Instruction Manual commercial gas water heaters MODELS BTR 500 SERIES 120/121 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. WHAT TO DO IF YOU SMELL GAS: • Do not try to light any appliance.
Table Of Contents Safe Installation, Use and Service........................................ 3 Air From Other Indoor Spaces........................................................ 17 APPROVALS......................................................................................... 3 Technical Data Venting................................................................... 18 General Safety Information..................................................... 4 Water heater installation.......................
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. below) in the field involved. Installation skills such as plumbing, air supply, venting, gas supply and electrical supply are required in addition to electrical testing skills when performing service. Abbreviations Used Abbreviations found in this Instruction Manual include : ANSI Z223.1 2006 Sec. 3.3.
Features and components The Eliminator (self-cleaning system) Electronic Ignition Control 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. Do not install the Eliminator inlet tube in either the top or back inlet water connection. The Eliminator must be oriented correctly for proper function.
Installation considerations Rough In Dimensions Recovery Capacities Gas and Electrical Characteristics FRONT VIEW BACK VIEW TOP OUTLET 1 1/2” NPT TOP INLET 1 1/2” NPT F TOP VIEW FIGURE 5 TABLE 1. ROUGH-IN-DIMENSIONS Connections Inlet (NPT) Outlet (NPT) Top Front Back Top Front Back Dimensions in Inches/cm Model BTR 500 BTR500 Input Rate Btu/Hr Kw/Hr 500,000 147 Approximate Tank Cap G/L 85 322 A B C D E F 81.50 17.50 77.25 67.50 27.13 21.00 207 44 196 171 69 53 Gas Inlet G 1.00 3 H 67.
Installation Considerations Locating the Water Heater IS NOT SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE. CAUTION 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. Property Damage Hazard • All water heaters eventually leak. • Do not install without adequate drainage.
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.
ON See the Circulation Pump Wiring Diagrams (Figure 8, Figure 9) in this manual for electrical hookup information. Install in accordance with the current edition of the National Electrical Code, NFPA 70 or the Canadian Electrical Code, CSA C22.1. Breathing Hazard - Carbon Monoxide Gas All-bronze or stainless steel circulating pumps are recommended for use with commercial water heaters. Under no circumstances should the input exceed the rate shown on the water heater’s rating label.
Installation Requirements Gas Supply Systems 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. 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 19 and the Water Piping Diagrams beginning on page 34.
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.
Never obstruct the flow of ventilation air. If you have any doubts or questions at all, call your gas supplier. Failure to provide the proper amount of combustion air can result in a fire or explosion and cause property damage, serious bodily injury or death. through the water heater’s vent system causing poor combustion. Sooting, serious damage to the water heater and the risk of fire or explosion may result. It can also create a risk of asphyxiation.
Outdoor Air Through One Opening vent with an oil burning furnace, the vent pipe should enter the smaller common vent or chimney at a point above the large vent pipe. Multiple Heater Manifold Figure 13 and Table 7 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 15.
Outdoor Air Through Two Vertical Ducts 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. 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.
Technical Data Venting 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. 2006. Model 500 Input: 500,000 btu/hr Total Vent Height (Feet) Vent connector size: 8 inches 6 8 10 15 30 50 100 9 8 8 7 9 9 8 8 7 9 9 8 7 7 30 50 100 Input (btu/hr) Rise 500,000 1 Ft.
Water heater installation Water Line Connections T&P Valve Discharge Pipe The water piping installation must conform to these instructions and to all local code authority having jurisdiction. Good practice requires that all heavy piping be supported. Explosion Hazard Read and observe all requirements in the following sections before installation of the water piping begins: Temperature-Pressure Relief Valve must comply with ANSI Z21.22CSA 4.4 and ASME code. 1.
Installation Diagrams - Top Inlet/Outlet Usage TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL AND MIXING VALVE WARNING ON PAGE 12. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTISCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES. Use of the top inlet water connection requires an inlet dip tube (refer to figure 19). The tube is supplied in the heater. Follow caution labels if applying heat to this fitting.
Heater Wiring All electrical work must be installed in accordance with the latest version of the National Electrical Code ANSI/NFPA No. 70 and must conform to all local code authority having jurisdiction. AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF ELECTRICAL SHOCK OR POSSIBLE ELECTROCUTION. If any of the original wire as supplied with the appliance must be replaced, use only type 105°C thermoplastic or equivalent and 2500C type F must be used for the flame sensor and igniter leads.
