Instruction Manual commercial gas water heaters MODELS BTR 120 - 400(A) BTRC 120 - 400(A) SERIES 118/119 INSTALLATION - OPERATION - SERVICE - MAINTENANCE - LIMITED WARRANTY 500 Tennessee Waltz Parkway Ashland City, TN 37015 Low Lead Content WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
Table Of Contents Safe Installation, Use and Service ���������������������������������������� 3 Air From Other Indoor Spaces �������������������������������������������������������� 18 Approvals ������������������������������������������������������������������������������������������ 3 Technical Data Venting ��������������������������������������������������������������19-20 General Safety Information �������������������������������������������������4-5 Mechanical Venting �����������������������������
Safe 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.
General Safety Information Fire or Explosion Hazard Fire Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. For continued protection against risk of fire: Avoid all ignition sources if you smell gas. Do not expose water heater controls to excessive gas pressure. Do not install water heater on carpeted floor. Do not operate water heater if flood damaged. Use only the gas shown on the water heater rating label.
General Safety Information Read and understand this instruction manual and the safety messages herein before installing, operating or servicing this water heater. Explosion Hazard Overheated water can cause water tank explosion. Failure to follow these instructions and safety messages could result in death or serious injury. Properly sized temperature and pressure relief valve must be installed in the opening provided. This manual must remain with the water heater.
Introduction Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service. the safety rules, the water heater will not operate properly. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE. Abbreviations Used This manual contains instructions for the installation, operation, and maintenance of the gas-fired water heater. It also contains warnings throughout the manual that you must read and be aware of.
FEATURES AND COMPONENTS burns during each running cycle. The main burner and pilot gases are cut off during the OFF cycle. Pilot gas ignition is proven by the pilot sensor. Main burner ignition will not occur if the pilot sensor does not first sense pilot ignition. the eliminator (self-cleaning system) These units include The Eliminator (Self-Cleaning System) installed in the front water inlet, See Figure 1. The Eliminator inlet tube can only be used in the front water inlet connection.
installation considerations Rough In Dimensions MODELS BTR(C) 120 THROUGH 500 See Models Below * BTR(C) - 120 Models are approved for 5” (13 cm) venting using a 6” (15 cm) to 5” (13 cm) reducer. FIGURE 5. TABLE 1A . BTR MODELS 120 THROUGH 400A MODEL BTR120 BTR154 BTR180 BTR197 BTR198 BTR199 BTR 200 BTR 250 BTR 251 BTR 275 BTR 305 BTR 365 BTR 400 INPUT RATE BTU/Hr. APPROX TANK CAP. A B C D E F GAS INLET G H VENT DIA I J 120,000 BTU/Hr.
installation considerations TABLE 2. HEATER PERFORMANCE DATA BTR MODELS MODEL BTR 120 BTR 154 BTR 180 BTR 197 BTR 198 BTR 199 BTR 200 BTR 250 BTR 251 BTR 275 BTR 305 BTR 365 BTR 400 INPUT RATE BTUH 120,000 BTUH 35 Kw/Hr 154,000 BTUH 45 Kw/Hr 180,000 BTUH 53 Kw/Hr 199,000 BTUH 58 Kw/Hr 199,000 BTUH 58 Kw/Hr 199,000 BTUH 58 Kw/Hr 199,000 BTUH 58 Kw/Hr 250,000 BTUH 73 Kw/Hr 251, 000 BTUH 73 Kw/Hr 275,000 BTUH 80 Kw/Hr 305,000 BTUH 89 Kw/Hr 365,000 107 Kw/Hr 390,000 BTUH 1 14 Kw/Hr APPROX. GAL. CAP.
Installation Considerations Flammable items, pressurized containers or any other potential fire hazardous articles must never be placed on or adjacent to the heater. Open containers or flammable material should not be stored or used in the same room with the heater. locating the water heater CAUTION Property Damage Hazard The heater must not be located in an area where it will be subject to freezing. • All water heaters eventually leak. Locate it near a floor drain.
INSULATION BLANKET Breathing Hazard - Carbon Monoxide Gas Do not obstruct water heater air intake with insulating blanket. Gas and carbon monoxide detectors are available. Install water heater in accordance with the instruction manual. Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual. Insulation blankets are available to the general public for external use on gas water heaters but are not necessary with these products.
must be periodically oiled. Refer to the pump manufacturer’s instructions for lubrication requirements.
