A.O. Smith 100 Series User manual

PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE WHENEVER MAINTENANCE
ADJUSTMENT OR SERVICE IS REQUIRED.
100355302_2000548888CPRINTED 0322
Instruction Manual
INDUSTRIAL ELECTRIC WATER HEATERSINDUSTRIAL ELECTRIC WATER HEATERS
Thank you for buying this energy efcient water heater. We
appreciate your condence in our products.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
MODELS 52/80/120 (SERIES 100)
Saudi Arabia and Kuwait Manual
Installation - Service
- Maintenance - Operation
If the water heater becomes immersed in water up to or
above the level of the bottom of the element doors,
the heater should be examined by a qualified service
agency before it is placed in operation.
Electrical Shock Hazard
Printed on 5/6/2022 7:17 AM CT

2
Note: USER/OWNER (BOLD TEXT)
QUALIFIED INSTALLER/SERVICE AGENCY ONLY (STANDARD TEXT).
CONTENTSCONTENTS
SAFE INSTALLATION, USE, AND SERVICE.................................... 3
Important Definitions ............................................................. 3
GENERAL SAFETY INFORMATION ................................................. 4
Limiting the Risk of Scalding ................................................. 4
Precautions........................................................................... 4
Hydrogen Gas (Flammable) .................................................. 4
Hazard Messages ................................................................. 4
INTRODUCTION ................................................................................ 7
Preparing for the Installation ................................................. 7
FEATURES AND COMPONENTS ..................................................... 8
Model And Rating................................................................ 10
INSTALLATION CONSIDERATIONS................................................11
Rough-In Dimensions.......................................................... 11
Locating the Water Heater .................................................. 11
INSTALLING THE WATER HEATER ............................................... 12
Required Ability................................................................... 12
General............................................................................... 12
Contaminated Water ........................................................... 12
Circulating Pump................................................................. 12
Insulation Blankets.............................................................. 12
Temperature-Pressure Relief Valve..................................... 13
Water Line Connections...................................................... 13
Closed Water Systems........................................................ 13
Thermal Expansion ............................................................. 14
Electrical ............................................................................. 14
Amperage Table/Over-current Protection ............................ 15
Heater Circuits - Electronic Control Models......................... 15
Control Circuit - Electronic Control Models.......................... 15
Sequence of Operation ....................................................... 16
START UP......................................................................................... 17
Filling the Water Heater ...................................................... 17
Initial Start Up ..................................................................... 17
Draining the Water Heater................................................... 17
TEMPERATURE REGULATION ...................................................... 18
Limiting the Risk of Scalding ............................................... 18
High Temperature Limit Controls (ECO).............................. 18
Thermostat Controls ........................................................... 18
CONTROL SYSTEM OPERATION .................................................. 20
Control System Features .................................................... 20
Control System Navigation.................................................. 20
Home Screen ...................................................................... 20
Temperatures Menus .......................................................... 23
Economy Mode Setup Menu ............................................... 26
Economy Mode Settings ..................................................... 27
Alarm Output Setup Menu................................................... 30
Display Settings Menu ........................................................ 31
Heater Information Menu .................................................... 31
Current Fault / Alert Menu................................................... 32
Fault History Menu.............................................................. 32
Fault Occurrence Menu....................................................... 33
Restore Factory Defaults Menu........................................... 33
MAINTENANCE................................................................................ 34
Draining and Flushing ......................................................... 34
Anode Maintenance ............................................................ 34
Sediment Removal.............................................................. 35
Lime Scale Removal ........................................................... 35
Temperature-Pressure Relief Valve Test ............................. 36
TROUBLESHOOTING...................................................................... 37
Checklist ............................................................................. 37
Checking for Leaks ............................................................. 38
DIAGRAMS....................................................................................... 39
Wiring Diagrams ................................................................. 39
Piping Diagrams.................................................................. 48
MANIFOLD KITS .............................................................................. 56
Printed on 5/6/2022 7:17 AM CT

