A.O. Smith ATO-510-P Technical Documents
OFF
ON
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
OFF
ON
110
Outdoor
110
Direct Vent
Indoor
If the error code is indicated on the Red LED (Refer to the Section C) on the PCB (Part #701) of
the water heater (and/or the remote control er), 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 wil 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
instal ation manual.
・
Check cross plumbing between cold water lines and hot water lines.
・
Check if the gas supply valve ful y open, the gas line sized properly and the gas supplies
pressure enough. Refer to the “Gas supply and gas pipe sizing” of the instal ation
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 #406)
・
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 control er, turn the power button on and then the set
temperature wil be displayed on the screen.
・
Check if the filter on the cold water inlet cleaned. (Part #406)
B. Error codes
03 (One Time): Incorrect dipswitch setting
・
Check the dipswitch settings on the PCB. Refer to Section D.
10 (Five Times): Warning for the “99” 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 instal ed on the
terminator, Snow build up around terminator, Instal ed 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 instal ation manual.
・
If the water heater is instal ed 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 instal ation 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 instal ed. Refer to the
“High-altitude function” of the Section D. And change the dipswitch settings.
・
Check if there is grease and/or dirt in the burner (Part #101) and the fan motor (Part
#103), especial y if the water heater has been instal ed in a contaminated area.
・
Check if there is dust and lint in heat exchanger.
・
Check the manifold pressure of the water heater. Refer to instal ation manual.
11 (Three Times): Ignition failure
1. Check gas supply and inlet gas pressure.
2. Check if the Hi-limit switch (Part #412) is properly functioning.
3. Check for connection/breakage of wires (Part #413, 708, 709, 712), burn marks on the
computer board (Part #701), and/or soot on the flame rod (Part #108). And then if
O.H.C.F (Part #413) is breakage, Consult the manufacturer.
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 valves assembly (Part #102)
when water heater goes into combustion.
6. (Only no sparking and/or kick sound) Check voltage on each wire to gas valves assembly
(Part #102) and/or the igniter (Part #711). 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)
8. Check if there is dust and lint in nozzles of the manifold (Part #102).
9. Check current on the flame rod (Part #108). Refer to the #3 at “Appendix A” in Section C.
12 (Three Times): Loss of flame
1. Check gas supply and inlet gas pressure.
2. Check if the Hi-limit switch (Part #412) is properly functioning.
3. Check for connection/breakage of wires (Part #413, 708, 709, 712), burn marks on the
computer board (Part #701), soot on the flame rod (Part #108). And then if O.H.C.F (Part
#413) is breakage, Consult the manufacturer.
4. Check if there is leakage from heat exchanger (Part #401).
5. Check if there is dust and lint in nozzles of the manifold (Part #102).
6. Check current on the flame rod (Part #108). Refer to the #3 at “Appendix A” in Section C.
Maintenance sheet 62Q064
A. Troubleshooting
C. Wiring Diagram and check point of the Water heater
31, 32 (Two Times): Disconnected/short-circuited thermistor
・
Check for connection/breakage of wires and/or debris on thermistor (Part #407, 408).
・
Check thermistor resistance. Refer to the “Appendix D” in Section C.
39 (Two Times): Air-fuel Ratio Rod failure
・
Check for connection/breakage of wires (Part #709) and/or soot on the AFR rod. (Part #108).
51, 55 (Six Times): Abnormal Gas Solenoid Valve and Main Gas Valve
・
Check for connection/breakage of wires (Part #708) 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 #102). Refer to the
“Appendix C” in Section C.
61 (Four Times): Fan motor fault
・
Check for connection/breakage of wires, dust buildup in the fan motor (Part #103) and/or
burn marks on the computer board (Part #701).
・
Check for frozen/corrosion of connectors of the fan motor (Part #103).
・
Check voltage between blue wire and each wire of the fan motor (Part #103), and check
resistance between white wire and red wire. Refer to the “Appendix B” in Section C.
70 (One Time): Computer board fault
・
Check for connection/breakage of wires (Part #714) and/or burn marks on the computer
board (Part #701).
72 (Six Times): False flame detection
1. Clean the flame rod (Part #108).
2. For indoor models, check if condensate drain is instal ed on the vent col ar of the water
heater.
3. Check if there is leaking from heat exchanger (Part #401).
74: Miscommunication between water heater and remote control er
1. Check the model type of the remote control er. Model No. 9007666005 is the correct one.
2. Inspect the connections between the water heater and remote control er. Refer to
“Remote control er connections” of the Instal ation manual.
3. Check the power supply of the water heater.
4. If this error code appears only the Red LED on the PCB (Part #701), check the voltage on
the remote control er terminal on the PCB. Refer to the “Appendix E” in Section C.
5. If this error code appears only remote control er, replace the PCB (Part #701).
6. If this error code appears both the PCB (Part #701) and the remote control er, replace the
remote control er.
99 (Five Times): Imperfect combustion
・
Refer to the “10” error code in this section.
<<The fan motor stil spinning after operation has stopped>>
・
This is normal. After operation has stopped, the fan motor keeps running from 15 to 70
seconds in order to re-ignite quickly, as wel as purge al 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
instal ations. The water heater needs more combustion air. Refer to the “10” error code
in the section B.
<<Power supply circuit>>
1. If the remote control er instal ed, press the “ON/OFF” button of the remote control er,
and make sure that the set temperature is displayed on the remote control er. Restart the
water heater.
