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- 110
- Service Manual
A.O. Smith 110 Service Manual
Summary of 110
Page 1
110 indoor / 110 outdoor service manual ver. 1.01 1 confidential 110 direct vent indoor and outdoor models on-demand water heater service manual 110 indoor a.O. Smith water products company 500 tennessee waltz parkway ashland city, tn 37015 toll free: 1-877-737-2840 110 outdoor.
Page 2: Table Of Contents
110 indoor / 110 outdoor service manual ver. 1.01 2 confidential table of contents 1. Specifications………………………………………...…...………….……………………...………………………… 3 2. Exterior view……………………...…….…………………………………………………………………………….... 4 3. Interior view…………………………….……………………………………………………………………………….. 6 4. List of main comp...
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110 indoor / 110 outdoor service manual ver. 1.01 3 confidential 1. Specifications of the 110 direct vent indoor* and 110 outdoor model 110 indoor 110 outdoor dimensions h20.5"×w13.8"×d6.7" weight 33 lbs. Co m bu st io n input btu/h max 140,000 min 19,500 combustion system power vent installation in...
Page 4: 2. Exterior View
110 indoor / 110 outdoor service manual ver. 1.01 4 confidential 1 3- 3/ 4 " ( 35 0m m ) 1 0" (2 5 4m m) 2 - 1/ 4" (5 6m m ) 2 1 - 3 / 8 " ( 5 4 4 m m ) 2 0 - 1 / 4 " ( 5 2 0 m m ) 2 -1 /4 " ( 5 6 mm ) c ol d 3 -7 /8 " ( 9 8m m) ga s 4 -7 /8 " ( 12 4 mm ) h ot 1" (2 6 mm ) 4 " ( 10 2 mm ) 4- 7/ 8 " ...
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110 indoor / 110 outdoor service manual ver. 1.01 5 confidential 1 3 - 3 / 4 " ( 3 5 0 m m ) 1 0 " ( 2 5 4 m m ) 2 1 - 3 / 8 " ( 5 4 4 m m ) 2 0 - 1 / 4 " ( 5 2 0 m m ) 2 - 1 / 4 " ( 5 6 m m ) c o l d 3 - 7 / 8 " ( 9 8 m m ) g a s 4 - 7 / 8 " ( 1 2 4 m m ) h o t 1 " ( 2 6 m m ) 4 - 7 / 8 " ( 1 2 3 m...
Page 6: 3. Interior View
110 indoor / 110 outdoor service manual ver. 1.01 6 confidential 3. Interior view 110 indoor 1 1 0 1 1 2 4 2 4 2 8 2 7 2 9 1 7 1 3 1 4 8 2 5 6 7 9 3 5 2 0 2 6 2 2 2 3 1 8 1 2 1 6 1 9 1 5 3 0
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110 indoor / 110 outdoor service manual ver. 1.01 7 confidential 110 outdoor 1 10 1 1 2 4 2 4 2 8 2 7 2 9 1 7 1 3 1 4 8 2 5 6 7 9 3 5 2 0 2 6 2 2 2 3 1 8 1 2 1 6 1 9 1 5 3 0
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110 indoor / 110 outdoor service manual ver. 1.01 8 confidential 4. List of main components in the interior view no. Description item# in components diagram aos part # common parts for other models 1 case assembly 001 319143-159 (110 indoor) 319143-172 (110 outdoor) 2 manifold assembly with gas valv...
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110 indoor / 110 outdoor service manual ver. 1.01 9 confidential no. Description item# in components diagram aos part # common parts for other models 20 surge box 703 319143-168 310, 510 21 outlet drain plug 410 319143-199 310, 510, 910 22 air-fuel ratio rod (afr rod) 108 319143-339 23 flame rod 108...
Page 10: 5. Schematic Diagram
110 indoor / 110 outdoor service manual ver. 1.01 10 confidential 5. Schematic diagram the diagram below refers to both the 110 indoor and 110 outdoor. 1. When a hot water tap is opened, cold water enters the 110 indoor or 110 outdoor. 2. The water flow sensor detects this water flow and sends this ...
Page 11: 6. Wiring Diagram
110 indoor / 110 outdoor service manual ver. 1.01 11 confidential 6. Wiring diagram the diagram below refers to both the 110 indoor and 110 outdoor. W: white r: red bk: black p: purple lb: light blue bl: blue g: green y: yellow o: orange br: brown 9007666005 gas propor- tional valve 3 9 53 73 g w b ...
