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- A.O. Smith
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- 510
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A.O. Smith 510 Service manual
Summary of 510
Page 1
510 indoor / 510 outdoor service manual ver. 1.00 1 confidential 510 direct vent indoor and outdoor models on-demand water heater service manual 510 indoor a.O. Smith water products company 500 tennessee waltz parkway ashland city, tn 37015 toll free: 1-877-737-2840 510 outdoor.
Page 2: Table Of Contents
510 indoor / 510 outdoor service manual ver. 1.00 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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510 indoor / 510 outdoor service manual ver. 1.00 3 confidential 1. Specifications of the 510 direct vent indoor* and outdoor model 510 indoor 510 outdoor dimensions h20.5"×w13.8"×d8.5" weight 39 lbs. Co m bu st io n input btu/h max 199,000 min 11,000 combustion system power vent installation indoor...
Page 4: 2. Exterior View
510 indoor / 510 outdoor service manual ver. 1.00 4 confidential 1 3- 3 /4 " ( 3 50 m m) 1 0 " (2 5 4 mm ) 1- 3 /4 " ( 4 5m m ) 1 - 3/ 4 " ( 4 5 mm ) 1 - 3/ 8 " (3 6 m m) 3- 9 /8 ( 1 0 1 mm ) 2 1 - 3 / 8 " ( 5 4 4 m m ) 2 0 - 1 / 4 " ( 5 2 0 m m ) 1- 7 /8 " ( 4 7m m ) h o t 5 -1 / 4 " (1 3 3 mm ) 1 ...
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510 indoor / 510 outdoor service manual ver. 1.00 5 confidential side view front view bottom view top view 510 outdoor 1 3- 3 /4 " (3 50 m m ) 1 0 " ( 2 54 mm ) 1 -3 / 4" ( 45 m m) 1- 3 /4 " (4 5m m ) 2 1 - 3 / 8 " ( 5 4 4 m m ) 2 0 - 1 / 4 " ( 5 2 0 m m ) 1- 7 /8 " (4 7 mm ) ho t 5 - 1/ 4 " ( 1 33 ...
Page 6: 3. Interior View
510 indoor / 510 outdoor service manual ver. 1.00 6 confidential 3. Interior view 510 indoor 1 3 4 5 6 7 9 8 3 1 1 0 1 1 1 3 1 4 1 5 1 6 1 7 1 8 1 8 1 9 2 2 1 1 2 2 3 2 4 3 2 2 5 2 2 2 8 2 9 2 7 3 0 2 0 2 6.
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510 indoor / 510 outdoor service manual ver. 1.00 7 confidential 510 indoor 1 3 4 5 6 7 9 8 3 1 1 0 1 1 1 3 1 4 1 5 1 6 1 7 1 8 18 19 2 2 1 1 2 23 2 4 3 2 2 5 2 2 2 8 2 9 2 7 3 0 2 0 2 6.
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510 indoor / 510 outdoor service manual ver. 1.00 8 confidential 4. List of main components in the interior view no. Description items# in components diagram aos part # common parts for other models 1 case assembly 001 319143-151 (510 indoor) 319143-211 (510 outdoor) 2 manifold assembly with gas val...
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510 indoor / 510 outdoor service manual ver. 1.00 9 confidential no. Description items# in components diagram aos part # common parts for other models 21 outlet drain plug 410 319143-199 110, 310, 910 22 air-fuel ratio rod (afr rod) 108 319143-035 23 flame rod 108 319143-035 24 igniter rod 109 31914...
Page 10: 5. Schematic Diagram
510 indoor / 510 outdoor service manual ver. 1.00 10 confidential 5. Schematic diagram the diagram below refers to both the 510 indoor and 510 outdoor. 1. When a hot water tap is opened, cold water enters the 510 indoor or 510 outdoor. 2. The water flow sensor detects this water flow and sends this ...
Page 11: 6. Wiring Diagram
510 indoor / 510 outdoor service manual ver. 1.00 11 confidential 6. Wiring diagram the diagram below refers to both the 510 indoor and 510 outdoor. Gas propor- tional valve 3 9 53 73 g b k w trans- former i g igniter rod heater freeze protection thermostat heater ground b k b k m v s v 3 s v 2 s v ...
