A.O. Smith fps50, FPS40, FPS 75, FPSE50 User Manual

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Models

FPS 40 and 50

Series 226-227

Prepared by the

Technical

Information Dept.

Irving, Texas

Printed in the U.S.A. 596 4575

ruc Wc ~~D~w

WATER PRODUCTS

COMPANY

A DIVISION OF A.O. SMITH CORPORATION

FPSE 40 and 50

Series 226E

FPD 40 and 50

Series 226-227

F PS 75

Series 230-233

Part No. TC-O34

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

WORKBOOK INTRODUCTION

@1995 A.D. Smith Water Products Co.

Technical Information

Irvino. Texas

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

TABLE OF CONTENTS

SUBJECT

Choosing the Best Water Heater

Introduction When to choose the FPS When to choose the FPSE When to choose the FPD

Venting Installation

Interior clearances FPS, FPSE, FPD

Exterior clearances FPS, FPSE

Exterior clearances FPD

Condensation

Sealing the vent Horizontal Length Calc. FPS, FPSE

Vertical Length Calc. FPS, FPSE

Horizontal Length Calc. FPD

PAGE

3 4

6 7

8 9

10 11 12

SUBJECT

Service and Operation FPS 40 & 50

Sequence of Operation Wiring Diagram

Troubleshooting Index 23

Parts List 40

FPSE & FPD 40 -50

Sequence of Operation 42 Wiring Diagram

Troubleshooting Index 44

Parts List 66

FPS 75

Sequence of Operation

Wiring Diagram

PAGE

Vertical Length Calc. FPD

Down Length Calc. FPD

Air for Combustion

Checking the draft

Additional Problems

Negative Pressure Make-up Air

Troubleshooting

Parts List 94

Part Infom1ation 96

Service Checklist 97 General Q & A

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

CHOOSING THE BEST WATER HEATER

@1995

A.D. Smith

Water Products Co.

Technical Information

Irving, Texas

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

CHOOSING THE BEST WATER HEATER cant.

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

CHOOSING THE BEST WATER HEATER cant.

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

VENTING INSTALLATION

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

VENTING INSTALLATION cant.

Exterior Clearances:

FPS FPSE

Exterior installation clearance requirements are crucial and must be met to ensure compliance with all safety and code requirements. If all clearances cannot be met, do not unpack the heater.

All exterior clearance requirements for the FPS and FPSE are measured from the vent termination.

Min. clearances for side wall venting: Min. clearances for vertical:

Inside corner - 3' l' above or 4' to the side of any Side of door or window - 4' gable, dormer, or roof structure Above door or window - l' with building interior access. Below a window - 4' l' above snow level. Above public walkway - 7'

Above ground or snow level -1' Air intake to a living space - 3' above if air intake is within 10'

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

VENTING INSTALLATION cant.

Exterior Clearances: FPD

@1995 A.D. Smith

Water Products Co.

Exterior installation clearance requirements are crucial and must be met to ensure compliance with all safety and code requirements. If all clearances cannot be met, do not unpack the heater.

All exterior clearance requirements for the FPO are measured from the vent termination.

Min. clearances for side wall venting: Min. clearances for vertical:

Inside corner - 3' l' above or 4' to the side of any

Side of door or window - 9" gable, dormer, roof structure Above door of window - 9" with building interior access. Above public walkway - 7' l' above snow level.

Above ground or snow level -1' Air intake to a living space - 3' above if air intake is within 10'

Technical Information

IrvinQ. Texas

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

VENTING INSTAllATION cant.

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

VENTING INSTAllATION cant.

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

VENTING INSTAllATION cant.

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

VENTING INSTAllATION cant.

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

VENTING INSTALLATION cant.

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

VENTING INSTAllATION cant

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

AIR FOR COMBUSTION

Checking for Draft

On initial start up, check for the correct draft on the Power Shot. To check the draft, place a smoke stick directly in front of the inlet air damper while the heater is firing. A properly operating system will draw the smoke into the inlet air damper as shown in the right illustration. The illustration on the left shows a negative

To check for a negative condition close all windows, outside doors, and fireplace dampers. Turn on all exhausting appliances, including kitchen draft hoods, clothes dryers, furnaces, bathroom vents, etc. Open all inner doors between these appliances and the Power Shot.

Once all appliances are on and inner doors open, open the inlet air damper on the Power Shot when the heater is not firing. Using your hand, check for air movement. If air is being blown back into the room, a negative pressure condition exists.

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

AIR FOR COMBUSTION cant.

CONDITION

Burnt gas odor when heater is operatinq

CAUSE

Leaking vent joints

Blocked vent

SOLUTION

Seal vent joints

Clear vent blockaQe

The majority of the complaints associated with the operation of the will likely be a direct result of improper venting. If the customer complains of smelling burnt gas around the water heater, first check for vent gases that may be leaking from the PVC joints or around the area between the blower assembly and water heater. Seal all leaks with the high temperature silicone sealant provided.