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110 indoor / 110 outdoor service manual ver. 1.01 12 confidential 7. Wiring diagram check points for diagnosis the table below applies to both the 110 indoor and 110 outdoor. Check- point part and description color of wires normal range a, a1 100v power supply white – black (a) brown – brown (a1) 90...
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110 indoor / 110 outdoor service manual ver. 1.01 13 confidential check- point part and description color of wires normal range h1 gas proportional valve white - red 1 to 15 vdc (during operation) and 20 to 40 Ω h2 flow sensor red - black 4 to 5.5 vdc white - black 1 to 4 vdc (pulse) 1,080 pulse / m...
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110 indoor / 110 outdoor service manual ver. 1.01 14 confidential 8. Resistance values of the temperature thermistors the 110 indoor and 110 outdoor use the same thermistors. ºf 32 41 50 59 68 77 86 95 104 113 ºc 0 5 10 15 20 25 30 35 40 45 resistance k Ω 23.76 19.08 15.43 12.56 10.28 8.47 7.02 5.85...
Page 15: 9. Operational Flow Chart
110 indoor / 110 outdoor service manual ver. 1.01 15 confidential 9. Operational flow chart the diagram below refers to both 110 indoor and 110 outdoor. Power supply on operation sw on fav open pre-check normal? Faucet opens water flow above 0.75gpm? Fm speed (below 1,000rpm?) fan moter start operat...
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110 indoor / 110 outdoor service manual ver. 1.01 16 confidential 10. Component specifications 10-1. Burners……………………..…………………………………………………….......................………. 17 10-2. Gas manifold………….………………………………………………………….............................. 18 10-3. Fan motor………………………………………………………………………...…………………...
Page 17: 10-1. Burners
110 indoor / 110 outdoor service manual ver. 1.01 17 confidential 10-1. Burners unit part # #101 aos part # 319143-161 checkpoint n/a function there are 2 types of burners in the water heater: the gas-rich burner stabilizes the flames within the combustion chamber and the air-rich burner produces mo...
Page 18: 10-2. Gas Manifold
110 indoor / 110 outdoor service manual ver. 1.01 18 confidential 10-2. Gas manifold unit part # included in #102 aos part # 319143-169 (lp) 319143-165 (na) checkpoint n/a function 1. The manifold distributes gas from the gas valves to the burners. The manifold has two types of the nozzles: one type...
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110 indoor / 110 outdoor service manual ver. 1.01 19 confidential 10-3. Fan motor unit part # #103 aos part # 319143-347 checkpoint g function to provide combustion air into the burner chamber and to exhaust flue gas. Failure events 1. Fan speed failure, causing abnormal sounds with or without combu...
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110 indoor / 110 outdoor service manual ver. 1.01 20 confidential 10-4. Gas valve assembly unit part # #102 aos part # 319143-169 (lp) 319143-165 (na) checkpoint c,h1 function opens and closes the gas pathways of the water heater (main and solenoid gas valves) modulates the gas flow from the gas inl...
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110 indoor / 110 outdoor service manual ver. 1.01 21 confidential 10-5. Flame rod unit part # #108 aos part # 319143-339 checkpoint i function to detect flames while the water heater is in operation. Failure events 1. Unable to detect flames when flames actually do occur 2. Detecting a false flame w...
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110 indoor / 110 outdoor service manual ver. 1.01 22 confidential 10-6. Afr rod unit part # #108 aos part # 319143-339 checkpoint i function -checks flame conditions during combustion. -when afr rod detects unexpected flame conditions, the computer of the water heater makes adjustments in the fan mo...
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110 indoor / 110 outdoor service manual ver. 1.01 23 confidential 10-7. Heat exchanger unit part # #401 aos part # 319143-162 (in) 319143-166 (out) checkpoint n/a function absorbs heat from combustion and transfer it to water through the heat exchanger pipes. Failure events 1. Clogged heat exchanger...
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110 indoor / 110 outdoor service manual ver. 1.01 24 confidential 10-8. Flow adjustment valve unit part # #402 aos part # 319143-167 checkpoint j function controls water flow to properly control the output hot water temperature. Failure events 1. Water leakage from valve. 2. The valve cannot modulat...
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110 indoor / 110 outdoor service manual ver. 1.01 25 confidential 10-9. Flow sensor unit part # #402 aos part # 319143-167 checkpoint h2 function detects and measures water flow rate using a spinning impeller and magnetic pick-up. Failure events unable to detect or measure any water flow rate. Effec...