Page 12
510 indoor / 510 outdoor service manual ver. 1.00 12 confidential 7. Wiring diagram check points for diagnosis the table below applies to both the 510 indoor and 510 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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510 indoor / 510 outdoor service manual ver. 1.00 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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510 indoor / 510 outdoor service manual ver. 1.00 14 confidential 8. Resistance values of the temperature thermistors the 510 indoor and 510 outdoor use the same thermistors. Resistance values at different temperatures 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 ...
Page 15: 9. Operational Flow Chart
510 indoor / 510 outdoor service manual ver. 1.00 15 confidential 9. Operational flow chart the diagram below refers to both the 510 indoor and 510 outdoor. Power supply on operation sw on fav&bv open pre-check normal? Faucet opens water flow above 0.75gpm? Fm speed (below 1,000rpm?) fan moter start...
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510 indoor / 510 outdoor service manual ver. 1.00 16 confidential 10. Component specifications 10-1. Burners……………………..………………………………………………………………………....………. 17 10-2. Gas manifold………….…………………………………………………………………………………..... 18 10-3. Fan motor………………………………………………………………………...…………………………… 19 10-4. Gas valve asse...
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510 indoor / 510 outdoor service manual ver. 1.00 17 confidential 10-1. Burners unit part # #101 aos part # 319143-030 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
510 indoor / 510 outdoor service manual ver. 1.00 18 confidential 10-2. Gas manifold unit part # included in #102 aos part # 319143-046 (lp) 319143-368 (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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510 indoor / 510 outdoor service manual ver. 1.00 19 confidential 10-3. Fan motor unit part # #103 aos part # 319143-043 (510 indoor) 319143-217 (510 outdoor) checkpoint g function to provide combustion air into the combustion chamber and to exhaust flue gas. Failure events 1. Fan speed failure, cau...
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510 indoor / 510 outdoor service manual ver. 1.00 20 confidential 10-4. Gas valve assembly unit part # included in #102 aos part # 319143-046 (lp) 319143-368 (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...
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510 indoor / 510 outdoor service manual ver. 1.00 21 confidential 10-5. Flame rod unit part # #108 aos part # 319143-035 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 ...
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510 indoor / 510 outdoor service manual ver. 1.00 22 confidential 10-6. Afr rod unit part # #108 aos part # 319143-035 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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510 indoor / 510 outdoor service manual ver. 1.00 23 confidential 10-7. Heat exchanger unit part # #401 aos part # 319143-369 (510 indoor) 319143-177 (510 outdoor) checkpoint n/a function absorbs heat from combustion and transfer it to water through the heat exchanger pipes. Failure events 1. Clogge...
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510 indoor / 510 outdoor service manual ver. 1.00 24 confidential 10-8. Flow adjustment valve unit part # #402 aos part # 319143-178 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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510 indoor / 510 outdoor service manual ver. 1.00 25 confidential 10-9. Flow sensor unit part # #402 aos part # 319143-178 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...
Page 26
510 indoor / 510 outdoor service manual ver. 1.00 26 confidential 10-10. Bypass valve unit part # #403 aos part # 319143-186 checkpoint j1 function 1. Mixes hot water from the heat exchanger with cold water from the water inlet in order to modulate and control the water heater’s outlet water tempera...
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510 indoor / 510 outdoor service manual ver. 1.00 27 confidential 10-11. Thermistors unit part # #407 (inlet) #408 (mixing) #411 (output) aos part # 319143-085 (inlet) 319143-190 (mixing) 319143-096 (output) checkpoint e1 (mixing) e2 (output) e3 (inlet) function measures cold/hot water temperatures ...
Page 28
510 indoor / 510 outdoor service manual ver. 1.00 28 confidential 10-12. Hi-limit switch unit part # #412 aos part # 319143-095 checkpoint c1 function -based on bi-metal thermal expansion. -detects excessively high water temperature (more than 194˚f or 90˚c) in pipes of the heat exchanger. -after de...
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510 indoor / 510 outdoor service manual ver. 1.00 29 confidential 10-13. Overheat cut off 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, espec...