Gas Piping than 14.0” W.C. (3.48 kPa). A supply gas regulator is necessary if higher gas pressures are encountered. See Gas Pressure Requirements and Supply Gas Regulator sections on page 12. Contact your local gas service company to ensure that adequate gas service is available and to review applicable installation codes for your area. 1. Supply gas regulators must be rated at or above the input Btu/ hr rating of the water heater they supply. Size the main gas line in accordance with Table 8.
Start Up Prior to Start Up Initial Start Up Installation and start up of this water heater requires abilities and skills equivalent to that of a licensed tradesman in the field involved, see Qualifications on page 6. Required Test Equipment U-tube manometer, pressure gauge, or digital manometer. Recommended range: 20” W.C. (5 kPa). Note: All test equipment must be acclimated to ambient temperature before calibration and use. Preparation 1. Adjust the thermostat to the lowest temperature setting. 2.
On multiple water heater installations the supply gas line regulators shall be adjusted to provide gas pressure to each water heater within the minimum and maximum supply pressure requirements listed in Table 3 on page 8 with all gas fired appliances connected to a common gas main firing at full capacity. Checking the Input For appliance installation locations with elevations above 2000 feet, refer to HIGH ALTITUDE INSTALLATIONS section of this manual for input reduction procedure. 1.
SEQUENCE OF OPERATION 10. From the time the Gas Valve opens, the Ignition Control Board waits 3 seconds and then shuts off power to the Silicon Nitride Igniter. 11. From the time the Silicon Nitride Igniter’s power is shut off, the Ignition Control Board waits 3 more seconds to monitor the Flame Sensor. 12. If the Flame Sensor does not detect a strong enough flame, the Ignition Control Board shuts off the Gas Valve and allows the Exhaust Inducer to purge the unit for 20 seconds.
Sequence of Operation Flow Chart Description of this flow chart can be found in the “SEQUENCE OF OPERATION” section found on page 25. FIGURE 24.
Maintenance Check the Igniter Assembly and Main Burners If the storage tank temperature control is out of calibration, replace with new control. At least once a year, check the igniter assembly, Figure 25, and the main burner, Figure 26, for proper operation. Refer to the following igniter assembly and main burner sections. SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE.
Draining and Flushing Explosion Hazard Burn harzard. Temperature-Pressure Relief Valve must comply with ANSI Z21.22CSA 4.4 and ASME code. Hot water discharge. Keep hands clear of drain valve discharge. Properly sized temperaturepressure relief valve must be installed in opening provided. Can result in overheating and excessive tank pressure. It is recommended that the water heater storage tank be drained and flushed every 6 months to reduce sediment buildup.
Tank Cleanout Procedure Lime accumulation not only reduces the life of equipment but also reduces efficiency of the heater and increases fuel consumption. The following practices will ensure longer life and enable the unit to operate at its designed efficiency: The usage of water softening equipment greatly reduces the hardness of the water. However, this equipment does not always remove all of the hardness (lime). For this reason it is recommended that a regular schedule for deliming be maintained. 1.
threads. Tighten firmly by hand and use wrench or adjustable pliers to check for secure connection. Do not over tighten to avoid damage to threads and fittings. Chemical Hazard Prepare the Up-N-Down Transfer Kit The next step is the preparation on the Up-N-Down Transfer Kit, if you have not already done so: • Product contains phosphoric acid. • Keep out of reach of children. 1.
SERVICE The installer may be able to observe and correct certain problems which may arise when the unit is put into operation. HOWEVER, it is recommended that only qualified service agents, using appropriate test equipment, be allowed to service the heater. TABLE 9: 1 FLASH As preliminary step, check wiring against diagram, check for grounded, broken or loose wires. Check all wire ends to be sure that they are making good contact.
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. 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.
Troubleshooting COMPLAINT 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 Upper and/or lower temperature probe out of calibration. Call qualified service agency Main manual gas shutoff valve partially closed. Open main manual gas shutoff valve to fullest extent.
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 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 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 Manifold Kits TWO UNIT MANIFOLD KIT (PART NO. 9003426205) MODEL BTR-500 DIMENSION "A" 81.5" THREE UNIT MANIFOLD KIT (PART NO. 9003427205) FOUR UNIT MANIFOLD KIT (PART NO.
Limited Warranty 50
Notes 51
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