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110 indoor / 110 outdoor service manual ver. 1.01 26 confidential 10-10. Thermistors unit part # #407 (inlet) #408 (outlet) aos part # 319143-214 (inlet) 319143-218 (outlet) checkpoint e1 (outlet) e2 (inlet) function measures cold/hot water temperatures in the water heater. Failure events unable to ...
Page 27
110 indoor / 110 outdoor service manual ver. 1.01 27 confidential 10-11. Hi-limit switch unit part # #412 aos part # 319143-228 checkpoint c1 function -based on bi-metal thermal expansion. -detects excessively high water temperature (more than 185˚f or 85˚c) in pipes of the heat exchanger. -after de...
Page 28
110 indoor / 110 outdoor service manual ver. 1.01 28 confidential 10-12. Overheat cutoff fuse unit part # #413 aos part # 319143-149 checkpoint c2 function -the overheat cutoff fuse contains solder with a melting point of 430˚f (221˚c). -detects excessive temperatures within the water heater, especi...
Page 29
110 indoor / 110 outdoor service manual ver. 1.01 29 confidential 10-13. Freeze protection heaters unit part # #414 #415 aos part # 319143-200 319143-078 checkpoint b1 function prevents the heat exchanger, water valves, and water pipes within the water heater from freezing. The heaters are but one o...
Page 30
110 indoor / 110 outdoor service manual ver. 1.01 30 confidential 10-14. Computer board unit part # #701 aos part # 319143-164 checkpoint n/a function controls the functions of most of the parts in the water heater. Failure events malfunctioning computer effects on the water heater if the computer b...
Page 31
110 indoor / 110 outdoor service manual ver. 1.01 31 confidential 10-15. Transformer unit part # #702 aos part # 319143-182 checkpoint a1,a2 function -to transform input voltage from 120 to 100 vac. -every electrical component of the water heater is designed to only work with a 100 vac power supply,...
Page 32
110 indoor / 110 outdoor service manual ver. 1.01 32 confidential 10-16. Igniter unit part # #711 aos part # 319143-052 checkpoint b function -to ignite the gas/air mixtures when the water heater is ready to burn gas on its burner surface. -the output voltage of the igniter is more than 14 kvdc. Fai...
Page 33
110 indoor / 110 outdoor service manual ver. 1.01 33 confidential 10-17. Freeze protection thermostat unit part # #713 #710 aos part # 319143-185 319143-210 checkpoint b1 function temperature detecting device which prevents the pipes within the water heater from freezing. When this device detects te...
Page 34
110 indoor / 110 outdoor service manual ver. 1.01 34 confidential 10-18. Surge box unit part # #703 aos part # 319143-168 checkpoint a2,a3 function protects the unit from high voltage and/or high electric current caused by lightning. There are 2 types of surge absorbers in the water heater. Surge ab...
Page 35
110 indoor / 110 outdoor service manual ver. 1.01 35 confidential 11. Fault analysis & specifications remarks: 1. Proper range of values of voltage & resistance shown below. 2. Please refer to the wiring diagram for checkpoint positions. 3. Remove power to the water heater when checking for continui...
Page 36
110 indoor / 110 outdoor service manual ver. 1.01 36 confidential natural of fault diagnosis checkpoint ・ the hot water is not available when a fixture is opened 5 check that the filter on the cold water inlet is clean. 6 check whether or not the unit is frozen. 7 check if there is enough gas in the...
Page 37
110 indoor / 110 outdoor service manual ver. 1.01 37 confidential natural of fault diagnosis checkpoint ・ fluctuation of hot water temperature 4 fault of pcb in the water heater [1] no voltage to gas solenoid valve (sv 1 ) normal: 78 to 100 vdc between com (blue) & #9 (green) (during operation) [2] ...
Page 38
110 indoor / 110 outdoor service manual ver. 1.01 38 confidential error code diagnosis checkpoint 10 7 check if there is dust and lint in burner and heat exchanger, when the water heater has been installed in laundry room. 8 check if there is grease and dirt in burner and fan motor, when the water h...
Page 39
110 indoor / 110 outdoor service manual ver. 1.01 39 confidential error code diagnosis checkpoint 11 error code is shown after three failed attempts at ignition 6 disconnected/damaged hi-limit switch. (refer to section 10-11) visual inspection: connection/breakage of wires. Normal: 1 Ω or less betwe...