Installation Requirements 4. When installing multiple water heaters in the same gas supply system it is recommended that individual positive lock-up gas pressure regulators be installed at each unit. Gas supply Systems Low pressure building gas supply systems are defined as those systems that cannot under any circumstances exceed 14” W.C. (1/2 PSI Gauge). These systems do not require pressure regulation.
A properly sized thermal expansion tank must be installed on all closed systems to control the harmful effects of thermal expansion. Contact a local plumbing service agency to have a thermal expansion tank installed. HOT WATER OUTLET See Water Line Connections on page 21 and the Water Piping Diagrams beginning on page 40.
No valve or other obstruction is to be placed between the Temperature-Pressure Relief Valve and the tank. Do not connect discharge piping directly to the drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in adequate quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water flow may cause property damage.
Unconfined Space Direct Vent Appliances An Unconfined Space is one whose volume IS NOT LESS THAN 50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input rating of all appliances installed in the space. Rooms communicating directly with the space, in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconfined space.
Multiple heater manifold Outdoor Air Through One Opening Figure 13 and tables on pages 19 and 20 should be used for horizontally manifolding two or more heaters. Figure 15. Alternatively a single permanent opening, commencing within 12 inches (300 mm) of the top of the enclosure, shall be provided. See Figure 14. The water heater shall have clearances of at least 1 inch (25 mm) from the sides and back and 6 inches (l50 mm) from the front of the water heater.
When ducts are used, they shall be of the same cross sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall be not less than 3 inches. Outdoor Air Through Two Vertical Ducts The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only. Air From Other Indoor Spaces Do not refer to these illustrations for the purpose of vent installation.
TABLE 7. TECHNICAL DATA VENTING TYPE B GAS VENT Multiple Gas Fired Tank-Type Heaters When venting multiple tank type heaters using Type B vent pipe, follow the installation diagram (figure 13) and tables below which give sizing and data based upon NFPA 54/ANSI Z223. 1992.
Mechanical venting VENT INSTALLATION SINGLE UNIT INSTALLATION Seal all joints between the power venter and the vent termination. This is to prevent leakage of exhaust products into the room(s) due to positive pressure of blower. When mechanical venting of these heaters is desired, the following kits are available. The “Sequence of Operation” description will be the same with mechanical venting except; Models 120 through the 200/A A. O.
This water heater is provided with a properly rated/sized and certified combination temperature - pressure (T&P) relief valve by the manufacturer. See Temperature-Pressure Relief Valve on pages 14-15 for information on replacement and other requirements. • Shall be of material listed for hot water distribution. • Shall be installed so as to allow complete drainage of both Temperature-Pressure Relief Valve and the discharge pipe.
heater wiring All electrical work must be installed in accordance with the current edition of the National Electrical Code ANSI/NFPA No. 70 or Canadian Electrical Code CSA C22.1 and must conform to all local code authority having jurisdiction. AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF ELECTRICAL SHOCK OR POSSIBLE ELECTROCUTION.
GAS PIPING Gas Meter Size – Natural Gases Only Contact your local gas service company to ensure that adequate gas service is available and to review applicable installation codes for your area. Be sure the gas meter has sufficient capacity to supply the full rated gas input of the water heater as well as the requirements of all other gas fired equipment supplied by the meter. If gas meter is too small, ask the gas company to install a larger meter having adequate capacity.
OPERATION Light the water heater in accordance with the Lighting and Operation Instruction label on the water heater and in this manual on pages 27 and 28. Fire or Explosion Hazard The water heaters covered by this manual are equipped with an electronic control system that automatically sequences the Igniter, the 24 VAC Gas Valve, the Burner ignition, and flame sensing. Gas line purging is required with new piping or systems in which air has entered.
SEQUENCE OF OPERATION FLOW CHART Description of this flow chart can be found in the “SEQUENCE OF OPERATION” section found on page 25.
LIGHTING & OPERATION LABEL FOR YOUR SAFETY READ BEFORE OPERATING OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING FIGURE 22.
FOR YOUR SAFETY READ BEFORE OPERATING OPERATING INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE FIGURE 23.
FAILURE TO CORRECT BACK DRAFTS MAY CAUSE AIR CONTAMINATION AND UNSAFE CONDITIONS. Adjustments ON INITIAL STARTUP SOME ADJUSTMENTS MAY BE NECESSARY. • If the back draft cannot be corrected by the normal method or if a suitable draft cannot be obtained, a blower type flue gas exhauster must be employed to assure proper venting and correct combustion. Check Manifold and inlet gas pressures (see GAS SUPPLY SYSTEMS on page 13 and CHECKING THE INPUT on page 29-30.
