Instruction Manual COMMERCIAL GAS WATER HEATERS POWER VENTED GAS MODELS W/HOT SURFACE IGNITION MODEL BTX-80 SERIES 110 500 Tennessee Waltz Parkway Ashland City, TN 37015 LOW LEAD CONTENT • For Your Safety • AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER. ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
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 Hazard For continued protection against risk of f ire: • Do not install water heater on carpeted floor. • Do not operate water heater if any part has been exposed to flooding or water damage.
GENERAL SAFETY INFORMATION CAUTION Improper installation, use and service may result in property damage. • • • • • Do not operate water heater if any part has been exposed to flooding or water damage. Inspect anode rods regularly, replace if damaged. Install in location with drainage. Fill tank with water before operation. Properly sized thermal expansion tanks are required on all closed water systems. Refer to this manual for installation and service.
TABLE OF CONTENTS Vent Pipe Assembly..................................................................... 19 Venting........................................................................................ 19 Vent Pipe Termination................................................................. 20 Planning the Vent System........................................................... 21 Polypropylene Installations.......................................................... 22 Condensate............................
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS COMMONWEALTH OF MASSACHUSETTS INSPECTION For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, i
TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER - GAS MODELS A B C D F G H J K L M N O P Vent Pipe Anode Hot Water Outlet Outlet (120 VAC) Gas Supply Main Manual Gas Shut Off Valve Ground Joint Union Sediment Trap Outer Door Union Inlet Water Shut Off Valve Cold Water Inlet Inlet Dip Tube Temperature & Pressure Relief Valve Q R S T U W X Y AA CC DD EE FF GG Rating Plate Insulation Vent Terminal Drain Valve Igniter And Main Burner Drain Pan Gas Control Valve/T-Stat Control Harness* Motor & Blower
TYPICAL INSTALLATION CONDENSATE HOSE AND DRAIN PAN FIGURE 1 (continued).
TYPICAL INSTALLATION MIXING VALVE / THERMAL EXPANSION TANK USAGE AND SPACE HEATING MIXING VALVES DANGER FIGURE 2. Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death. Children, the elderly and the physically or mentally disabled are at highest risk for scald injury. Feel water before bathing or showering. Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at fixtures. TABLE 1.
ROUGH-IN-DIMENSIONS Rough-In-Dimensions Model BTX-80 Units Inches cm A 71.12 180.64 B 68.70 174.50 C 51.90 131.83 D 20.90 53.09 E 9.15 23.24 F 12.00 40.48 G 22.00 55.88 Top/Side Inlet and Outlet: 3/4″ NPT Gas Inlet: 1/2″ NPT Capacity and Gas and Electrical Characteristics All models - Maximum Supply Pressure: 14 inches W.C. (3.48kPa) Minimum Supply Pressure Natural Gas: 5.0 inches W.C. (1.24kPa) Minimum Pressure must be maintained under both load and no load (static and dynamic) conditions.
LOCATING THE NEW WATER HEATER FACTS TO CONSIDER ABOUT THE LOCATION Carefully choose an indoor location for the new water heater, because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance. This water heater is not for use in manufactured (mobile) homes or outdoor installation. Whether replacing an old water heater or putting the water heater in a new location, the following critical points must be observed: 1.
in an alcove or closet, the entire floor must be covered by the panel. Failure to heed this warning may result in a fire hazard. If this water heater will be used in beauty shops, barber shops, cleaning establishments, or self-service laundries with dry cleaning equipment, it is imperative that the water heater or water heaters be installed so that combustion and ventilation air be taken from outside these areas.
Such a condition often will result in a yellow, luminous burner flame, causing sooting of the combustion chamber, burners and flue tubes and creates a risk of asphyxiation. free area and metal louvers and grilles will have 75% free area. Non motorized louvers and grilles shall be fixed in the open position.
Figure 7. The water heater shall have clearances of at least 1 inch (25 mm) from the sides and back and 6 inches (150 mm) from the front of the appliance.
INSTALLING THE NEW WATER HEATER CHEMICAL VAPOR CORROSION This water heater should not be connected to any heating systems or component(s) used with a non-potable water heating appliance. CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS. SUCH CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION. All piping components connected to this unit for space heating applications should be suitable for use with potable water.
