A.O. Smith 510 User manual

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

510 Indoor / 510 Outdoor Service Manual
Ver. 1.00
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CONFIDENTIAL
Table of Contents
1.
Specifications………………………………………...…...………….……………………...…………………………
3
2.
Exterior view……………………...…….……………………………………………………………………………....
4
3.
Interior view…………………………….………………………………………………………………………………..
6
4.
Listof main components in the interior view…….…………………………………………………….…
8
5.
Schematic diagram…………………………………………………………………………………………………….
10
6.
Wiring diagram………………………………………………………………………………………………………….
11
7.
Wiring diagram checkpoints for diagnosis………………………..………………….………………….…
12
8.
Resistance values of the temperature thermistors…………..…………………………………………
14
9.
Operationalflow chart…………………………………………………………………………………………….…
15
10.
Component specifications………………...…………………………………………………………………….…
16
11.
FaultAnalysis &Specifications…………………………………………………………………………………..
36
12.
Controls and settings……………………………………………………………………………………………….…
46
13.
Components diagrams………………………………………………………………..................................
70
14.
Parts list……………………………………………………………………………………………………………………..
73
15.
Revisions……………………………………………………...………………………………………………………......
77

510 Indoor / 510 Outdoor Service Manual
Ver. 1.00
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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.
Combustion
INPUT
BTU/h Max 199,000
Min 11,000
Combustion System
Power vent
Installation Indoor & Direct-vent Outdoor
Fan motor PWM turbo fan PWN multi blade fan motor
Manifold
Pressure*
Max LP 3.5” WC
Natural 2.0” WC LP 4.4” WC Natural 2.8” WC
Min LP 0.7” WC
Natural 0.4” WC LP 0.9” WC Natural 0.5” WC
Water control
Flow rate 0.75 to 10.0 GPM
Available set
temperatures 99 to185°F default: 122°F
Temperature
dipswitch settings
104°F, 113°F, 122°F, 131°F, 140°F, 158°F, 176°F, 185°F
Bypass valve Yes
Thermistors 3 thermistors (In, Out, Mixing)
Operation
Remote controller
model 9007603005
PCB model 510
Indicators Red LED on PCB during operation & 7-SEG LED
Power supply
control Surge absorber & Power ON-OFF switch
Features
Freezeprotection
Ceramicheaters and Auto-firing system
Self-combustion
improvement Air-Fuel Ratio Detection System
Easy-Link system
Yes (Up to 4 units)
Multiple-system
N/A
*The 510 DirectVent Indoormeansthe 510 Indoor in thetext.
**Themanifold pressuremeasurement isbased on conditions withoutfrontcover.

510 Indoor / 510 Outdoor Service Manual
Ver. 1.00
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CONFIDENTIAL
13-3/4" (350mm)
10" (254mm)
1-3/4" (45mm) 1-3/4" (45mm)
1-3/8" (36mm)
3-9/8 ( 101mm)
21-3/8" (544mm) 20-1/4" (520mm)
1-7/8" (47mm)
HOT 5-1/4" (133mm)
120V 1-3/8" (36mm)
GAS 4-7/8" (124mm)
COLD 3-1/4" (84mm)
4-3/8" (113mm)
1-5/8" (43mm)
19-3/8" (493mm)
COLD 2-7/8" (71mm)
1" (26mm)
HOT 6-1/2" (164mm)
9-1/2" (241mm)
120VAC 3-7/8" (99mm)
GAS 5-1/4" (135mm)
2. Exterior view
Top view Bottom view
Side view Front view
COLD 2-7/8" (71mm)
HOT 6-1/2" (164mm)
HOT 5-1/4" (133mm) GAS 4-7/8" (124mm)
GAS 5-1/4" (135mm)
120VAC 3-7/8" (99mm)
120VAC 1-3/8" (36mm)COLD 3-1/4" (84mm)
13-1/8" (334mm)
4-3/8" (113mm)
5-1/8" (130mm)
510 Indoor

510 Indoor / 510 Outdoor Service Manual
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CONFIDENTIAL
Side view Frontview
Bottom view
Top view
510 Outdoor
13-3/4" (350mm)
10" (254mm)
1-3/4" (45mm) 1-3/4" (45mm)
21-3/8" (544mm) 20-1/4" (520mm)
1-7/8" (47mm)
HOT 5-1/4" (133mm)
120V 1-3/8" (36mm)
GAS 4-7/8" (124mm)
COLD 3-1/4" (84mm)
4-3/8" (113mm)
19-3/8" (493mm)
COLD 2-7/8" (71mm)
1" (26mm)
HOT 6-1/2" (164mm)
9-1/2" (241mm)
120VAC 3-7/8" (99mm)
GAS 5-1/4" (135mm)
1-5/8" (43mm)
5" (128mm)
7-7/8" (203mm)
13-1/8" (334mm)
COLD 2-7/8" (71mm)
HOT 6-1/2" (164mm)
HOT 5-1/4" (133mm) GAS 4-7/8" (124mm)
GAS 5-1/4" (135mm)
120VAC 3-7/8" (99mm)
120VAC 1-3/8" (36mm)COLD 3-1/4" (84mm)