Should it be necessary to adjust the gas pressure to the burners to obtain the full input rate, the steps below should be followed: 3. Remove the regulator adjustment sealing cap and adjust the pressure by turning the adjusting screw with a screwdriver. See Figure 24. Clockwise to increase gas pressure and input rate. Counterclockwise to decrease gas pressure and input rate. 4. “Clock” the meter as in step 2 above. FIGURE 24. 5. Repeat steps 3 and 4 until the specified input rate is achieved.
mAINTENANCE venting system Examine the venting system every six months for obstructions and/or deterioration of the vent piping. Remove all soot or other obstructions from chimney which will retard free draft. remote storage tank temperature control The water temperature in the remote storage tank (if used) is controlled by the storage tank temperature control. The sensing element is mounted in the hot water storage tank, see Water Piping Diagram section. Figure 25.
water ions attack and eat away the anode rod. This does not affect water’s taste or color. The rod must be maintained to keep tank in operating condition. 5. Ensure the drain hose is secured before and during the entire flushing procedure. Flushing is performed with system water pressure applied to the water heater. 6. Open the water heater drain valve to flush the storage tank. 7. Flush the water heater storage tank to remove sediment and allow the water to flow until it runs clean. 8.
deliming solvents UN•LIME is recommended for deliming. UN•LIME is a patented food grade acid which is safe to handle and does not create the harmful fumes which are associated with other products. Explosion Hazard UN•LIME may be obtained from your dealer, distributor or water heater manufacturer. Order Part Number 9005416105, 1 gallon, packed 4 gallons per case or Part Number 9005417105, 5 gallon container. Flammable hydrogen gases may be present.
While the water is being run through the tank, insert a stiff wire, copper tube flattened at one end or an opened wire coat hanger through the cleanout opening and scrape out any loose deposits of scale or sediment. This is an economical way to avoid unnecessary usage of the deliming solution. Repeat the opening and closing of the cold water inlet valve as necessary but be sure the heater is completely drained when ready to introduce the UN•LIME.
Pilot sensing device must sense a flame before sparking will stop. Loose wires or a draft may cause intermittent or abnormal sparking. To eliminate this condition, first correct loose wiring condition, and then, if necessary, increase pilot flame. Gas Control Valve Figure 31 shows the two types of combination gas control valves used on these heaters. If gas control valve becomes defective, repairs should not be attempted. A new valve should be installed in place of defective one.
Troubleshooting • Check electrical supply to the water heater for possible blown (or tripped) fusing or power interruption. IGNITION MODULE Before calling your service agent, the following checklist should be examined to eliminate obvious problems from those requiring replacement or servicing. • Is the water temperature in tank below the thermostat dial setting on the thermostat (calling for heat)? • Check that “main manual gas shut-off valve” is fully open and that gas service has not been interrupted.
EFFIKAL RVGP-KSF-SERIES FLUE DAMPER TROUBLE SHOOTING GUIDE Do not turn damper open manually or motor damage will result, use the service switch. All readings are taken from harness receptacle. Do not push meter leads into harness receptacle. This opens the pins and will create connection problems. Effikal Pinouts Adapter wire & wire colors Function colors in* 1. Brown 24 VAC HOT Black 2. Orange Signal In Yellow Signal Out Red 3. Yellow 4.
Troubleshooting checklist COMPLAINT Water not hot enough. Insufficient hot water CAUSE USER REMEDY QUALIFIED SERVICE AGENCY Thermostat set too low. Set thermostat dial to a higher temperature. Upper and/or lower temperature probe out of calibration. Call qualified service agency. Thermostat set too low. Set thermostat dial to a higher temperature. Check continuity and resistance (Ohms) of upper and lower thermostat probes. Replace probes if out of specification.
For Your Information start up conditions c. A sulfate reducing bacteria which has accumulated within the water heater (this harmless bacteria is nontoxic to humans). d. An excess of active hydrogen in the tank. This is caused by the corrosion protective action of the anode rod. SMOKE/ODOR It is not uncommon to experience a small amount of smoke and odor during the initial start-up. This is due to burning off of oil from metal parts, and will disappear in a short while.
ALT. COLD WATER CONNECTION HOT WATER TO FIXTURES NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s). 5.
HOT WATER TO FIXTURES ALTERNATE LOCATION NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s). 5.