Page 30
510 indoor / 510 outdoor service manual ver. 1.00 30 confidential 10-14. 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 31
510 indoor / 510 outdoor service manual ver. 1.00 31 confidential 10-15. Computer board unit part # #701 aos part # 319143-179 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 32
510 indoor / 510 outdoor service manual ver. 1.00 32 confidential 10-16. 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 33
510 indoor / 510 outdoor service manual ver. 1.00 33 confidential 10-17. 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 34
510 indoor / 510 outdoor service manual ver. 1.00 34 confidential 10-18. Freeze protection thermostat unit part # #713 #710 aos part # 319143-185 (510 indoor) 319143-210 (510 outdoor) checkpoint b1 function temperature detecting device which prevents the pipes within the water heater from freezing. ...
Page 35
510 indoor / 510 outdoor service manual ver. 1.00 35 confidential 10-19. 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 36
510 indoor / 510 outdoor service manual ver. 1.00 36 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 37
510 indoor / 510 outdoor service manual ver. 1.00 37 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 38
510 indoor / 510 outdoor service manual ver. 1.00 38 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]...
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510 indoor / 510 outdoor service manual ver. 1.00 39 confidential error code diagnosis checkpoint 101 8 check if there is grease and dirt in burner and fan motor, when the water heater has been installed in restaurant. 9 check the manifold pressure in the water heater. Error code malfunction descrip...
Page 40
510 indoor / 510 outdoor service manual ver. 1.00 40 confidential error code diagnosis checkpoint 111 error code is shown after three failed attempts at ignition 5 disconnected/damaged o.H.C.F. (refer to section 10-13) visual inspection: connection/breakage of wires. Normal: 1 Ω or less between blue...
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510 indoor / 510 outdoor service manual ver. 1.00 41 confidential error code diagnosis checkpoint 121 error code is shown after three failed attempts at ignition 4 check for soot on the flame rod [1] clean the flame rod [2] pcb fault during operation: more than 1 μa through the flame rod wire (orang...
Page 42
510 indoor / 510 outdoor service manual ver. 1.00 42 confidential error code malfunction description cancellation method 391 disconnected afr rod turn off the power or water supply diagnosis checkpoint 1 afr rod fault (refer to section 10-6) visual inspection: connection/breakage of wires, soot on i...
Page 43
510 indoor / 510 outdoor service manual ver. 1.00 43 confidential error code malfunction description cancellation method 611 fan motor fault turn off the power or water supply diagnosis checkpoint 1 pcb and fan motor fault (refer to section 10-3 & 10-15) visual inspection of fan motor: connection/br...
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510 indoor / 510 outdoor service manual ver. 1.00 44 confidential error code malfunction description cancellation method 701 1 pcb fault [1] fault of preparation for the mixing thermistor operation. [2] fault of driving circuit for gas proportional valve(vg 0 ) turn off the power or water supply dia...
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510 indoor / 510 outdoor service manual ver. 1.00 45 confidential error code malfunction description cancellation method 761 miscommunication between parent and child units for easy link systems. Restoring proper cable connections among all the water heaters. When the computer detects proper connect...
Page 46: 12. Controls And Settings
510 indoor / 510 outdoor service manual ver. 1.00 46 confidential 12. Controls and settings 12-1. Diagnosis using the 9007603005…………………………………………………………………….……………….. 47 12-2. The error-code button: verifying functionality of computer board, displaying error code history, and clearing error code histor...
Page 47
510 indoor / 510 outdoor service manual ver. 1.00 47 confidential 12-1. Diagnosis using the 9007603005 1. Press the "hot" button and the "cold" button simultaneously for at least 5 seconds to enter “diagnostic mode”. 2. Scroll up or down to the needed information (mode #) of the 510 indoor or 510 ou...
Page 48
510 indoor / 510 outdoor service manual ver. 1.00 48 confidential 1. Press and hold the "hot" and "cold" buttons simultaneously for at least 5 seconds to enter “diagnostics mode”. 2. "0" will be displayed on the 9007603005. (see fig. 1) 3. Scroll to the desired 510 indoor or 510 outdoor unit # in th...
Page 49
510 indoor / 510 outdoor service manual ver. 1.00 49 confidential description of mode numbers in “diagnostics mode” mode # whole multi-unit system information (#0) unit information (#1 to #4) 1 total system flow rate 0 to 999 (×0.1 gpm) total operation time 0 to 9999 (hours) 2 n/a on/off cycles 0 to...
Page 50
510 indoor / 510 outdoor service manual ver. 1.00 50 confidential 12-2. Verifying functionality of computer board and displaying error code history, and clearing error code history memory the 510 indoor and 510 outdoor has an “error-call button” on the computer board that provides the functions list...