2. Check if the Red LED on the PCB (Part #701) of the water heater is lit for a few seconds
right after the power is supplied. 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 #703), 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 Red LED on the PCB (Part #701) isn’t lit, some electrical parts can be broken.
Consult the manufacturer.
<<Water circuit>>
1. If you set the remote control er, turn the power button on and then the set temperature
wil be displayed on the screen.
2. Open al hot water faucets, and make sure that there is enough water flow. This water
heater needs at least 0.75 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 #406)
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
instal ation 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 #402).
9. Check if the motor drive of the flow adjustment valve (Part #402) is locked due to scale
buildup, and/or water leakage. Consult the manufacturer.
The dipswitches have certain special functions and general y should not need adjustment.
They have settings for four functions, shown below.
D. Dipswitch Settings on the computer board of the water heater
Change the dipswitch settings when the power supply is turning off.
The dark square is the direction the dipswitch should be set to.
DEFAULT is the factory setting.
The Gas Type dipswitch
should
already
be
properly preset from
the factory.
The numbers in parentheses below are the numbers of blinking of the Red LED on the PCB to indicate the error codes.
Appendix D (For error code 31 and 32)
・
Outlet thermistor (Find the marking of No.113 on the connector)
Check point “E1”
・
Inlet thermistor (Find the marking of No.42 on the connector)
Check point “E2”
Check resistance between black wire and black wire.
°F
50
59
68
77
86
95
Temperature
°C
10
15
20
25
30
35
Resistance
kΩ
15.4
12.6
10.3
8.5
7.0
5.9
Al check points are normal?
Yes >> Replace the PCB. (Part #701)
No >> Replace the wrong thermistor. (Part #407, 408)
Appendix E (For error code 74)
Refer to check point “F” on the wiring diagram above.
Check voltage on the remote control er terminal on the PCB.
(Normal: DC 11 to 25 V)
This check point is normal?
Yes >> Replace the remote control er.
No >> Replace the PCB. (Part #701)
Appendix C (For error code 51 and 55)
Refer to check point “C” in the diagram to the left and fol owings.
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)
Al check points are normal?
Yes >> Replace the gas valves assembly. (Part #102)
No >> Replace the PCB. (Part #701)
Appendix B (For error code 61)
Refer to check point “G” in the diagram to
the left and fol owings.
・
Check voltage between red wire and
blue wire.
(Normal: DC 110 to 160 V)
・
Check voltage between yel ow 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)
Al check points are normal?
Yes >> Replace the fan motor.
(Part #103)
No >> Replace the PCB. (Part #701)
W: WHITE
R: RED
BK: BLACK
P: PURPLE
LB: LIGHT BLUE
BL: BLUE
G: GREEN
Y: YELLOW
O: ORANGE
BR: BROWN
Appendix A (For error code 11)
Check these points during ignition stage.
# 1. Refer to check point “B” on the wiring diagram above.
Check voltage between purple wires.
(Normal: AC 90 to 110 V)
This Check point is normal?
Yes >> Replace the igniter (Part #711)
No >> Go to Next
# 2. Refer to check point “C” and “H1” on the wiring diagram above.
Check the voltage bel ows.
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 #102)
No >> Replace the PCB. (Part #701)
# 3. Check current thought the orange flame rod wire (Part #709).
(Normal: more than 1μA)
This check point is normal during operation?
Yes >> Replace the PCB. (Part #701)
No >> Replace the flame rod. (Part #108)
Dipswitches
Natural
Gas
Propane
1 2 3 4 5 6 7 8
OFF
ON
1 2 3 4 5 6 7 8
OFF
ON
Gas type
Temperature set
1 2 3 4 5 6 7 8
O FF
ON
1 2 3 4 5 6 7 8
O FF
ON
1 2 3 4 5 6 7 8
O FF
ON
1 2 3 4 5 6 7 8
O FF
ON
(45 C)
113 F
(60 C)
140 F
(55 C)
131 F
(50 C)
122 F
D E F A U LT
ATKJ2
FM speed is increased automatical y.
High-altitude function
1 2 3 4 5 6 7 8
OFF
ON
1 2 3 4 5 6 7 8
OFF
ON
1 2 3 4 5 6 7 8
OFF
ON
1 2 3 4 5 6 7 8
OFF
ON
FM+
(2,000 to 4,000 ft)
FM++
(4,000 to 6,000 ft)
Over 6,000 ft:
Consult the manufacturer.
DEFAULT
(0 to 2,000 ft)
The Model Type dipswitch should
already be properly preset from
the factory.
Propor-
tional
Valve
3
9
53
73
G
W
B K
Trans-
former
I G
Elect rod
Heater
Thermostat
Heater
Ground
B K
B K
M V
S V 3
S V 2
SV 1
L B
G
O
R
O.H.C.F
H i-
l im i t
B L
B L
B L
B L
B L
B L
B L
W
Y
B L
O
R
F M
W
R
Flow
Sensor
Flame rod Ground
Air-fuel ratio rod
Y
G
O
Inlet
thermistor
Outlet
thermistor
9007666005
Remote
controller
6
5
4
3
2
1
B K
Flow
Adjust
Valve
R
BK
O F F
P
P
P
P
B R
B R
AC120V
G
Ground
B K
W
W
B K
B R
B R
SW
Surge
box
W
B K
B K
Increase button
Decrease button
Dipswitches
Red LED
MAX button
MIN button
7 8
A2
I
A
G
B
C
H1
H2
C1
A1
J
F
E1
E2
C2
A3
B1
110
Indoor
110
Outdoor
Model type
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