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110 indoor / 110 outdoor service manual ver. 1.01 40 confidential error code diagnosis checkpoint 12 error code is shown after three failed attempts at ignition 5 disconnected/damaged o.H.C.F. (refer to section 10-12) visual inspection: connection/breakage of wires. Normal: 1 Ω or less between blue ...
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110 indoor / 110 outdoor service manual ver. 1.01 41 confidential error code malfunction description cancellation method 51 fault of driving circuit for main gas solenoid valve (mv) turn off the power supply (the computer checks the condition of the main gas valve immediately after every operation) ...
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110 indoor / 110 outdoor service manual ver. 1.01 42 confidential error code malfunction description cancellation method 61 fan motor fault turn off the power or water supply diagnosis checkpoint 1 pcb and fan motor fault (refer to section 10-3 & 10-14) visual inspection of fan motor: connection/bre...
Page 43
110 indoor / 110 outdoor service manual ver. 1.01 43 confidential error code malfunction description cancellation method 74 miscommunication between water heater and temperature remote controller restoring proper cable connections between the water heater and the remote controller (9007666005). When...
Page 44: 12. Controls And Settings
110 indoor / 110 outdoor service manual ver. 1.01 44 confidential 12. Controls and settings 12-1. Diagnosis using the 9007666005…..…….………………………………………………………….…………….…… 45 12-2. Verifying functionality of computer board and….................................................................… 46 12-3. Dis...
Page 45
110 indoor / 110 outdoor service manual ver. 1.01 45 confidential 12-1. Diagnosis using the 9007666005 1. Press and hold the "hot" and "cold" buttons simultaneously for at least 5 seconds to enter “diagnostics mode”. 2. Number "1" will be displayed. (fig.1) 3. Scroll through the needed information (...
Page 46
110 indoor / 110 outdoor service manual ver. 1.01 46 confidential 12-2. Verifying functionality of computer board how to check if the computer board works properly 1. Check the power on-off switch of the water heater. The factory setting is on position. 2. Turn on the power supply of the water heate...
Page 47
110 indoor / 110 outdoor service manual ver. 1.01 47 confidential 12-3. Display patterns for error codes display patterns for error codes the red led will blink in the patterns shown below when the water heater has an error code. When the water heater does not have an error code and is operating und...
Page 48
110 indoor / 110 outdoor service manual ver. 1.01 48 confidential 12-4. Clearing the “10” and “99” error code the “10” and “99” error codes signify imperfect (abnormal) combustion, caused by insufficient intake air and/or obstructions in the exhaust. A. If the “10” and “99” error code occurs, please...
Page 49
110 indoor / 110 outdoor service manual ver. 1.01 49 confidential 12-5. Afr rod function the afr rod checks flame conditions during combustion. When the afr rod detects unexpected flame conditions, the computer board of the 110 adjusts the fan motor speed to ensure that air and fuel are always at a ...
Page 50
110 indoor / 110 outdoor service manual ver. 1.01 50 confidential 12-6. Dipswitch settings the 110 indoor shares the computer board with the 110 outdoor. Each dipswitch has a special function shown on the following table. The gas type and model type should not need adjustment. Carefully verify the f...
Page 51
110 indoor / 110 outdoor service manual ver. 1.01 51 confidential 12-7. (a) on/off conditions: overview the following table shows the on/off conditions of the water heater. On/off conditions conditions needed to turn on. The btu requirement is more than 29,800 btu/h. Or inlet temperature is lower 5....
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110 indoor / 110 outdoor service manual ver. 1.01 52 confidential 12-7. (b) on/off conditions: btu requirements a. C alculating the on/off conditions of the 110 indoor or 110 outdoor 【 condition needed to turn the 110 indoor or 110 outdoor on】 ( t set – t in ) × gpm × 500 > 14,880 【 condition needed...
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110 indoor / 110 outdoor service manual ver. 1.01 53 confidential 12-8. High-altitude region support functions (fm+, fm++ and fm+++) ＜ using these functions＞ the high-altitude region support functions have four operation levels, with the appropriate level being set up by the installer until the abno...
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110 indoor / 110 outdoor service manual ver. 1.01 54 confidential 12-9. Adjusting manifold gas pressure the manifold gas pressure on the 110 indoor or 110 outdoor can be adjusted by following the procedures below. Adjusting the manifold pressure can cause unexpected combustion conditions during oper...
