A.O. Smith INTELLI-VENT Programming manual
INTELLI-VENT™ CONTROL INFORMATION
When Used On Gas, Residential, Power Vented
Water Heaters
Printed in the USA – 0605 Part No. GTC-070 R3
Revision 2 includes updated troubleshooting information for error codes 3, 4, and 6.
Revision 3 includes updated troubleshooting for error codes 4 and 6 and technical bulletins
http://waterheatertimer.org/How-to-troubleshoot-gas-water-heater.html#intellivent
INTELLI-VENT TROUBLESHOOTING GUIDE
Technical Training Department Ashland City, Tennessee © 2005
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INTELLI-VENT™ FEATURES
The Intelli-Vent™ is a combination control incorporating all temperature control, ignition control,
blower and ignitor control, flame sensing, and gas regulation into a single device.
Advanced Diagnostics - Error Codes
The Intelli-Vent™ features advanced diagnostics with 15 specific error codes including reversed
polarity and inadequate grounding notification. Diagnostic information is conveyed via 6 LED
lights on the control. These error codes will help diagnose and repair the water heater quickly and
accurately.
Tamper Resistant
The Intelli-Vent™ features tamper resistant temperature settings. In order to access
temperature settings both temperature adjust buttons must be pressed simultaneously for one full
second to review the temperature settings. Temperature settings are displayed by illuminating
various combinations of LED lights.
Precise Temperature Control
The Intelli-Vent™ controls temperature electronically. Tighter cut out and cut in differentials
produce less temperature swing than standard residential controls.
Temperature Probe - Thermistor
The temperature probe houses the ECO and a temperature sensor which is a “thermistor.”
Thermistors are thermally sensitive variable resistors. A change in water temperature changes
the resistance (measured in ohms) of the thermistor. The Intelli-Vent™ control interprets this
change in resistance as a change in temperature and uses this information to activate and
deactivate a call for heat.
Silicon Nitride Ignitor
The Intelli-Vent™ control uses a silicon nitride ignitor which is more durable than the silicon
carbide ignitors previously used. Body oils transferred to the ignitor during handling will not
damage silicon nitride ignitors nor will minor bumps or drops. This ignitor is also highly resistant to
damage caused by condensation.
Adaptive Learning Technology
Adaptive Learning Technology refers to the programed control of voltage to the ignitor. The Intelli-
Vent™ varies voltage to the ignitor and “learns” to use the lowest voltage necessary that insures
consistent ignition. Lower voltage increases ignitor life.
Water Resistant
While not being a “water proof” control the Intelli-Vent control does have a greater degree of
resistance to water damage than previous controls. Wiring connections are on the bottom of the
control and less susceptible to damage.
INTELLI-VENT TROUBLESHOOTING GUIDE
Technical Training Department Ashland City, Tennessee © 2005
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INTELLI-VENT™ CONSTRUCTION
Manifold Gas;
Main Burner Connection
• RH thread Natural
• LH thread Propane
Bottom View
Right Side View
Manifold Gas
Pressure Tap
Control
Information
6 Pin Molex Plug
• Line Voltage
• Blower Voltage
• Pressure Switch
5 Pin Molex Plug
• Hot Surface Ignitor
• Flame Sensor
• Resistor Wire Ignitor Assembly
Flame Sensor
Silicon Nitride Ignitor
(Hot Surface Ignitor)
Front & Left Side View
Temperature Probe/ECO
6 LED indicator lights
• Temperature Settings
• Error Codes / Diagnostics
Supply Gas Connection
Future side connect model is
shown here. Top connect models
are in use currently.
Temperature adjust buttons
Temperature adjust buttons
must be pressed together for
one second to “wake up” the
control in order to view or
change temperature settings.
