CYCLONE Xi® Model BTH 300A, 400A, 500A COMMERCIAL GAS WATER HEATER GAS-FIRED POWER BURNER FOR DOMESTIC HOT WATER • INSTALLATION • OPERATION • SERVICE • MAINTENANCE • LIMITED WARRANTY WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. – Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
ROUGH-IN-DIMENSIONS GAS VALVE PIPING BTH-300 BTH-400 BTH-500 1 1/4" NPT 1 1/4" NPT 1 1/2" NPT TABLE 1 RECOVERY CAPACITIES. U.S. Gallons/Hr and Litres/Hr at TEMPERATURE RISE INDICATED TYPE OF INPUT MODEL GAS BTUH KW 300,000 BTH-300 NATURAL 88 300,000 BTH-300 PROPANE 88 399,900 NATURAL BTH-400 117 399,900 BTH-400 PROPANE 117 BTH-500 NATURAL 499,900 146 499,900 BTH-500 PROPANE 146 Approx. Capacity 130 US Gals.
TABLE OF CONTENTS Water (Potable) Heating & Space Heating........................................... 17 Heater Wiring..................................................................................17-19 OPERATION............................................................................................. 20 Sequence of Operation........................................................................ 20 ELECTRONIC CONTROL........................................................................ 20 Overview..
“AT A GLANCE” BTH 300/400/500 QUICK INSTALLATION TIPS Horizontal Sidewall Venting Vertical Rooftop Venting
The temperature may be adjusted from 80°F/27°C to 180°F/82°C. The temperature was adjusted to 120°F/49°C before the heater was shipped from the factory. It is recommended that lower water temperatures be used to avoid the risk of scalding. It is further recommended, in all cases, that the water temperature be set for the lowest temperature which satisfies your hot water needs. This will also provide the most energy efficient operation of the water heater and minimize scale formation.
CIRCULATING PUMP THE HEATER SHALL BE LOCATED OR PROTECTED SO IT IS NOT SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE. A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the heater. Refer to the piping diagrams at rear of manual for electrical hookup information and install in accordance with the current edition of the National Electrical Code, NFPA 70 or the Canadian Electrical Code, CSA C22.1.
CLEARANCES MECHANICAL EXHAUSTING OF ROOM AIR These heaters are approved for installation on combustible flooring in an alcove when the minimum clearances from any combustion construction are followed as indicated in Figure 4. Where an exhaust fan is installed in the same room with a heater, sufficient openings for air must be provided in the walls. UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE HEATER’S VENTING SYSTEM, CAUSING POOR COMBUSTION.
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS EXEMPTIONS The following equipment is exempt from 248 CMR 5.
US DIRECT VENT CAUTION TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN THESE TWO TERMINALS IS RECOMMENDED. CANADIAN DIRECT VENT FIGURE 5.
US HORIZONTAL VENT CAUTION TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN THESE TWO TERMINALS IS RECOMMENDED. CANADIAN HORIZONTAL VENT FIGURE 6.
WARNING WARNING NEVER OPERATE THE HEATER UNLESS IT IS VENTED TO THE OUTDOORS AND HAS ADEQUATE AIR SUPPLY TO AVOID RISKS OF IMPROPER OPERATION, FIRE, EXPLOSION OR ASPHYXIATION. WHEN THE UNIT IS TO BE SETUP AS A DIRECT VENT, THE INTAKE GUARD AND THE BALANCE PLATE MUST BE REMOVED. THE INLET VENT PIPE MAY THEN BE GLUED TO THE AIR INTAKE (see Figure 8) PROVIDED ON THE UNIT. VENT PIPE TERMINATION NOTE: Before installing venting, determine place of vent pipe termination. See Figure 5 and 6 before proceeding.
Slide the pipe through the wall and insert into coupling on the other side of the wall, making sure that the vent terminal ends up pointed in the correct position. See Figure 10. 2. The horizontal centerline of the intake vent terminal may not be located lower than the horizontal centerline of the exhaust vent terminal (see Figure 9). EXHAUST VENT TERMINAL FIGURE 9.
2. Drill a pilot hole approximately 1/4" (6 mm) outside of the marked circle. This pilot hole is used as a starting point for a sawsall or sabre saw blade. Cut around the marked circle staying approximately one quarter inch outside the line. (This will allow the vent pipe to easily slide through the opening). The resulting gap will be covered by the roof boot/flashing. 3. The unit is certified to a minimum amount of 4-inch pipe for the exhaust venting arrangement of 15-equivalent feet.