3
SAFE INSTALLATION, USE, AND SERVICESAFE INSTALLATION, USE, AND SERVICE
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you
and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very
important that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
DANGER
WARNING
CAUTION
CAUTION
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death. Keep this manual near the water heater.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result
in minor or moderate injury.
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and
how to avoid the risk of injury.
IMPORTANT DEFINITIONS
• Qualied Installer or Service Agency:
Installation and service of this water heater requires ability
equivalent to that of a Qualied Agency (as dened by
ANSI below) in the eld involved. Installation skills such
as plumbing, electrical supply are required in addition to
electrical testing skills when performing service.
• ANSI Z223.1 2006 Sec. 3.3.83:
“Qualied Agency” - “Any individual, rm, corporation or
company that either in person or through a representative
is engaged in and is responsible for (a) the installation,
testing or replacement of gas piping or (b) the connection,
installation, testing, repair or servicing of appliances and
equipment; that is experienced in such work; that is familiar
with all precautions required; and that has complied with all
the requirements of the authority having jurisdiction.”
Electrical Shock Hazard
Installation and Service, including
Maintenance, shall be conducted by
a Qualified Installer or Service
Agency only.
Printed on 5/6/2022 7:17 AM CT

4
GENERAL SAFETY INFORMATIONGENERAL SAFETY INFORMATION
LIMITING THE RISK OF SCALDING
For a variety of reasons, water heaters can produce water that is
much hotter than its temperature setting. Take precautions to prevent
this higher temperature water from reaching the water xtures.
Burn Hazard
To reduce the risk of unusually hot
water reaching the fixtures in the
house, install thermostatic mixing
valves at each point of use.
A properly adjusted thermostatic mixing valve at each point of use
allows you to set the tank temperature to a higher setting without
increasing risk of scalds. A higher temperature setting allows the
tank to provide much more hot water and can help provide proper
water temperatures for appliances such as dishwashers and washing
machines.
PRECAUTIONS
DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN
EXPOSED TO FLOODING OR WATER DAMAGE. Immediately
call a qualied service technician to inspect the water heater and to
replace any part of the control system which has been under water.
If the unit is exposed to the following, do not operate heater until all
corrective steps have been made by a qualied service technician.
1. External re.
2. Damage.
3. Firing without water.
This appliance is not to be used by children or persons with reduced
physical, sensory or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision or instruction
concerning use of the appliance by a person responsible for their
safety.
Children should be supervised to insure they do not play with the
appliance.
GROUNDING INSTRUCTIONS
This water heater must be grounded in accordance with the National
Electrical Code and/or local/national codes. These must be followed
in all cases. Failure to ground this water heater properly may also
cause erratic control system operation on ELECTRONIC CONTROL
models.
This water heater must be connected to a grounded metal,
permanent wiring system; or an equipment grounding conductor must
be run with the circuit conductors and connected to the equipment
grounding terminal or lead on the water heater.
HYDROGEN GAS (FLAMMABLE)
Explosion Hazard
Flammable hydrogen gases
may be present.
Keep all ignition sources away
from faucet when turning on
hot water.
Hydrogen gas can be produced in a hot water system served by this
heater that has not been used for a long period of time (generally two
weeks or more). Hydrogen gas is extremely ammable. To reduce
the risk of injury under these conditions, it is recommended that the
hot water faucet be opened for several minutes at the kitchen sink
before using any electrical appliance connected to the hot water
system. If hydrogen is present there will probably be an unusual
sound such as air escaping through the pipe as the water begins to
ow. THERE SHOULD BE NO SMOKING OR OPEN FLAME NEAR
THE FAUCET AT THE TIME IT IS OPEN.
When servicing this unit, verify the power to the unit is turned off prior to opening the control cabinet door.
HAZARD MESSAGES
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
If the water heater becomes immersed in water up to or
above the level of the bottom of the element doors,
the heater should be examined by a qualified service
agency before it is placed in operation.
Electrical Shock Hazard
Electrical Shock Hazard
Installation and Service, including
Maintenance, shall be conducted by
a Qualified Installer or Service
Agency only.
Printed on 5/6/2022 7:17 AM CT