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3. Interior view
510 Indoor
1
3
4
5
67
9
8
31
10
11
13
14
15
16
17
18
18
19
2
21
12
23
24
32
25
22
28
29
27
30
20
26

510 Indoor / 510 Outdoor Service Manual
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510 Indoor
1
3
4
5
67
9
8
31
10
11
13
14
15
16
17
18
18
19
2
21
12
23
24
32
25
22
28
29
27
30
20
26

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4. List of main components in the interior view
No. Description Items# in components
diagram
AOS
Part # Common parts forothermodels
1 Case assembly 001 319143-151 (510 Indoor)
319143-211 (510 Outdoor)
2 Manifold assemblywith gas
valve assembly 102 319143-046 (LP model)
319143-368 (NA model)
3 Computerboard 701 319143-179
4 Igniter 711 319143-052 110, 310,710,
910, 520
5 Transformer 702 319143-182 110, 310
6 Water inlet 404 319143-193 110,310
7 Wateroutlet 409 319143-194 110,310
8 Inlet thermistor 407 319143-085
9 Mixing thermistor 408 319143-190
10 Overheatcut-off fuse 413 319143-149 110, 310,910
11 Burner assembly (Burners) 101 319143-030
12 Hi-limitswitch 412 319143-095
13 Fan motor 103 319143-043 (510 Indoor)
319143-217 (510 Outdoor)
310
14 Freeze protection
thermostat
713 319143-185 (510 Indoor)
710 319143-210 (510 Outdoor)
110, 310
15 Flow sensor 402 319143-178
16 Heatexchanger assembly 401 319143-369 (510 Indoor)
319143-177 (510 Outdoor)
17 Gas inlet 118 319143-050 110, 310, 520
18 Heater 414 319143-200 110,310
19 Flow adjustmentvalve 402 319143-178
20 Surge box 703 319143-168 110, 310

510 Indoor / 510 Outdoor Service Manual
Ver. 1.00
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CONFIDENTIAL
No.
Description Items# in components
diagram
AOS
Part # Common parts forothermodels
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 Igniterrod 109 319143-037
25 Inlet drain plug (water filter)
405 319143-197 110,310
26 120 VAC PowerON-OFF
switch 706 319143-141 110, 310, 520
27 Gas valve assembly Included in
#102
319143-046 (LP model)
319143-368 (NA model)
28 Manifold port N/A N/A
29 Gas inletport N/A N/A
30 Exhaust chamber Included in
#401
319143-369 (510 Indoor)
319143-177 (510 Outdoor)
31 Outputthermistor 411 319143-096
32 Bypass valve 403 319143-186

510 Indoor / 510 Outdoor Service Manual
Ver. 1.00
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CONFIDENTIAL
5. Schematic diagram
Thediagram below refers to both the 510 Indoorand 510 Outdoor.
1. When a hot water tap is opened,cold water enters the 510 Indoor or510 Outdoor.
2. The water flow sensor detects this water flowand sends this information to computer.
3. The computer initiatesfan motorand sends signal to igniter to createignition spark.
4. The main, proportional, and solenoid gas valves open to allow gas input.
5. The gas ignitesand flames appear inside the burner chamber.
6. Water circulates through the heat exchanger and isheated up to the settemperature.
7. Using thermistors to measure temperatures, the computer modulates the gas and water valves to
ensureproperoutput water temperatures.
8. When the tap is closed, the 510 Indoor or 510 Outdoor shutsdown.
H
O
T
C
O
L
D
G
A
S
PCB
Hi-limit SW
Inlet drain
plug filter
Mixing
Thermistor
Drain plug
Main gas valve
Gas solenoid valve 2
Fan motor
Flame rod
Igniter rod
Igniter
O.H.C.F
Heater
Flow adjustment valve
with Flow sensor
Gas proportional valve
Gas solenoid valve 1
Air-fuel ratio rod
Gas solenoid valve 3
Output
Thermistor
Bypass valve
Inlet
Thermistor Transformer