Page 51
510 indoor / 510 outdoor service manual ver. 1.00 51 confidential 12-3. Clearing the “101” and “991” error code the “101” and “991” error codes signify imperfect (abnormal) combustion, caused by insufficient intake air and/or obstructions in the exhaust. A. If the “101” and “991” error code occurs, ...
Page 52
510 indoor / 510 outdoor service manual ver. 1.00 52 confidential 12-4. Afr rod function the afr rod checks flame conditions during combustion. When the afr rod detects unexpected flame conditions, the computer board of the 510 adjusts the fan motor speed to ensure that air and fuel are always at a ...
Page 53
510 indoor / 510 outdoor service manual ver. 1.00 53 confidential 12-5. Dipswitch settings the 510 indoor shares the computer board with the 510 outdoor. There are two banks of dipswitches (upper and lower bank) on the computer board. The upper bank has certain special functions as shown on the foll...
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510 indoor / 510 outdoor service manual ver. 1.00 54 confidential the function of the lower bank of dipswitches no. Functions on position off position 1 parent/child setting for easy-link systems parent child (default) 2 model type (default) 510 indoor disable 3 (default) 510 outdoor disable 4 5 6 o...
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510 indoor / 510 outdoor service manual ver. 1.00 55 confidential 12-6. Assigning unit numbers in the easy-link system a. How to display the unit number press the “increase” button on the computer board. The 7-seg led will then display the assigned number for that 510 indoor or 510 outdoor unit for ...
Page 56
510 indoor / 510 outdoor service manual ver. 1.00 56 confidential 12-7. (a) on/off conditions: overview the following table shows the on/off conditions of the 510 indoor or 510 outdoor. On/off conditions conditions needed to turn on. The btu requirement is more than 14,880 btu/h and the water flow r...
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510 indoor / 510 outdoor service manual ver. 1.00 57 confidential 12-7.(b) on/off conditions: btu requirements a. Calculating the on/off conditions of the 510 indoor or 510 outdoor 【 condition needed to turn the t-h2-dv or t-h2-os on】 ( t set – t in ) × gpm × 500 > 14,880 【 condition needed to turn ...
Page 58
510 indoor / 510 outdoor service manual ver. 1.00 58 confidential 12-8. (a) pump control on/off conditions (only for single and easy-link system) to run circulation pumps efficiently and effectively, the 510 indoor / 510 outdoor offers mode of pump control. The following table shows the pump control...
Page 59
510 indoor / 510 outdoor service manual ver. 1.00 59 confidential 12-8.(b) pump control on/off conditions: btu requirements a. Calculating the on/off conditions of the pump 【 condition needed to turn the pump on】 ( t set – t in ) × gpm × 500 > 18,600 【 condition needed to turn the pump off】 5 minute...
Page 60
510 indoor / 510 outdoor service manual ver. 1.00 60 confidential 12-9. Multi-unit system on/off conditions in an easy-link system, the amount of 510 indoor or 510 outdoor called on to activate depends on the flow rate and the set temperature. 1. Condition required to activate an additional 510 indo...
Page 61
510 indoor / 510 outdoor service manual ver. 1.00 61 confidential 12-10. 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 abn...
Page 62
510 indoor / 510 outdoor service manual ver. 1.00 62 confidential 12-11. Relay selection for the pump control connection the maximum current capacity of 510 indoor or 510 outdoor pump control connection is 1 amp. Before using any relay with the pump control, please check the specifications of that p...
Page 63
510 indoor / 510 outdoor service manual ver. 1.00 63 confidential 12-12. Adjusting manifold gas pressure the manifold gas pressure on the 510 indoor or 510 outdoor can be adjusted by following the procedures below. Adjusting the manifold pressure can cause unexpected combustion conditions during ope...
Page 64
510 indoor / 510 outdoor service manual ver. 1.00 64 confidential desired value. 6. After gas pressure has been set, deactivate the 510 indoor or 510 outdoor, remove the manometer tube, and replace the port screw. Computer board figure 3 max button min button increase button decrease button figure 1...
Page 65
510 indoor / 510 outdoor service manual ver. 1.00 65 confidential 12-13. Manually adjusting the fan motor speed while the fm+ dipswitch will automatically increase the fan speed by 6%, the fan motor speed on the 510 indoor or 510 outdoor can also be manually adjusted. In order to perform manual adju...
