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TB-A028-06 - A. O. SMITH - FVIR INTELLI-VENT TROUBLESHOOTING CHART TB-A028-06 - A. O. SMITH - FVIR INTELLI-VENT TROUBLESHOOTING CHART
A. O. Smith Water Products Company
AHSTB02807
Technical Training Department
Ashland City, Tennessee © 2006
1 of 5
Intelli-Vent Trouble Chart FVIR AOS.fm
#
LED STATUS
PROBLEM
SOLUTION
1
Inadequate or no earth ground
sensed by the Intelli-Vent
control.
1 Ensure the wall outlet is properly grounded.
2 Ensure all ground connections/wires on the water
heater are secure.
2
Power supply to Intelli-Vent
control has reversed polarity.
1 Ensure the wall outlet is properly wired.
2 Ensure all internal 120 VAC wiring connections and
wiring harness have no reversed wires. 120 VAC
hot wire must connect to the on/off switch.
3
Pressure switch circuit remaining
closed for more than 5 seconds
after heating cycle begins.
Blower does not start.
1 Ensure air pressure switch circuit wiring is correct
and the air pressure switch is not jumpered.
2 Secure power to water heater, check continuity of air
pressure switch contacts with wires disconnected.
A If pressure switch contacts show continuity (closed
circuit) replace the pressure switch.
B If pressure switch contacts are open and all wiring
is correct - turn the power off for 10-20 seconds
then on again to clear the error code - if the error
code persists replace the Intelli-Vent control.
4
Pressure switch circuit remains
open longer than 5 seconds after
the blower is energized.
Blower may run continuously
in this condition.
1 Ensure the blower is running - check for 120 VAC to
the blower when the heating cycle begins, check the
wiring. If the control does not energize the blower -
replace the Intelli-Vent control. If the blower fails to
start when energized - replace the blower assembly.
2 Ensure the air pressure switch sensing tube is
properly connected - not kinked or damaged.
3 Check continuity of vent temperature limit switch -
replace switch if contacts remain open under 160°F.
4 Ensure the correct size of vent pipe (2, 3, 4) was
used per the installation manual for vent length.
Ensure maximum number of elbows or equivalent
feet of vent pipe has not exceeded maximum limits.
5 Ensure there are no obstructions in the vent pipe.
6 Check air pressure switch performance - check
pressure with a digital manometer - check continuity
of contacts. (see service note in left column) If the
switch proves defective - replace the air pressure
switch and/or the blower assembly as required.
7 If air pressure switch performance test results prove
the air pressure switch is working properly and error
code 4 persists - replace the Intelli-Vent control.
5
The Intelli-Vent control has
detected an open ignitor circuit.
1 Check wiring to the hot surface ignitor - replace
ignitor assembly if wiring is damaged or worn.
2 Check ignitor assembly plug and the socket on the
Intelli-Vent body for good connection. Replace
ignitor assembly and/or control if necessary.
3 Check resistance of ignitor at room temperature
(77°F) at the plug end. Replace ignitor if resistance is
not within 11.5 and 18.8 ohms at room temperature.
4 If results from the above tests were good and error
code 5 persists - replace the Intelli-Vent control.
Service Note:
To learn more about performing
Air Pressure Switch tests visit
our web site www.hotwater.com
to download technical bulletin
TB-A023-06 Air Pressure
Switches.
Service Note:
Secure power - disconnect one
wire from the air pressure switch
or the vent temperature limit
switch. Turn power back on -
blower should start.
Service Note:
Ignitors are wearing parts; the
resistance (ohms) of a hot
surface ignitor will increase over
time. If the resistance at room
temperature is near 18.8 ohms -
consider replacing the ignitor as a
preventative measure. A. O. Smith Water Products Company
AHSTB02807
Technical Training Department
Ashland City, Tennessee © 2006
2 of 5
Intelli-Vent Trouble Chart FVIR AOS.fm
TB-A028-06 - A. O. SMITH - FVIR INTELLI-VENT TROUBLESHOOTING CHART
#
LED STATUS
PROBLEM
SOLUTION
6
Ignition/flame failure.
The water heater has reached
the maximum number of retries
and is currently locked out for
one hour.
Cycle the power to the water
heater off and on to reset.
1 Gas supply is turned off - pressure too low. Ensure
supply and manifold gas pressures are within
requirements in the installation manual. Manifold gas
pressure is non-adjustable if pressure is off by more
than 0.3 W.C. replace the Intelli-Vent control.
