A.O. Smith ATI-510-N Technical Documents
Contents
1. l i i i Gast ype i 123456 on 222485 Natural ond22426 i Parent onf Propane MEHHHH Gas WAHHHH i Unit OFF OFF OFF i The Gas Type dipswitch should already be properly i Child azis preset from the factory i ON Unit m High altitude function DEFAULT OFE Temperature set DEFAULT on 22456 i Single unit is the same as the child unit 04 F ONS AG 13 F ong EE Oto 2 000ft opp nn Model type 40 C opp OOOBmEL 450 op UCU l 22 F 123456 123456 FM ON Talal Tal 510 422456 sooj ON ane aie On Hwy 2 000 to 4 000 ft E Indoor m DEFAULT opel HH 55 C opel HHU i pas 40 F ont 1S8 F ON oe FM ont 2 an la i fae HPs eae HEA We 4 000 to 6 000 ft E 510 aoa ue OFF SEE A m 76 F onts 185F oon ee Over 6 000 ft Outdoor fe fae ABBY coo Haae Consult the manufacturer i OFF OFF The Model Type dipswitch should already i FM speed is increased automatically be properly preset from the factory E Components Diagram Parts List Case assembly Burner assembly Burner assembly 510 Indoor2. 510 Outdoor Manifold assembly Exhaust section for 510 Outdoor 510 Indoor 510 Outdoor Fan motor section for 510 Outdoor Item Part Description 001 319143 151 Case assembly for 510 Indoor 319143 211 Case assembly for 510 Outdoor 002 319143 174 Front cover for 510 Indoor 319143 175 Front cover for 510 Outdoor 003 319143 150 004 319143 184 005 319143 014 Air blockage plate Only 510 Indoor Bracket Junction box 006 319143 128 007 319143 221 050 319143 025 051 319143 325 052 319143 026 Junction box inner plate Back guard panel Screw M4x12 W Washer Screw M4x10 W Washer Screw M4x10 Coated 053 319143 060 054 319143 326 055 319143 063 056 319143 372 057 319143 330 Screw M4x10 Hex head screw M4x12 W Washer Hex head screw M4x8 Screw M4x10 Screw M3x6 SUS3 058 319143 327 059 319143 061 060 319143 332 061 319143 201 062 319143 062 Screw M3x10 Pan screw M4x12 W Washer Pan screw M4x10 FEZN Tap tight screw M4x12 FEZN Pan screw M4x10 063 319143 087 064 319143 328 065 319143 059 066 319143 143 067 319143 048 Item Part Description 101 319143 030 Burner assembly 102 319143 046 Manifold assembly with gas valve assembly LP 319143 368 Manifold assembly with gas valve assembly NA 103 319143 043 Fan motor for 510 Ind
3. Yes Refer to check point G in the diagram to the left and followings Appendix B For error code 611 Check voltage between red wire and blue wire Normal DC 110 to 160 V Check voltage between yellow wire and blue wire Check voltage between orange wire and blue wire Normal DC 2 0 to 6 5 V All check points are normal Yes gt gt Replace the fan motor Part 103 No gt gt Replace the PCB Part 701 Normal DC 13 to 17 V Appendix C For error code 510 Refer to check point C in the diagram to the left and followings i Check voltage on the each valve on the gas valves assembly i 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 i All check points are normal i Yes gt gt Replace the gas valves assembly Part 102 i No gt gt Replace the PCB Part 701 i Check point E1 Check point E2 Check point E3 Check resistance between black wire and black wire Mixing thermistor Find the marking of No 113 on the connector Output thermistor Find the marking of No 12 on the connector Inlet thermistor Find the marking of No 42 on the connector F 50 59 68 77 86 95 Temperature P r T N iz ap anna T
4. i C 10 15 20 25 30 35 Resistance kQ 15 4 12 6 10 3 8 5 7 0 5 9 Normal DC 11 to 15 V This check point is normal Yes gt gt Replace the remote controller No gt gt Replace the PCB Part 701 This check point is normal Yes gt gt Replace the Flow adjustment valve Part 402 No gt gt Replace the PCB Part 701 All check points are normal Yes gt gt Replace the PCB Part 701 No gt gt Replace the wrong thermistor Part 407 408 411 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 i Refer to check point J on the wiring diagram above Check voltage between black wire and red wire Normal DC 7 to 16 V Appendix F For error code 651 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 lt Left bank of dipswitches gt The left bank has certain special functions lt Right bank of dipswitches gt The right bank has settings for three functions shown below and generally should not need adjustment Easy Link system