INTELLI-VENT TROUBLESHOOTING GUIDE
Technical Training Department Ashland City, Tennessee © 2005
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INTELLI-VENT™ OPERATION
PRE START UP CHECK LIST
• Correct polarity on electrical supply
• Water heater is properly grounded
• Owner’s manual safety statements have been reviewed
START UP PROCEDURE
1Plug in water heater and turn on power. All lights on the control will come on for
about 1 - 5 seconds. All lights will then turn off. If the stored water is above 70°F
(residential) and the control setting has not been increased from it’s factory setting,
nothing more will happen. (Residential controls are factory set at 70°F, the “vacation”
setting per ANSI requirements; Commercial controls are factory set at 120°F)
2Wake Up the control by holding down both of the temperature adjust buttons at the
same time for about one second; then release the buttons and the LED lights will
indicate the current temperature setting.
3Push then release the “hotter” temperature adjust button repeatedly to increase the
water temperature setting and the “colder” temperature adjust button to decrease the
setting.
THE RECOMMENDED STARTING TEMPERATURE IS 120°F
See the illustration on the following page indicating which temperature setting
corresponds to the various combinations of LED lights.
SLEEP MODE - NORMAL OPERATION
Without any further user input the control will go back into the “sleep mode” in 30
seconds. All LED indicator lights will turn off. This is the normal operating mode.
6 LED indicator lights
• Temperature Settings
• Error Codes / Diagnostics
Temperature adjust buttons
INTELLI-VENT TROUBLESHOOTING GUIDE
Technical Training Department Ashland City, Tennessee © 2005
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TEMPERATURE SETTINGS
Residential and commercial Intelli-Vent controls differ in appearance:
• The far left LED light is green on the residential control and the remaining 5 LEDs
are yellow.
• On the commercial control all six LEDs are yellow.
• The residential control has a “vacation’ temperature setting (70°F) and it is
referenced on the display.
• There is no vacation setting on a commercial control.
• The residential control uses an inverted triangle (delta symbol) above the third
LED and uses A, B, and C as temperature set point references.
• The commercial control places the inverted triangle above the far left LED and
uses B, C, D, E, and F for temperature set point references.
Residential Commercial
INTELLI-VENT TROUBLESHOOTING GUIDE
Technical Training Department Ashland City, Tennessee © 2005
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INTELLI-VENT™ SPECIFICATIONS
GAS PRESSURE REQUIREMENTS
INTELLI-VENT™ CONTROL SPECIFICATIONS
Body ½ inch NPT inlet.
½ inch inverted flare outlet. (RH thread natural, LH thread propane)
Electrical Ratings 120 VAC, 60 Hz, 1Ø, 5-7 FLA.
Ignitor load: 2 amps maximum.
Blower/inducer motors: 3 amps full load - 4 amps locked rotor.
Max Inlet Gas Pressure ½ PSI maximum (14.0" W.C.)
Temperature Range 70 - 160°F Residential.
120 - 180°F Commercial.
High Temp Cut Off - ECO 195°F Residential - single use (control must be replaced)
195°F Commercial - resettable (reset temp 120°F)
OPERATING SEQUENCE
Pre-Purge Time 5 seconds.
Ignitor Warm-up Time 20 seconds.
Trial for Ignition Period 4 seconds.
Inter-Purge Time 5 seconds.
Post-Purge Time 5 seconds.
Ignition Retries 2 retries; 3 trials before lockout.
Ignition Recycles 2 recycles, 3 losses of flame before lockout.
NATURAL GAS
Supply gas • 4.5 to 5.0" W.C. minimum -14.0" W.C. maximum
Always check control/water heater label
†Manifold gas
†. Manifold gas pressure is non adjustable. Always verify correct main burner orifice
before replacing a control for failing to maintain correct manifold pressure.
• 3.5 to 4.0" W.C.
Always check control/water heater label
PROPANE GAS
Supply gas • 11.0" W.C. minimum 14.0" W.C. maximum
†Manifold gas • 10.0" W.C.
