace the fan motor. (Part #416) No >> Replace the PCB. (Part #701)

Appendix C (For error code 510 and 551)

Refer to check point “C” in the diagram to the left and followings.

Check voltage on the each valve on the gas valves assembly.

・

Between blue wire and light blue wire (#3). (Normal: DC 78 to 100 V)

・ Between blue wire and green wire. (#9). (Normal: DC 78 to 100 V) ・ Between blue wire and orange wire (#53). (Normal: DC 78 to 100 V) ・ Between blue wire and red wire (#73). (Normal: DC 78 to 100 V)

All check points are normal?

r e t a e H

Yes >> Replace the gas valves assembly. (Part #114) No >> Replace the PCB. (Part #701)

Appendix D (For error code 311, 321 and 331)

・ Mixing thermistor (Find the marking of No.113 on the connector)

Check point “E1”

・ Output thermistor (Find the marking of No.12 on the connector)

Check point “E2”

・ Inlet thermistor (Find the marking of No.42 on the connector)

Check point “E3”

Check resistance between black wire and black wire.

Temperature

Resistance kΩ 15.4 12.6 10.3 8.5 7.0 5.9

All check points are normal?

°F 50 59 68 77 86 95

°C 10 15 20 25 30 35

Yes >> Replace the PCB. (Part #701) No >> Replace the wrong thermistor. (Part #405, 424, 430)

# 2. Refer to check point “C” and “H1” on the wiring diagram above.

Check the voltage bellows.

C: Between blue wire and light blue wire (#3).

(Normal: DC78 to 100 V)

C: Between blue wire and orange wire (#53).

(Normal: DC78 to 100 V)

H1: Check the voltage between white wire and red wire.

(Normal: DC 1 to 15 V)

These check points are normal? Yes >> Replace the gas valves assembly. (Part #114) No >> Replace the PCB. (Part #701)

# 3. Check current thought the orange flame rod wire (Part #705).

(Normal: more than 1μA)

This check point is normal during operation? Yes >> Replace the PCB. (Part #701) No >> Replace the flame rod. (Part #103)

Appendix E (For error code 741)

Refer to check point “F” on the wiring diagram above. Check voltage on the remote controller terminal on the PCB. (Normal: DC 11 to 15 V)

This check point is normal? Yes >> Replace the remote controller. No >> Replace the PCB. (Part #702)

Appendix F (For error code 651 and 661)

Refer to check point “J” on the wiring diagram above. Check voltage between black wire and red wire. (Normal: DC 13 to 16 V)

This check point is normal? Yes >> Replace the Water control valve. (Part #418) No >> Replace the PCB. (Part #701)

D. Dipswitch Settings on the computer board of the water heater

The dark square is the direction the dipswitch should be set to. DEFAULT is the factory setting.

special functions and generally

should not need adjustment.

Gas type

1234567

Propa ne

Natu ral Ga s

OFF

1234567

OFF

should already be properly preset from the factory.

three functions, shown below.

Pa r ent U n it

Ch i ld U n it

DE FA UL T

In doo r

DE FA UL T

Dir ect ve nt

Out door

1234567

OFF

1234567

OFF

1234567

104 F

(40 C)

120 F

(49 C)

DEF AU LT

145 F

(63 C)

165 F

(74 C)

1234567

OFF

1234567

OFF

1234567

OFF

1234567

OFF

115 F

(46 C)

135 F

(57 C)

155 F

(68 C)

185 F

(85 C)

1234567

OFF

1234567

OFF

1234567

OFF

1234567

OFF

E. Components Diagram / Parts List

910 ASME

Case assembly

Burner assembly

114

115

705

116

113

117

707

102

705

113

117

121

123

126

125

718

108

103

109

112

707

118

119

121

114

115

116

707

102

123

124

113

107

104

106

111

110

105

113

107

108

103

104

106

109

707

111

112

707

Item# Part# Description

118

119

120

122

Item# Part# Description

001

319143-265

002

319143-012 003 004 005 006 007 008 009 010 011 012 013

319143-325

319143-026

319143-237

319143-277

319143-014

319143-230

319143-334

319143-236

319143-262

319143-246

319143-025

Screw M4x10 (W/Washer)

Power supply code assembly

Chamber fixing plate

Screw M4x12 (W/Washer)

Item# Part# Description

101

319143-308

102

319143-052

103

319143-035

104

319143-037

105

319143-192

106

319143-038

107

319143-033

108

319143-034

109

319143-036

110

319143-032

111

319143-039

112

319143-059

113

319143-060

114

319143-263

113

126 127 128 129 130 131 132 133 134 135 136 137 138 139 140

101

110

105

113

319143-090 319143-261 319143-276 319143-206 319143-238 319143-239 319143-249 319143-275 319143-260 319143-258 319143-240 319143-060 319143-147 319143-330 319143-252

115 116 117 118 119 120 121 122 123 124 125

101

113

319143-264

319143-044 319143-045 319143-051 319143-337 319143-062 319143-057 319143-257 319143-253 319143-350 319143-250 319143-063

Pan screw M4x6 (W/Washer)

Exhaust connector

Exhaust combining box

Silicon ring Exhaust gasket A Exhaust gasket B

Case beam

Exhaust auxiliary plate

Duct

Duct cover

Duct gasket

Screw M4x10

Fan damper Screw M3x6

Freeze protection thermostat

Case assembly

Brackets

crew M4x10 (Coated)