HOT WATER RETURN TEMPERED WATER OUTLET COLD HOT HOT WATER OUTLET NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
PIPE T&P TO OPEN DRAIN NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
PIPE T&P TO OPEN DRAIN NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s). 5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
PIPE T&P TO OPEN DRAIN NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s). 5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
PIPE T&P TO OPEN DRAIN HOT WATER TO FIXTURES DRAIN EXPANSION TANK COLD WATER SUPPLY TANK TEMPERATURE CONTROL CIRCULATING PUMP PRESSURE RELIEF VALVE TEMPERATURE & PRESSURE RELIEF VALVE ALTERNATE LOCATION NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4.
EXPANSION TANK COLD WATER SUPPLY HOT WATER RETURN HOT WATER TO FIXTURES PRE-HEATED WATER TO BOOSTER DRAIN BOOSTER HEATER WATER FLOW SWITCH TEMPERATURE GAGE CHECK VALVE FULL PORT BALL VALVE BOOSTER WATER RETURN TANK TEMPERATURE CONTROL CIRCULATING PUMP PRESSURE RELIEF VALVE TEMPERATURE & PRESSURE RELIEF VALVE BOOSTER WATER TO FIXTURES NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3.
PRE-HEATER PRE-HEATER MUST BE IDENTICAL HEATERS PIPE T&P TO OPEN DRAIN DRAIN BOOSTER RETURN (IF USED) EXPANSION TANK COLD WATER SUPPLY TANK TEMPERATURE CONTROL CIRCULATING PUMP PRESSURE RELIEF VALVE TEMPERATURE & PRESSURE RELIEF VALVE HOT OUTLET AT STORED TEMPERATURE BOOSTED WATER OUTLET TYPICAL BOOSTER HEATER PIPE T&P TO OPEN DRAIN NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3.
PIPE T&P TO OPEN DRAIN PIPE T&P TO OPEN DRAIN NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. PIPE T&P TO OPEN DRAIN HOT WATER TO FIXTURES WARNING: THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES; CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS.
HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN DRAIN TANK TEMPERATURE CONTROL CIRCULATING PUMP PRESSURE RELIEF VALVE ALT. COLD WATER CONNECTION EXPANSION TANK HOT WATER RETURN WATER FLOW SWITCH TEMPERATURE GAGE CHECK VALVE FULL PORT BALL VALVE COLD WATER SUPPLY LEGEND TEMPERATURE & PRESSURE RELIEF VALVE HOT WATER TO FIXTURES NOTES: 1. Preferred piping diagram. 2.
HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN HEATER AOS STORAGE TANK HOT WATER TO FIXTURES NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s). 5.
PIPE T&P TO OPEN DRAIN PIPE T&P TO OPEN DRAIN PIPE T&P TO OPEN DRAIN NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. FINISHED FLOOR HOT WATER TO FIXTURES WARNING: THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES; CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS.
HEATER HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN PIPE T&P TO OPEN DRAIN NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit. However, local codes shall govern their usage. 4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s). 5.
HEATER HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN DRAIN AOS STORAGE TANK ALTERNATE LOCATION PIPE T&P TO OPEN DRAIN TANK TEMPERATURE CONTROL CIRCULATING PUMP PRESSURE RELIEF VALVE TEMPERATURE & PRESSURE RELIEF VALVE HOT WATER TO FIXTURES NOTES: 1. Preferred piping diagram. 2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system. 3. Service valves are shown for servicing unit.
manifold kits TWO UNIT MANIFOLD KIT (9003426205) DIMENSIONS “A” INCHES (CM) MODEL LOW PROFILE VERTICAL HOOD “A” BTR MODELS BTRC MODELS 120 69.75” (177cm) 69.75” (177cm) 154 73.00” (185cm) 73.00” (185cm) 180 67.50” (171cm) 70.50” (179cm) 197 75.00 (192cm) 81.50” (207cm) 198 75.00” (192cm) N/A 199 67.50” (171cm) 70.50” (179cm) 200 72.00” (183cm) 72.00” (183cm) 250 72.00” (183cm) 72.00” (183cm) 251 75.00” (191cm) 75.00” (191cm) 275 72.00” (183cm) 72.00” (183cm) 305 75.00” (191cm) 75.
notes 56
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notes 58
Model BTR(C) 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 complete new A. O. Smith water heater of equivalent size and current model.
500 Tennessee Waltz Parkway, Ashland City, TN 37015 Technical Support: 800-527-1953 • Parts: 800-433-2545 www.hotwater.com Copyright © 2012 A. O. Smith, All rights reserved.