5. lit If so the power supply circuit of the water heater is under normal condition Next refer to the Water circuit in this section Check the fuse on the surge box Part 703 and if it has a brown spot need to replace it Check the power supply and make sure that the water heater has 120 VAC 5 If the 7 Seg LED on the PCB Part 701 isn t lit some electrical parts can be broken Consult the manufacturer Pw lt lt Water circuit gt gt 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 75 GPM water flow to operate Check for reverse connection and cross connection Check if the filter on the cold water inlet cleaned Part 406 Check if there is no debris or obstruction on the fixtures 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 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 nu fw B Error codes 031 Incorrect dipswitch setting Check the dipswitch setti
6. 143 065 Silicon ring Only 510 Indoor
7. ATD2 62S101 Maintenance sheet A Troubleshooting If the error code is indicated on the 7 Seg LED on the PCB Part 701 of the water heater and or the remote controller refer to Section B lt lt It takes long time to get hot water at the fixtures gt gt 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 lt lt Jhe water is not hot enough or turns cold and stays cold gt gt 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 lt lt The water is too hot gt gt Check the set temperature lower setting temperature lt lt The hot water is not available when a fixture is opened gt gt Refer to the Power supply circuit and Water circuit in this section lt lt Fluctuation in hot water temperatur
8. IG wire for 510 Indoor 319143 210 EH IG wire with freeze protection thermostat for 510 Outdoor 711 319143 052 Igniter 712 319143 039 High voltage igniter wire 713 319143 185 Freeze protection thermostat Only 510 Indoor 714 319143 133 Proportional gas valve wire 715 319143 204 Pump and multi cable 716 319143 195 Thermistors wire 717 319143 203 RS VG wire 718 319143 202 Water valves wire 719 319143 191 Computer board cover Item Part Description 401 319143 369 Heat exchanger assembly for 510 Indoor 319143 177 Heat exchanger assembly for 510 Outdoor 402 319143 178 Flow adjustment valve Flow sensor 403 319143 186 Bypass valve 404 319143 193 Water inlet 405 319143 197 Inlet drain plug 406 319143 198 Inlet water filter 407 319143 085 Inlet thermistor 408 319143 190 Mixing thermistor 409 319143 194 Water outlet 410 319143 199 Outlet drain plug 411 319143 096 Output thermistor 412 319143 095 Hi Limit switch 413 319143 149 Overheat cut off fuse 414 319143 200 Heater 415 319143 078 Inlet heater 450 319143 088 Pipe heater fixing plate 451 319143 125 Heater fixing plate 16 452 319143 066 Fuse fixing plate 18 453 319143 146 Fuse fixing plate 14 454 319143 082 O ring P4 FKM 455 319143 080 O ring P6 FKM 456 319143 100 O ring P14 FKM 457 319143 091 O ring P15 FKM 458 319143 083 O ring P16 FKM 459 319143 097 Fastener 4 11 460 319143 105 Fastener 14 22 461 319143 226 Fastener 16A 462 319143 205 Fastener 16 25A 463 319
9. ctors sK MAX button Dip switch Mixing thermistor te MIN button Increase button D 2 Decrease button B T7 o JF Output eo fo 4RHBBH Dd thermistor Red LED AA ED Error call button 90076030055 Inlet Remote thermistor E controller FBK O Appendix A For error code 111 7 Seg LED Check these points during ignition stage i 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 gt gt Replace the igniter Part 711 No gt gt Go to Next i 2 Refer to check point C and H1 on the wiring diagram above Check the voltage bellows i C Between blue wire and light blue wire 3 i Normal DC78 to 100 V i C Between blue wire and orange wire 53 i 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 i Yes gt gt Replace the gas valves assembly Part 102 i No gt gt Replace the PCB Part 701 i Check current thought the orange flame rod wire Part 709 i Normal more than 1A This check point is normal during operation gt gt Replace the PCB Part 701 i gt gt Replace the flame rod Part 108
10. e gt gt 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 lt lt Unit does not ignite when water goes through the water heater gt gt 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 406 Refer to Water circuit in this section lt lt The fan motor still spinning after operation has stopped gt gt This is normal After operation has stopped the fan motor keeps running from 15 to 70 seconds in order to re ignite quickly as well as purge all the exhaust gas out of the flue lt lt Abnormal sound from water heater gt gt 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 lt lt Power supply circuit gt gt 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 OFF button of the remote controller is lit Restart the water heater 2 Check if that the 7 Seg LED on the PCB Part 701 of the water heater is