Back guard panel

Junction box

Rubber bush

Exhaust fixing plate

Front cover for 910

Air blockage plate

Burner assembly

Igniter

Flame rod

Igniter rod

Damper Rod cap

Burner window

Burner holder gasket

Rod holder

Burner holder gasket

High voltage ignite cable

Pan screw M4

Screw M4x10

Manifold assembly with

gas valve assembly LP

Manifold assembly with

gas valve assembly NA

Manifold gasket A Manifold gasket B

Igniter plate

Gas connection plate

Pan screw M4x10

O-ring P20 NBR (Black)

Gas pipe left

Gas pipe right

O-ring P18 NBR (Black)

Gas inlet

Hex head screw M4x8

Computer board assembly

426

411

418

419

411

419

420

422

421

419

411

424

406

407

419

435

411

427

419

411

419

449

419

407

448

427

406

430

440

411425

441

442

443

436

113

437

438

425

Item# Part# Description

701 702 703 704 705 706 707 708 709 710 711 712 713 714 715

319143-266 319143-267 319143-232 319143-233 319143-243 319143-231 319143-248 319143-245 319143-183 319143-274 319143-247 319143-234 319143-235 319143-244 319143-048

910 PCB MC50 PCB PV-FS wire

Thermistor connecting wire

Flame rod wire

Igniter wire

Gas valve wire

AC 100V wire

910 PCB cover

MC50 PCB cover

Multi com munication wire

Left communication wire

Right communication wire

Remote controller terminal

Wire Cramp

701

719

710

715

418 703

704

416705

708

701

707 70 6

708

709

715

418 703

704

416705

709

707 70 6

708

Item# Part# Description

716 717 718 719 720

319143-241 319143-242 319143-127 319143-343 319143-227

Left PCB fixing plate

Right PCB fixing plate

Transformer

Screw M4x12

Ground fault circuit

interrupter 721 722 723

319143-331 319143-284 319143-215

Screw M3x12

Surge box

Surge connecting wire

910 ASME

427

419

411

425

422

439

411

434

411

433

702

113

712

713

711

714

113

719

113

720

411

419

721 714

418

419

411

420

421

411

419

425

451

411

429

430

407

406

424

429

Combustion and Exhaust assembly

T-M50 ASME

444

446

447

113

113 113 7 16

711

717

723

722



113

418

411

419

411

419

411

422

419

411

426

427

419

425

450

406

424

406

407

419

Water way assembly

136

135

445446

137

402

403

401

404

406

405

407

408

409

411

410

113

412

413

414

415

113

411

420

421

419

407

423

427

430

442

435

436

437

438

426

419

428

427

425

406

440

411425

441

443

434

113

425

433

Item# Part# Description

401

319143-268

427

402 403 404 405

319143-149 319143-095 319143-087 319143-096

910

419

411

422

439

411

407

430

411

418

419

411

419

411

425

429

431

406

419

432

411

420

421

411

407

425

429

Heat exchanger assembly

for 910

Overheat cut-off-fuse

Hi-Limit switch

Screw M3X6

Output thermistor

426

427

419

406

Item# Part# Description

406

319143-097

407

319143-082

408

319143-224

409

424

319143-088

Fastener “14-11”

Heater fixing plate

O-ring P4 FKM

Pipe heater 122

Item# Part# Description

411

129

127

130

132

133

417

139

138

128

131

133

134

402

403

401

404

406

405

407

408

409

411

410

113

412

416

413

415

417

414

139

113

137

113

416

138

319143-083

412

319143-061

413

319143-229

414

319143-042

415

319143-344

416

319143-043

417

319143-066

418

319143-086

419

319143-077

420

319143-091

421

319143-092

422

319143-251

423

319143-254

424

319143-085

425

319143-333

426

319143-068

427

319143-125

428

319143-273

429

319143-124

430

319143-190

431

319143-256

432

319143-255

433

319143-076

434

319143-259

435

319143-070

436

319143-071

437

319143-072

438

319143-073

439

319143-269

440

319143-328

441

319143-223

442

319143-199

443

319143-080

444

319143-270

445 446 447 448 449 450

319143-271 319143-349 319143-278 319143-310 319143-313 319143-312

451 319143-311 Right cold pipe for 9 10 A SME

O-ring P16 FKM

Pan screw M4x12 (W/Was her

Fan motor fixing plate

Pressure port

Urethane tube

Fan motor Fuse fixing plate 18 Water control valve

Fastener “16AG”

O-ring P15 FKM

Flow sensor

Connecting pipe

Left cold pipe for 910

Inlet thermistor

Heater 502 Heater 101

Heater fixing plate 16

Left hot pipe for 910

Heater fixing plate 20

Mixing thermistor

Right hot pipe for 910

Right cold pipe for 910

Heater plate

Water inlet

Filter plug

O-ring P25 FKM

Water inlet filter

O-ring JASO #1021 FKM

Water outlet

Screw M4x6 Heater 117

Outlet drain plug

O-ring P6 FKM

Heat exchanger assembly

for 910 ASME

Connecting pipe for 910AS ME

O-ring P18 FKM

Connecting pipe for 910 AS ME

Left cold pipe for 91 0 AS ME

Left hot pipe for 910 ASM E

Right hot pipe for 91 0 ASME

)