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110 indoor / 110 outdoor service manual ver. 1.01 55 confidential desired value. 6. After gas pressure has been set, deactivate the 110 indoor or 110 outdoor, remove the manometer tube, and replace the port screw. Figure 1 figure 2 to manometer tube increase button computer board for burner control ...
Page 56
110 indoor / 110 outdoor service manual ver. 1.01 56 confidential 12-10. Freeze protection system the 110 indoor or 110 outdoor freeze protection system is comprised of the ceramic heating blocks. The ceramic heating blocks will heat up whatever portion of the heat exchanger the blocks are strapped ...
Page 57
110 indoor / 110 outdoor service manual ver. 1.01 57 confidential 12-11. Draining the unit and cleaning the inlet water filter 1. Close the manual gas shut off valve. 2. Turn off power to the 110 indoor or 110 outdoor, wait a few seconds. And then turn on again. 3. Wait 30 seconds for water valves s...
Page 58
110 indoor / 110 outdoor service manual ver. 1.01 58 confidential 13. Components diagrams case assembly 110 indoor 110 outdoor 0 0 2 0 5 0 7 0 2 0 5 2 0 0 7 7 0 4 0 0 6 0 0 5 0 5 3 0 6 6 0 5 3 0 5 2 0 5 2 0 0 1 0 0 4 0 5 6 0 0 2 0 5 0 7 0 2 0 5 2 0 0 7 7 0 4 0 0 6 0 0 5 0 5 3 0 6 6 0 5 2 0 5 2 0 5 2...
Page 59
110 indoor / 110 outdoor service manual ver. 1.01 59 confidential 1 06 1 0 7 1 0 8 1 0 9 1 1 0 0 6 5 7 1 2 7 0 1 0 5 3 1 2 0 0 5 3 7 1 2 7 1 1 0 5 3 7 1 4 0 6 2 0 5 5 1 1 9 1 5 1 1 1 8 0 5 2 1 2 1 7 0 3 0 53 7 0 4 7 0 5 4 0 1 1 0 4 1 0 5 1 0 1 7 0 9 1 1 1 0 5 2 05 3 1 1 2 1 1 3 1 1 4 7 0 8 0 5 3 0 6...
Page 60
110 indoor / 110 outdoor service manual ver. 1.01 60 confidential water way assembly 7 01 7 0 7 7 0 9 7 1 4 7 1 0 7 0 8 1 03 4 0 2 4 0 2 4 0 7 4 08 7 1 9 computer board assembly 110 indoor /outdoor 110 indoor /outdoor 4 0 2 4 6 1 4 5 8 0 5 2 4 1 5 0 6 4 4 6 0 4 5 6 4 0 4 4 0 6 4 0 5 4 5 4 4 0 7 4 5 ...
Page 61: 14. Parts List
110 indoor / 110 outdoor service manual ver. 1.01 61 confidential 14. Parts list item # part # description common parts for other model 001 319143-159 case assembly (in) 319143-172 case assembly (out) 002 319143-163 front cover (in) 319143-173 front cover for (out) 003 319143-150 air blockage plate ...
Page 62
110 indoor / 110 outdoor service manual ver. 1.01 62 confidential item # part # description common parts for other model 104 319143-341 burner holder gasket 105 319143-031 burner gasket 520, 310, 510 106 319143-033 burner window 520, 310, 510, 910, 710 107 319143-034 rod holder gasket 520, 310, 510,...
Page 63
110 indoor / 110 outdoor service manual ver. 1.01 63 confidential item # part # description common parts for other model 409 319143-194 water outlet 310, 510 410 319143-199 outlet drain plug 310, 510, 910 412 319143-228 hi-limit switch 310 413 319143-149 overheat-cut-off fuse 310, 510, 910 414 31914...
Page 64
110 indoor / 110 outdoor service manual ver. 1.01 64 confidential item # part # description common parts for other model 711 319143-052 igniter 520, 310, 510, 910, 710 712 319143-039 high voltage igniter cable 520, 310, 510, 910 713 319143-185 freeze protection thermostat 310, 510, 710 714 319143-22...
Page 65: 15. Revisions
110 indoor / 110 outdoor service manual ver. 1.01 65 confidential 15. Revisions version description of changes date 1.00 1.01 first edition revision of wrong information in the section 1, 4 and 12-6 11/01/10 12/22/10