VENT PIPE PREPARATION contacts are normally open. When the fan increases the pressure in the burner, the pressure switch will allow the electrical contacts to close. The pressure switch is connected to the burner tap by a piece of tygon tubing. This tubing must be connected in order for the switch to change the electrical contacts. The controller requires that the electrical contacts on this air flow switch be open before it will allow the blower to come on. See Figure 13. 1. INITIAL PREPARATION A.
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. HOT SURFACE IGNITER The Hot Surface Igniter is a device that ignites the main burner by high temperature (>1800°F or >982°C). When 120VAC is applied to the igniter, sufficient heat is generated to ignite the main burner.
RELIEF VALVE To prevent damage, care must be taken not to apply too much torque when attaching gas supply pipe to gas valve inlet. This heater is equipped with an approved temperature and pressure relief valve. ASME ratings cover pressure relief. CSA ratings cover release rate with temperature actuation. Apply joint compounds (pipe dope) sparingly and only to the male threads of pipe joints. Do not apply compound to the first two threads.
codes or contact the water supplier or local plumbing inspector on how to control this situation. WATER (POTABLE) HEATING AND SPACE HEATING 1. All piping components connected to this unit for space heating applications shall be suitable for use with potable water. 2. Toxic chemicals, such as those used for boiler treatment, shall NEVER be introduced into this system. 3. This unit may never be connected to any existing heating system or component(s) previously used with non-potable water heating appliance.
BTH 300 WIRING DIAGRAM FIGURE 15.
BTH 400 AND 500 WIRING DIAGRAM FIGURE 16.
OPERATION inside the tank. The second temperature on this screen is the Operating Set Point. The Operating Set Point is the temperature at which the water heater will maintain the water inside the tank. The third line on the screen is a text description of the Operational State of the water heater (please see Operating States for more details). SEQUENCE OF OPERATION Typical Control/Appliance Operating Sequence 1.
3. Adjusting the Operating Set Point The Operating Set Point of this water heater determines the regulated temperature for the water in the tank. This parameter is adjusted in the Temperature menu. Items in this menu allow you to monitor different temperature readings in the tank along with adjusting the Operating Set Point and Differential.
4. Changing the Display Units The display interface to the heater has the option of selecting between degrees and Fahrenheit and degrees Celsius for temperature displays. This can be found in the "Display Settings" menu. Also in this menu, you may adjust how the backlight operates and the contrast of the LCD screen. 5. Fault and Warning Conditions This water heater is equipped with electronic controls that have the ability to monitor almost all aspects of the water heater operation.
• Faults: This is a safety related condition that has been detected by the heater. NOTE: When these conditions occur, the water heater will not continue any further heating cycles and the water will no longer be heated until the condition is corrected and, in most cases, power has been cycled. Example of a Fault: Advanced Diagnostics Information When a fault or warning has been declared, advanced information can be found in the control.
7. Viewing the Fault History The controller for this water heater will store a history of ten of the last Fault and Warning conditions that occurred. This is stored in the Fault History. Along with all the information about the fault, including a estimate time of when the fault occurred, information regarding the advanced diagnostics for that fault can be accessed at any time. 8.
PRIOR TO START UP - REQUIRED ABILITY INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, GAS SUPPLY AND ELECTRICAL WORK ARE REQUIRED. Before attempting start-up, thoroughly study and familiarize yourself with the exact sequence of operation and all other details on the specific heater being used.
c. Remove the pressure regulator cover screw (Figure 16) and adjust the pressure by turning the adjusting screw with a small screwdriver. In this example, with heater running on natural gas, do not exceed 4.0" (0.996 kPa) Water Column. Clockwise to increase gas pressure and input rate. Counterclockwise to decrease gas pressure and input rate. e. Repeat steps (c) and (d) until the specified input rate is achieved. f. Turn the manual gas valve to “OFF”. Replace the pressure regulator cover screw.
HIGH ALTITUDE INSTALLATIONS WARNING UNDER NO CIRCUMSTANCES SHOULD THE INPUT EXCEED THE RATE SHOWN ON THE HEATER RATING PLATE. OVERFIRING COULD RESULT IN DAMAGE OR SOOTING OF THE HEATER. CATHODIC PROTECTION CAUTION 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 FLAMMABLE.
FLUSHING Sediment and lime scale removal may be accomplished through the cleanout opening furnished on the heater, see Figure 24. The heater must be drained, see DRAINING, before removing cleanout cover on tank. 1. Turn off the heater electrical disconnect switch. 2. Open the drain valve and allow water to flow until it runs clean. 3. Close the drain valve when finished flushing. 4. Turn on the heater electrical disconnect switch.