5
Burn Hazard
To reduce the risk of unusually hot
water reaching the fixtures in the
house, install thermostatic mixing
valves at each point of use.
Explosion Hazard
Flammable hydrogen gases
may be present.
Keep all ignition sources away
from faucet when turning on
hot water.
Property Damage Hazard
• All water heaters eventually leak.
• Do not install without adequate drainage.
CAUTION
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or shower-
ing.
Temperature limiting devices such as
thermostatic point-of-use mixing
valves must be installed when
required by codes and to ensure safe
temperatures at fixtures.
Toxic Chemical Hazard
WARNING
● Do not connect to non-potable water system.
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22-
CSA 4.4 and ASME code.
Properly sized temperature-
pressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
Property Damage Hazard
●The temperature-pressure relief-valve discharge pipe
must terminate at an adequate drain.
Full power is present whenever the
cabinet door is opened, even with
the pilot switch turned off.
Electrical Shock Hazard
Property Damage Hazard
To avoid water heater damage, fill tank with water
before operating.
CAUTION
• Burn hazard.
• Hot water discharge.
• Keep hands clear of drain
valve discharge.
Burn Hazard
Controls may become hot during normal
operation. Care should be taken to
prevent burns.
CAUTION
Printed on 5/6/2022 7:17 AM CT

6
Burn hazard.
Hot water discharge.
Keep clear of Temperature-
Pressure Relief Valve
discharge outlet.
Avoid damage.
Property Damage Hazard
Inspection and replacement of anode rod required.
Property Damage Hazard
To avoid water heater damage, fill tank with water
before operating.
CAUTION
Printed on 5/6/2022 7:17 AM CT

7
INTRODUCTIONINTRODUCTION
Thank You for purchasing this water heater. Properly installed
and maintained, it should give you years of trouble free service.
Installation and service of this water heater requires ability equivalent
to that of a licensed tradesman or qualied agency (page 2) in the
eld involved. Plumbing and electrical work are required.
Abbreviations Found In This Instruction Manual:
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• GAMA - Gas Appliance Manufacturer’s Association
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• UL - Underwriters Laboratory
PREPARING FOR THE INSTALLATION
1. Read the “General Safety Information” section of this manual rst
and then the entire manual carefully. If you don’t follow the safety
rules, the water heater may not operate safely. It could cause
DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY
DAMAGE.
This manual contains instructions for the installation,
operation, and maintenance of the electric water heater.
It also contains warnings throughout the manual that you
must read and be aware of. All warnings and all instructions
are essential to the proper operation of the water heater
and your safety. READ THE ENTIRE MANUAL BEFORE
ATTEMPTING TO INSTALL OR OPERATE THE WATER
HEATER.
Detailed installation diagrams are provided for the Qualied
Installer in this manual. These diagrams will serve to
provide the installer with a reference for the materials and
method of piping suggested. IT IS NECESSARY THAT
ALL WATER PIPING AND THE ELECTRICAL WIRING
BE INSTALLED AND CONNECTED AS SHOWN IN THE
DIAGRAMS. See Wiring Diagrams (page 39) .
The model and rating plate in Model And Rating (page 10)
have certain markings and useful information. Use these
references to identify the heater.
2. The installation must conform with these instructions and the Local/
National code authority having jurisdiction and the requirements
of the power company. In the absence of Local/National codes,
the installation must comply with the latest editions of the National
Electrical Code, NFPA 70 or the Canadian Electrical Code CSA C22.1 . The
National Electrical Code may be ordered from: National Fire Protection
Association, 1 Batterymarch Park, Quincy, MA 02269. The
Canadian Electrical Code is available from the Canadian Standards
Association, 8501 East Pleasant Valley Road, Cleveland, OH
44131. Qualied Installer must install an all pole, full disconnect
switch, per the Local/National code.
3. If after reading this manual you have any questions or do not
understand any portion of the instructions, call the toll free number
listed on the back cover of this manual for technical assistance.
A sample rating plate is shown on page 6 of this manual. In
order to expedite your request, please have full model and
serial number available for the technician.
4. Carefully plan your intended placement of the water heater.
Examine the location to ensure the water heater complies with the
“Locating the New Water Heater” section in this manual.
Printed on 5/6/2022 7:17 AM CT