2 Low supply voltage - should be 115 - 125 VAC.
3 Ensure flame sensor is making good contact with the
burner flame, ensure flame is steady see #8 below.
4 Ensure the flame sensor is clean - use ultra fine steel
wool or Scotch-Brite pad to clean flame sensor.
5 Ensure the hot surface ignitor is positioned to provide
consistent ignition.
6 Check for any cracks in ignitor assembly ceramic
insulators - replace ignitor assembly if damaged.
7 Check resistance of ignitor at room temperature
(77°F) at the plug end. Replace ignitor if resistance is
not within 11.5 and 18.8 ohms at room temperature.
8 Ensure the correct size of vent pipe (2, 3, 4) was
used per installation manual for vent length. Using
larger pipe than required may cause excessive air
turbulence in the combustion chamber.
7
8
9
Self diagnostic tests have found
a problem with the gas valve
driver circuit, internal
microprocessor, or other internal
circuits.
1 Turn the power off for 10-20 seconds then on again
to clear these error codes.
2 If any of these error codes persist or cannot be
cleared - replace the Intelli-Vent control.
10
Flame signal has been sensed
out of proper sequence.
1 Turn the power off for 10-20 seconds and then on
again to clear this error code.
2 Replace the Intelli-Vent control if this error code
persists.
11
Water temperature in the tank
has exceeded 195°F and has
activated the ECO.
1 Turn the power off for 10-20 seconds then on again
to clear this error code.
2 Replace the control if the error code persists.
12
The self diagnostic check
detected one or both of the
temperature adjust buttons are
stuck.
1 Press and release temperature adjust buttons. If the
above action does not clear the error, the control will
continue to regulate water temperature at the last
setting. However, settings will no longer be
adjustable - the control should be replaced.
13
The self diagnostic test has
detected the water temperature
sensor (thermistor) is either
open or shorted.
1 Turn the power off for 10-20 seconds then on again
to clear this error code.
2 Replace the Intelli-Vent control if this error code
persists.
Service Note:
Ignitors are wearing parts; the
resistance (ohms) of a hot
surface ignitor will increase over
time. If the resistance at room
temperature is near 18.8 ohms -
consider replacing the ignitor as a
preventative measure. TB-A028-06 - A. O. SMITH - FVIR INTELLI-VENT TROUBLESHOOTING CHART
A. O. Smith Water Products Company
AHSTB02807
Technical Training Department
Ashland City, Tennessee © 2006
3 of 5
Intelli-Vent Trouble Chart FVIR AOS.fm
Flammable Vapor Sensor Location / Testing
#
LED STATUS
PROBLEM
SOLUTION
14
The self diagnostic test has
detected the flammable vapor
sensor is either open or shorted.
The Intelli-Vent control is
programed to lock-out and
display this error code if the
resistance value it senses from
the FV sensor is below 5,000
ohms or above 1,700,000 ohms.
Service Note: To perform this
test the ohm meter used must be
capable of reading up to
2,000,000 ohms.
1 Turn off power to the water heater. Ensure all FV
sensor wiring, the ignitor assembly plug, and the
ignitor assembly socket on the bottom of the Intelli-
Vent control are making good contact. Repair or
replace any worn/damaged components that are not
making a good connection.
2 Restore power to the water heater - if the error code
has cleared place the water heater back in operation
and allow it to cycle several times to ensure the
problem has been resolved. If the error code persists
- continue to step 3 below.
3 Turn off power to the water heater. Remove the FV
sensor from its bracket on the base ring of the water
heater and disconnect both wires to the sensor. Take
a resistance reading between the two wiring
terminals of the FV sensor and note the resistance
value.
Service Note: Unless the ohm meter used has an
auto-range feature the resistance should be checked
twice. The first reading will be taken using an ohms
scale above 1,700,000 ohms. The second reading is
taken using an ohms scale just above 5,000 ohms.
4 If resistance of the FV sensor is lower than 5,000
ohms - replace the FV sensor.
5 If resistance of the FV sensor is above 1,700,000
ohms - replace the FV sensor.
6 If the resistance of the FV sensor is above 5,000
ohms and lower than 1,700,000 ohms and all the
above steps have been performed - ensure the
wiring and plug between the sensor and the Intelli-
Vent control are not damaged or worn - replace the
ignitor assembly if the wiring and/or plug are
damaged/worn.
If the wiring and plug are in good condition - replace
the Intelli-Vent control valve A. O. Smith Water Products Company
AHSTB02807
Technical Training Department
Ash