POWERED ANODE SYSTEM To insure a long, trouble-free operating life, BTH 300, 400 and 500 are factory equipped with a powered anode system. The anodes are of a permanent design and do not need replacing unless damaged. If the temperature and pressure relief valve on the heater discharges periodically or continuously, it may be due to thermal expansion of water in a closed water supply system, or, it may be due to a faulty relief valve. The heaters are equipped with a 3/4" drain valve.
INSTALLATION DIAGRAMS ONE TEMPERATURE - ONE HEATER VERTICAL STORAGE TANK FORCED CIRCULATION WITH OR WITHOUT BUILDING RECIRCULATION CAUTION: IF BUILDING COLD WATER SUPPLY HAS A BACK-FLOW PREVENTER, CHECK VALVE OR WATER METER WITH CHECK VALVE PROVISIONS FOR THERMAL EXPANSION OF WATER IN THE HOT WATER SYSTEM MUST BE PROVIDED NOTE: CONNECT RETURN L I N E F R O M H O T WAT E R CIRCULATING LOOP (IF USED) TO COLD WATER INLET LINE.
TWO TEMPERATURE - ONE HEATER HIGH TEMPERATURE WITH OR WITHOUT BUILDING RECIRCULATION DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 3. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES. *PIPE RELIEF VALVE TO OPEN DRAIN. N O T E : I F T E M P E R E D W AT E R I S RECIRCULATED, RETURN LINE SHOULD BE CONNECTED AT POINT “A”.
TWO TEMPERATURE - TWO HEATERS HIGH TEMPERATURE WITH OR WITHOUT BUILDING RECIRCULATION TWO TEMPERATURE - THREE HEATERS (TWO PRE-HEATERS/ONE BOOSTER HEATER) WITH OR WITHOUT BUILDING RECIRCULATION MUST BE IDENTICAL HEATERS FOR MULTIPLE HEATER INSTALLATION SEE MANIFOLD KIT SPECIFICATIONS, PAGE 35. CAUTION: IF BUILDING COLD WATER SUPPLY HAS A BACKFLOW PREVENTER, CHECK VALVE OR WATER METER WITH CHECK VALVE PROVISIONS FOR THERMAL EXPANSION OF WATER IN THE HOT WATER SYSTEM MUST BE PROVIDED.
TWO TEMPERATURE - TWO HEATERS (ONE PRE-HEATER/ONE BOOSTER HEATER) WITH OR WITHOUT BUILDING RECIRCULATION * PIPE RELIEF VALVE TO OPEN DRAIN DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 3. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES ** 140°F (60°C)TO 150°F (66°C) SHOULD BE MAXIMUM WATER TEMPERATURE MAINTAINED IN THE PRE-HEATERS.
TWO TEMPERATURE - ONE HEATER HIGH TEMPERATURE WITH RECIRCULATION OF SANITIZING LOOP DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 3. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
MULTIPLE UNIT INSTALLATIONS Proper installation of multiple water heaters assures water flow balance of all units. Without this balance, the full water heating and storage potential of the system cannot be achieved. Plus, the units with the higher water flow may have a shortened life. Dimensions shown are for minimum space occupied by the water heaters assemblies. Space for the venting system and unit servicing must be added.
CHECKLIST AND SERVICE INFORMATION 10. Condensate hose may be blocked where it connects to the exhaust elbow. IMPORTANT • Verify the condensate drains from the unit without restriction. The installer may be able to observe and correct certain problems which might arise when the unit is put into operation or when it is re-fired after a prolonged shutdown. HOWEVER, it is recommended that only qualified servicemen, using appropriate test equipment, be allowed to service the heater. WATER IS TOO HOT 1.
this tubing is damaged it must be replaced. If these steps do not eliminate the problem, replace the pressure switches. 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.
NOISY BURNER OPERATION NOTE: Always turn off and disconnect main supply wiring before servicing the unit. The exhaust of this unit produces some noise during ignition period. When combustion is too lean or too rich, start up noise will get worse. Check for flue gas CO2 reading, adjust gas valve manifold pressure if required to bring the flue gas CO2 to 9–9.5% level for natural gas, 10.75–11.25% for LP.
Model BTH Limited Warranty A. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this water heater. 1. THE TANK If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable water therein, during the first THREE years after initial installation, the warrantor will supply a replacement tank less burner and controls or a complete new A.O.
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