8
FEATURES AND COMPONENTSFEATURES AND COMPONENTS
This Instruction Manual covers two models of commercial electric
water heaters. These two models are equipped from the factory with
di󰀨erent controls.
In this Instruction Manual, one model is factory equipped with
a surface mounted thermostat/ECO combination control and is
referred to as: “Surface Mount Control” models.
In this Instruction Manual ,the other model is equipped with an
electronic control system and is referred to as: “Electronic Control”
models.
Figure 1. Electronic Control Models
Printed on 5/6/2022 7:17 AM CT

9
Figure 2. Surface Mount Control Models
Printed on 5/6/2022 7:17 AM CT

10
Table 1. Recovery Rate in Gallons per Hour* Temperature Rise °F
Standard
kW Input
Input
BTUH
DegF 30° 40° 50° 60° 70° 80° 90° 100° 110° 120° 130° 140°
DegC 17° 22° 28° 33° 39° 44° 50° 56° 61° 67° 72° 78°
620,478 Gallon 82 62 48 41 35 31 27 25 22 21 19 18
Liter 310 235 185 155 132 117 102 95 83 79 72 68
930,717 Gallon 123 92 74 62 53 46 41 37 34 31 28 26
Liter 466 348 280 235 201 174 155 140 129 117 106 98
12 40,956 Gallon 164 123 98 82 70 61 55 49 45 41 38 35
Liter 621 466 371 310 265 231 208 185 170 155 144 132
13.5 46,075 Gallon 184 138 111 92 79 69 62 55 50 46 43 40
Liter 696 522 420 348 299 261 235 208 189 174 163 151
15 51,195 Gallon 205 154 123 102 88 77 68 61 56 51 47 44
Liter 776 583 466 386 333 291 257 231 212 193 178 167
18 61,434 Gallon 246 184 148 123 105 92 82 74 67 61 57 53
Liter 931 696 560 466 397 348 310 280 254 231 216 201
24 81,912 Gallon 328 246 197 164 140 123 109 98 89 82 76 70
Liter 1241 931 746 621 530 466 413 371 337 310 288 265
27 92,151 Gallon 369 276 221 184 158 138 123 111 101 92 85 79
Liter 1397 1045 836 696 598 522 466 420 382 348 322 299
30 102,390 Gallon 410 307 246 205 176 154 137 123 112 102 95 88
Liter 1552 1162 931 776 666 583 519 466 424 386 360 333
36 122,868 Gallon 492 369 295 246 211 184 164 148 134 123 113 105
Liter 1862 1397 1117 931 799 696 621 560 507 466 428 397
40.5 138,226 Gallon 554 418 3332 277 237 208 1185 166 151 138 128 119
Liter 2097 1582 12612 1048 897 787 4485 628 572 522 484 450
45 153,585 Gallon 615 461 369 307 263 230 205 184 168 154 142 132
Liter 2328 1745 1397 1162 995 871 776 696 636 583 537 500
54 184,302 Gallon 738 553 443 369 316 277 246 221 201 184 170 158
Liter 2793 2093 1677 1397 1196 1048 931 836 761 696 643 598
MODEL AND RATING
Figure 3. Rating Plate
Printed on 5/6/2022 7:17 AM CT