Check for restrictions in the venting that may cause some spillage of burnt gas into the room and check your draft, visually inspecting the vent termination for blockage, clearing blockage as

necessary.

Improper venting is also a major cause of sooting in water heaters. If you experience sooting with the POWER SHO~, check that the inlet air damper swings freely and opens 1 1/4" when the blower is running.

If water is dripping from the blower, condensate is the culprit

To correct the problem, install a

condensate tee, and pipe to drain.

If the customer complains of nuisance pilot outage or pilot gas odor on standby, this may be due to a lack of combustion air, or other appliance (exhaust fans, clothes dryers, etc.) creating a backdratt in the FPS venting. In either case, install additional make-up air ducts.

@1995 A.D. Smith

Water Products Co.

Technical Information

Irving, Texas

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

AIR FOR COMBUSTION cont.

CONDITION CAUSE SOLUTION

Inlet air damper not

build-up in PVC venting

Intermittent fan cycling without burner

operation (Propane Only)

A malfunctioning vent damper may also cause excessive heat buildup in the PVC vent piping

unable to free the damper, replace the entire combustion control tee.

If blower does not run when the main burner fires, replace the control box. Also check burner orifice for correct size.

opening completely Blower does not run when

main burner fires

Wrong main burner

orifice size

Build up of pressure in the

main burner tube between thermostat gas valve and solenoid qas valve

Free air damperExcessive heat

Replace entire blower assembly

Install correct orifice

If cycling occurs more than twice per hour, see troubleshooting

procedures.

Intermittent cycling of the fan, without main burner operation, indicates a build-up of pressure in the

main burner tube between the thermostatic gas valve and solenoid gas valve.

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

AIR FOR COMBUSTION cont.

Negative Pressure

Diagnosing pilot outage complaints requires an examination of the environment in which the heater is installed. Mechanical vent fans are the chief cause of negative pressure. If the house is too tight, more air will be exhausted from the structure than is being brought in from the outside, resulting in a negative pressure condition. Fireplaces, furnaces, wind, and thermal stacking within the house can also playa role in creating negative pressure conditions.

Negative pressure can result from air being backdrafted through the water heater vent down into the combustion chamber, blowing out the pilot. This may happen randomly because it may be a particular combination of appliances which cause

the condition.

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

AIR FOR COMBUSTION cont.

A.D. Smith

Water Products Co

Technical Information

Irving, Texas

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

FPS 40 and 50 SERVICE AND OPERATION

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

FPS 40 and 50 SERVICE AND OPERATION cant.

-A~I

DISCONNECT FROM ELECTHICAL SUPPLY BEFORE SERVICING UNIT. REPLACE ALL DOORS AND PANELS BEFORE OPERATING HEATER.

115~LT

POWER SOURCE

SWITCH

OFF

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CONNECTOR,

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PRESSUREI COIL

SWITCH I ~~

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SUPPUED WIn! UNIT

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AIR

PRESSURE

B=BLACK W=WHITE R=RED G=GREEN G/Y=GREEN/

YELLOW

U=BLUE

@1995 A.D. Smith

Water Products Co

Technical Information

IrvinQ. Texas

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

FPS 40 and 50 SERVICE AND OPERATION cant.

@1995 A.D. Smith Water Products Co.

Technical Information

Irving, Texas

Troubleshooting cont

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

FPS 40 and 50 SERVICE AND OPERATION cant

PRELIMINARY CHECKS

1. Gas valve knob is in ON position

2. Pilot is burning

3. 120 VAG is supplied to heater.

4. Thermostat is calling for heat

(See page 25)

5. Blower ON/OFF switch is in the ON position

6. Connection between blower motor and blower control box is secure

7. Heater is installed per manual

@1995

A.D. Smith

Water Products Co.

Technical Information

Irving, Texas

Trouble-

shooting cont.

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

FPS 40 and 50 SERVICE AND OPERATION cant.

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

FPS 40 and 50 SERVICE AND OPERATION cant.

@1995 A.D. Smith

Water Products Co.

Technical Information

Irving, Texas

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

FPS 40 and 50 SERVICE AND OPERATION cont.

Trouble-

shooting cont.

BLOWER DOES NOT RUN cant.

RESULTS

If: then: the fan does not run, the fan does run,

@1995 A.D. Smith Water Products Co.

replace the fan assembly.

go to Step 2.

Technical Information

Irving, Texas

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

FPS 40 and 50 SERVICE AND OPERATION cant.

Troubleshooting cont.

BLOWER DOES NOT RUN cont.

RESULTS

If: the fan does not run, the fan does run

then' replace the cable go to Step 3.

FPS/FPSE/FPD TECHNICAL TRAINING AND SERVICE WORKBOOK

FPS 40 and 50 SERVICE AND OPERATION cant.

Trouble-

shooting cont

BLOWER DOES NOT RUN cant.

RESULTS If:

the fan does not run, the fan does run,

then replace the harness replace the gas pressure switch

+ 73 hidden pages