THERMAL EXPANSION As water is heated, it expands (thermal expansion). In a closed system the volume of water will grow when it is heated. As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty.
HIGH ALTITUDE INSTALLATION discharge opening must not be blocked or reduced in size under any circumstances. Excessive length, over 30 feet (9.14 m), or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve. 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.
SEDIMENT TRAPS A gas line of sufficient size must be run to the water heater. Consult the current edition of National Fuel Gas Code (ANSI Z223.1/NFPA 54) or the Natural Gas and Propane Installation Code (CAN/CSA B149.1) and your gas supplier concerning pipe size. There must be: • A readily accessible manual shut off valve in the gas supply line serving the water heater, and • A sediment trap ahead of gas control valve to help prevent dirt and foreign materials from entering the gas control valve.
Never use this water heater unless it is completely full of water. To prevent damage to the tank, the tank must be filled with water. Water must flow from the hot water faucet before turning “ON” gas to the water heater. the parts and cement back together using the alignment marks. After the cement dries, attach the assembly to the blower and the water heater exhaust using the supplied rubber boots and hose clamps. A condensate trap is incorporated in the bottom of this vent pipe assembly.
TERMINATION CLEARANCES SIDEWALL POWER VENT POWER VENT (using room air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION G V D H A v E L v B FI XE D CLOSED V F OPERABLE V OPERABLE V B B C B B FI XE D CLOSED V M X V K J A X V B V X VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED FIGURE 15. Vent terminal clearances for “Power Vent” installations. Power Vent configurations use room air for combustion.
PLANNING THE VENT SYSTEM cannot exceed equivalent pipe lengths discussed above where each elbow is equal to 5 feet (1.5 m) of straight pipe (3” vent pipe) or 8 feet (2.4 m) of straight pipe (4” vent pipe). Plan the route of the vent system from the discharge of the blower to the planned location of the vent terminal. Refer to VAA instruction on page 25 while planning the vent system. APPROVED VENT/INTAKE MATERIAL: Approved vent and intake air pipe materials that may be used in the United States: 1.
This water heater has been design certified to be vented with PVC pipe certified and marked as complying with ULC S636. This water heater is supplied with a 2 inch 22.5 degree termination elbow that is a special fitting that must be used with this appliance. Any outlet piping, fittings and glue used to vent this appliance that is not supplied by the manufacturer must comply with the ULC S636 requirements. the flue connection. The adapter is supplied by the vent manufacturer to adapt to its vent system.
The condensate trap may be primed by filling the CONDENSATE U-ASSEMBLY with tap water while the water heater is not operating. The system is fully primed when the water level reaches the adaptor connected into the Tee. In most installations the water heater will self-prime the condensate trap during the first full heat-up cycle.
bead of caulking (not supplied) around the gap between the pipe and cover plate. Apply enough to fill some of the gap between the pipe and wall. Place some of the caulking on the back of the plate to hold it against the wall after installation. If the vent pipe is installed up to the wall, with a coupling on the end against the wall opening, the pipe with the vent terminal can be prepared for gluing before inserting through the wall.
INSTALLATION OF VENT SYSTEM, SIDEWALL additional vent pipe when calculating maximum equivalent feet of venting. With the route of the venting system and selection of materials completed, as discussed in the section of this manual titled PLANNING THE VENT SYSTEM, the through the wall vent terminal in place and the first section of piping, up to first elbow, installed at the blower it is time to complete the installation of the venting system for the sidewall installation.
VENT ATTENUATION ASSEMBLY INSTALLATION INSTRUCTIONS 4. Make sure the VAA and vent pipe is supported securely to a permanent fixture (stud or wall). Use standard support straps (not supplied with kit) that may be found at a local hardware store. Failure to properly support the VAA and the surrounding vent pipe could create a hazardous situation. DO NOT puncture any surface of the VAA. The Vent Attenuation Assembly (VAA) is designed to provide a reduction in fan noise created in the blower wheel.
barb, use a wire tie or hose clamp (not supplied with kit) and secure. 6. Take the other end of the flexible tubing and slide it through the hose clamp on the jacket top cover and install it into one of the four barb fittings in vent pipe assembly #2. 7. Once installed along with the rest of the vent configuration, make sure to operate the unit through at least one heat up cycle to ensure there is no leakage around the hose barb or any joints of the VAA or vent pipe system.