Page 66
510 indoor / 510 outdoor service manual ver. 1.00 66 confidential 12-14. Freeze protection system there are two features to the 510 indoor or 510 outdoor’s freeze protection system: the automatic firing system and the ceramic heating blocks. The automatic firing system allows the 510 indoor or 510 o...
Page 67
510 indoor / 510 outdoor service manual ver. 1.00 67 confidential to sum it up in a chart: case 5 minutes have elapsed since prior operation? Inlet thermistor temperature output thermistor temperature will automatic firing be activated? 1 no any any no 2 yes above 37°f any no 3 yes any above 50°f no...
Page 68
510 indoor / 510 outdoor service manual ver. 1.00 68 confidential ceramic heating blocks the blocks will only activate based on what the freeze protection thermostat senses. The thermostat is located on the fan motor, close in vicinity to the inlet and outlet pipes within the 510 indoor or 510 outdo...
Page 69
510 indoor / 510 outdoor service manual ver. 1.00 69 confidential drain plug with filter water valve drain plug gas valve 12-15. Draining and cleaning the inlet water filter 1. Close the manual gas shut off valve. 2. Turn off power to the 510 indoor or 510 outdoor, wait a few seconds. And then turn ...
Page 70
510 indoor / 510 outdoor service manual ver. 1.00 70 confidential 13. Components diagrams case assembly 510 indoor 510 outdoor 0 0 4 0 0 1 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 5 6 0 5 2 0 0 4 0 0 1 0 5 2 0 0 3 0 0 2 0 5 0 7 0 2 0 5 2 0 0 7 7 0 4 0 0 6 0 0 5...
Page 71
510 indoor / 510 outdoor service manual ver. 1.00 71 confidential 1 1 6 1 1 7 0 5 3 1 0 3 0 5 4 1 1 5 0 5 7 0 5 8 7 1 3 1 0 6 1 0 7 1 0 8 1 0 9 1 1 0 0 6 5 7 1 2 1 2 1 7 0 3 0 5 3 7 0 6 7 0 4 7 0 5 1 2 0 0 5 3 7 1 1 0 5 3 7 1 4 0 6 2 0 5 5 0 5 3 1 1 7 4 0 1 0 5 9 0 6 0 1 0 3 4 0 1 1 0 4 1 0 5 0 5 2 ...
Page 72
510 indoor / 510 outdoor service manual ver. 1.00 72 confidential 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 7 4 5 6 4 6 0 4 0 9 4 5 5 4 1 0 4 5 4 4 0 8 0 6 4 4 0 3 4 6 2 4 5 8 4 6 0 4 5 6 4 5 4 4 1 1 4 5 9 0 5 3 1 5 3 1 5 4 1 5 2 4 6 3 4 1 3 4 5 2 4 5 0 4 5 3 ...
Page 73: 14. Parts List
510 indoor / 510 outdoor service manual ver. 1.00 73 confidential 14. Parts list item # part # description common parts for other models 001 319143-151 case assembly (in) 310 319143-211 case assembly (out) 310 002 319143-174 front cover (in) 319143-175 front cover (out) 003 319143-150 air blockage p...
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510 indoor / 510 outdoor service manual ver. 1.00 74 confidential item # part # description common parts for other models 103 319143-043 fan motor (in) 520, 310, 910, 710 319143-217 fan motor (out) 310 104 319143-032 burner holder gasket 520, 310, 910 105 319143-031 burner gasket 520, 110, 310 106 3...
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510 indoor / 510 outdoor service manual ver. 1.00 75 confidential item # part # description common parts for other models 405 319143-197 inlet drain plug 110, 310 406 319143-198 inlet water filter 110, 310 407 319143-085 inlet thermistor 520, 910, 710 408 319143-190 mixing thermistor 910 409 319143-...
Page 76
510 indoor / 510 outdoor service manual ver. 1.00 76 confidential item # part # description common parts for other models 706 319143-141 ac 120v power on-off switch 520, 110, 310 707 319143-181 switch wire 708 319143-188 gas valve wire 110, 310 709 319143-189 flame rod wire 110, 310 710 319143-187 e...
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510 indoor / 510 outdoor service manual ver. 1.00 77 confidential 15. Revisions version description of changes date 1.00 first edition 11/01/10