Checking these four (4) items first will often result in a timely solution to the service call.
WARNING
JUMPING OUT COMPONENTS AND/OR CIRCUITS DURING TROUBLESHOOTING CAN CAUSE SERIOUS PROBLEMS WITH THE UNIT’S OPERATING SEQUENCE AND IGNITION SAFETY. IF YOU DO NOT HAVE THE PROPER TEST EQUIPMENT, I.E. A VOLT-OHM METER AND A MICROMETER, DO NOT ATTEMPT TO TROUBLESHOOT OR REPAIR A.O. SMITH EQUIPMENT.
ALTERING THE CONTROLLER AND/OR CONTROLLER WIRING IN ANY WAY COULD RESULT IN INTERNAL DAMAGE TO THE MODULE CIRCUITS, POSSIBLY ALTERING THE IGNITION SEQUENCE ALLOWING GAS VALVES TO OPEN BEFORE THE HOT SURFACE IGNITER IS UP TO IGNITION TEMPERATURE.
NOTE: ANY BYPASS OR ALTERATION OF THE UNITS SAFETIES WILL RESULT IN VOIDING THE APPLIANCE WARRANTY.
Before performing any troubleshooting familiarize yourself with the particular appliance.
Refer to the SEQUENCE OF OPERATION and the connection diagram located on page 16 before continuing.
Make sure the appliance is connected to a 120V AC power supply, manual gas valve is in the ON position, and all electrical connections are secure before continuing to troubleshoot this appliance.
CAUTION
THE WATER HEATER IS POLARITY SENSITIVE. BEFORE APPLYING ELECTRICITY TO THIS HEATER BE CERTAIN THAT SUPPLY NEUTRAL WIRE TO GROUND CHECK INDICATES ZERO VOLTAGE.
MOTOR WILL NOT RUN
1.Confirm 120V AC. Also, to verify correct polarity, check for 120 V AC between hot supply and ground. If there is no voltage, check for a loose connection.
2.For BTH 400, a VFD (Variable Frequency Drive) is used. "rdy" (stands for ready) will be shown on display in standby heating mode. "152" (152 output Hz) shall be shown on VFD display during heater running. Any other display (other than "rdy" or "152") indicates the VFD fault. Check 120V AC to the VFD power input L1 and N terminals. Check the open contact of the relay (mounted on VFD) wired to VFD terminal +15V and LI1. When calling for heat, the relay should be energized, the relay contact will change from "open" to "close", and VFD display will change from "rdy" to "152", and blower starts to run. If there's no display change (from "rdy" to "152") on VFD during the call for heat, check the wire from the controller blower connector to the relay A1 and A2 terminal or replace the relay coil.
MOTOR RUNS, PREPURGE TIME ELAPSES BUT
MAIN FLAME NOT ESTABLISHED
1.Check to see if main manual gas valve is open.
2.Check for a loose connection at the transformer, or a defective transformer.
3.Check for a loose connection at the gas valve.
4.Check for open pressure switches or open reset button. Check for blockage in the intake and exhaust venting or at the vent hoods. If no blockage is found, check vinyl tubing for cuts or crimps. If this tubing is damaged it must be replaced. If these steps do not eliminate the problem, replace the pressure switches.
5.Check to see if there is resistance across the igniter terminal with an OHM meter. If there is no continuity, the igniter is broken and should be replaced.
If the igniter appears to function properly, then verify that the inlet pressure is 11.0" Natural Gas (2.74 kPa). The gas valve supplied on this appliance is not designed to open against a higher pressure. At this time also check that the inlet pressure is not lower than the minimal gas supply pressure, as shown in Table 4: that is, for Natural Gas, 5.2" (1.29 kPa) W.C. If the inlet pressure is not within these limits then adjust the supply pressure accordingly.
If the inlet pressure falls within the allowable limits, then verify that the manifold pressure, when the gas is fully open, with the heater running, is as called out in Table 4: that is, for Natural Gas, 4.0" (0.996 kPa) W.C. If the manifold pressure is not correct then adjust accordingly. See ADJUSTMENT PROCEDURE in OPERATING INSTRUCTIONS selection, page 19, for the manifold pressure adjustment procedure.
6.If the inlet and manifold pressures are within the limits specified in step 5, then reset the appliance. Verify 24V AC at the gas valve during the three (3) second ignition trial, after the igniter reaches operating temperature. If 24V AC at the gas valve is not seen during this period, the controller must be replaced.
If there is 24V AC at the gas valve during the four second ignition trial and the manifold pressure does not increase above 0" W.C. then verify that the manual gas control valve is in the “ON” position (see page 20). If the valve is in the “ON” position and the previous voltage and gas pressure conditions are met, then the gas valve is defective and must be replaced.
Note that a positive manifold pressure reading of approximately 1.5" (.38 kPa) W.C. is normal during the prepurge portion of the ignition cycle due to the location of the gas orifice.
MOTOR RUNS, BURNER LIGHTS MOMENTARILY,
THEN LOCKS OUT
1.Reset the appliance two more times to ensure that all of the air has been purged from the gas line.
2.If the burner lights momentarily but does not sustain ignition, verify that the inlet pressure is not greater than 11.0" (2.74 kPa) W.C. or lower than the minimal gas supply pressure, as shown in Table 4: that is, for Natural Gas, 5.2" (1.29 kPa) W.C. pressure. Also, the manifold pressure should rise during the three (3) second trial for ignition to the manifold pressure value for the individual unit listed in Table 4: that is, for Natural Gas, 4.0" (0.996 kPa) W.C. If the manifold pressure is not correct then adjust accordingly. See ADJUSTMENT PROCEDURE in OPERATING INSTRUCTIONS section, page 19, for the manifold pressure adjustment procedure.
3.Check for the reversed polarity in the supply wiring. This controller is polarity sensitive. If the hot and neutral supply wires are reversed, the controller will not sense flame. Reverse the supply wires and try to fire the unit.