11. e 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 valve 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 gt gt gt gt gt Refer to the 1 at Appendix A in Section C No kick sound gt gt gt gt gt Refer to the 2 at Appendix A in Section C Check if there is leaking from heat exchanger Part 401 Check if there is dust and lint in nozzles of the manifold Part 102 Check current on the flame rod Part 108 Refer to the 3 at Appendix A in Section C Loss of flame Check gas supply and inlet gas pressure Check if the Hi limit switch Part 412 is properly functioning 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 leakage from heat exchanger Part 401 Check if th
12. ere 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 hea N wne Poon oN 311 321 331 Disconnected short circuited thermistor Check for connection breakage of wires and or debris on thermistor Part 407 408 411 716 Check thermistor resistance Refer to the Appendix D in Section C 391 Air fuel Ratio Rod failure Check for connection breakage of wires Part 709 and or soot on the AFR rod Part 108 441 Flow Sensor failure Only Easy Link system Check for connection breakage of wires and or debris on the flow sensor impeller Part 402 717 510 Abnormal Main and Solenoid 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 611 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 651 Flow adjustment valve fault Only Easy Link system Inspect the flow adj
13. ngs 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 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 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 412 is properly functioning 3 Check for connection breakag
14. oor 319143 217 Fan motor for 510 Outdoor 104 319143 032 Burner holder gasket 105 319143 031 Burner gasket 106 319143 033 Burner window 107 319143 034 Rod holder gasket 108 319143 035 Flame rod 109 319143 037 Igniter rod 110 319143 036 Rod holder 111 319143 038 Rod cap 112 319143 156 Burner damper 113 319143 044 Manifold gasket A 114 319143 045 Manifold gasket B 115 319143 367 Fan damper Only 510 Indoor 116 319143 042 Pressure port 117 319143 041 Combustion chamber tube for 510 Indoor 319143 344 Combustion chamber tube for 510 Outdoor 118 319143 050 Gas inlet 119 319143 049 Gas inlet ring 120 319143 051 Igniter plate 121 319143 176 Surge box plate 150 319143 350 O ring P18 NBR Black 151 319143 057 O ring P20 NBR Black 152 319143 206 Silicon ring Only 510 Outdoor 153 319143 216 Rain protection plate in Exhaust chamber Only 510 Outdoor 154 319143 219 Exhaust port Only 510 Outdoor Screw M3x6 Screw M4x6 Pan screw M4x8 Nylon clamp Wire clamp 60 Computer board assembly Water way assembl section Water outlet section Item Part Description 701 319143 179 Computer board 702 319143 182 Transformer 703 319143 168 Surge box 704 319143 138 AC120V wire 705 319143 180 Transformer wire 706 319143 141 AC120V Power ON OFF switch 707 319143 181 Switch wire 708 319143 188 Gas valve wire 709 319143 189 Flame rod wire 710 319143 187 EH
15. t Refer to Easy Link system section in the Installation manual 991 Imperfect combustion Refer to the 101 error code in this section w C Wiring Diagram and check point of the Water heater A2 w Whi te BL Blue A AC120v R Red G Green w se ge pan ox BK Black Y Yellow E a He ound P Purple o Or ange 5 Wek Let 87 LB Light blue BR Brown gt 8K Trans L BR BR former j BRAIFBR F M 8 G Ground Sw 1 yet 2 G et ne Q w PE OW S BK I Propor w w mea el Heater tional lr BKH ay 8 H1 Akp W Heater B1 G i 415 Freeze 6 A 5 E protect ion Flow BK 8K 2 thermostat Sensor RER ul B 7 e PY P Q P P E Na Elect rod AFR rod i er w G BL a I 8 3 wy Ground Flame rod C BL HBL 0 BL ifer A SV 1 T 53 G O H C F ee re BL __ Adjust R BES rs 7sLe BL ment Bkk G J Valve ee T O Ml suave IN D oy w E eur BK Hl SLAVE OUT Mult i system On line LED MASTER w B R Tre BKB K w Pump conne
16. ustment valve Part 402 for connection breakage of wires Part 718 locked motor drive due to scale buildup and or water leakage Check voltage between black wire and red wire Refer to the Appendix F in Section C 701 Computer board fault Check for connection breakage of wires Part 714 and or burn marks on the computer board Part 701 721 False flame detection 1 Clean the flame rod Part 108 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 401 741 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 Check the power supply of the water heater 4 If this error code appears only the 7 Seg LED on the PCB Part 701 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 701 6 If this error code appears both the PCB Part 701 and the remote controller replace the 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 correc
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