INTELLI-VENT TROUBLESHOOTING GUIDE
Technical Training Department Ashland City, Tennessee © 2005
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INTELLI-VENT™ WIRING CONNECTIONS
FEMALE MOLEX RECEPTACLES
BOTTOM OF CONTROL
1. = Air Pressure Switch Circuit
2. = 120 VAC Neutral Wire to Blower
3. = 120 VAC Hot Wire to Control
4. = Air Pressure Switch Circuit
5. = 120 VAC Hot Wire to Blower
6. = 120 VAC Neutral Wire to Control
There are two female Molex plug receptacles on the bottom of the Intelli-Vent™ control. Keep in
mind the receptacles (female) and plugs (male) are mirror images of each other in regard to pin
number location and retaining clip orientation. Pin numbers and corresponding component wiring
are detailed above in relation to the retaining clip.
The male plug ends from the 6 conductor wire harness and 5 conductor ignitor assembly plug are
shown above; notice the raised ridges identifying the #1, #2, and #3 pins. A black marker was
used to highlight these ridges for the photograph.
Service Notes:
The Black Resistor Wire on the ignitor assembly plug is used to provide proper sensory input in
place of optional external variable resistance devices, none are currently used. This resistor wire
must not be cut, removed, or jumpered. The Intelli-Vent control would interpret this as a
component failure and lock out displaying error code 14 or 15.
Pins and sockets inside the plugs and receptacles should be visually inspected to insure good
connections are being made when servicing. Always depress retaining clip when unplugging
Molex connectors, failure to do so can damage plug connection.
Ignitor Assembly
Connections
Wiring Harness
Connections
1. = Ignitor hot wire
2. = Ignitor neutral wire
3. = Resistor wire
4. = Resistor wire
5. = Flame sense rod
Black Resistor Wire
(between pin 3 and 4)
Female Receptacle
Male Plug
Male Plug
Female Receptacle
INTELLI-VENT TROUBLESHOOTING GUIDE
Technical Training Department Ashland City, Tennessee © 2005
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Wiring Harness Connection Diagram
Models Equipped With Vent Temperature Limit Switch
INTELLI-VENT TROUBLESHOOTING GUIDE
Technical Training Department Ashland City, Tennessee © 2005
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INTELLI-VENT™ SEQUENCE OF OPERATION
INTELLI-VENT TROUBLESHOOTING GUIDE
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INTELLI-VENT™ TROUBLESHOOTING GUIDE
Error Codes & Diagnostics
The Intelli-Vent™ control will not have any LED lights illuminated during normal operation
(sleep mode) for the life of the water heater. When an LED is illuminated, it draws
attention to the water heater and the need to have it serviced.
There are 15 different diagnostic error codes the Intelli-Vent™ control is capable of
displaying by illuminating various combinations of LED lights. All 15 are covered in the
troubleshooting guide that follows.
The same combination of LED lights are used for error codes on residential and
commercial controls though the way they are displayed differs slightly:
Residential controls display error codes via constant illumination of the LED lights.
Commercial controls display error codes by flashing the LED lights on and off.
Important Service/Installation Notes:
1Always turn power off for 10 to 20 seconds and then back on again to clear an
error code before replacing an Intelli-Vent™ control.
2 When installing the water heater or a replacement Intelli-Vent™ control, do not use
the control face as a handle to move the water heater or turn (thread) the control.
3 When installing a replacement control do no pinch, pull, or cut exposed wires.
Troubleshooting Guide Notes:
• Residential error code displays are shown on the left and commercial on the right
for all 15 error codes that follow.
• LEDs filled in black indicate an Illuminated LED.
ERROR CODE 1 - NO EARTH GROUND
Inadequate or no earth ground sensed by Intelli-Vent™ control.
Check / Repair:
• Insure the wall outlet is properly grounded.
• Insure all ground connections on the water heater are secure.
• Insure ground path wires (if so equipped) between wiring boxes and heater jacket
are properly secured.
• Insure the ground (green) wire in the power cord is continuous with an ohm meter.
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