VENT PIPE PREPARATION PRIMER 1. INITIAL PREPARATION It is recommended that Tetrahydrofuran (THF) be used to prepare the surfaces of pipe and fittings for solvent welding. Do not use water, rags, gasoline or any other substitutes for cleaning PVC or CPVC surfaces. A chemical cleaner such as MEK may be used. A. Make sure the solvent cement you are planning to use is designed for the specific application you are attempting. B.
B. Deburring Use a knife, plastic pipe deburring tool, or file to remove burrs from the end of small diameter pipe. Be sure to remove all burrs from around the inside as well as the outside of the pipe. A slight chamfer (bevel) of about 10°-15° should be added to the end to permit easier insertion of the pipe into the end of the fitting. Failure to chamfer the edge of the pipe may remove cement from the fitting socket, causing the joint to leak. STEP E F.
FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do NOT try to light the burner by hand. B. BEFORE OPERATING smell all around the appliance area for gas.
TEMPERATURE REGULATION To avoid any unintentional changes in water temperature settings, the control has a tamper resistant feature for changing the temperature setting. To change the temperature setting follow these instructions: 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.
FOR YOUR INFORMATION START UP CONDITIONS If the smelly water persists after the anode replacement and chlorination treatment, we can only suggest that chlorination or aeration of the water supply be considered to eliminate the water problem. 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. Do not remove the anode leaving the tank unprotected.
PERIODIC MAINTENANCE VENTING SYSTEM INSPECTION Soot build-up indicates a problem that requires correction before further use. Turn “OFF” gas to water heater and leave off until repairs are made, because failure to correct the cause of the sooting can result in a fire causing death, serious injury, or property damage. FIGURE 27. BURNER CLEANING In the event your burner or burner air openings require cleaning, turn the blower switch to the “OFF” position and allow the burner to cool.
The anode rod is used to protect the tank from corrosion. Most hot water tanks are equipped with an anode rod. The submerged rod sacrifices itself to protect the tank. Instead of corroding tank, 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. Explosion Hazard Anode deterioration depends on water conductivity, not necessarily water condition.
SERVICE the water heater contact a service agency. If you are not thoroughly familiar with gas codes, your water heater, and safety practices, contact your gas supplier or qualified installer to check the water heater. Use this guide to check a “Leaking” water heater. Many suspected “Leakers” are not leaking tanks. Often the source of the water can be found and corrected. Read this manual first.
TROUBLESHOOTING GUIDELINES TROUBLE SHOOTING Please check guidelines below. For your safety, water heater service should be performed only by a qualified service technician. Read the GENERAL SAFETY INFORMATION section first. INTELLI-VENT TROUBLESHOOTING CHART - USER CONTROL # LED STATUS PROBLEM SOLUTION B C D E F Inadequate or no earth ground 1. Ensure the wall outlet is properly grounded. 1 sensed by the Intelli-Vent™ control. 2.
TROUBLESHOOTING GUIDELINES TROUBLE SHOOTING Please check guidelines below. For your safety, water heater service should be performed only by a qualified service technician. Read the GENERAL SAFETY INFORMATION section first. INTELLI-VENT TROUBLESHOOTING CHART - USER CONTROL # 6 LED STATUS B C D E F PROBLEM SOLUTION Ignition/flame failure. The water heater has reached the maximum number of retries and is currently locked out for one hour.
TROUBLESHOOTING GUIDELINES TROUBLE SHOOTING Please check guidelines below. For your safety, water heater service should be performed only by a qualified service technician. Read the GENERAL SAFETY INFORMATION section first. INTELLI-VENT TROUBLESHOOTING CHART - USER CONTROL # 15 B C D E F B C D E F PROBLEM SOLUTION The self-diagnostic test determined resistance of the black resistor wire on ignitor assembly plug is not within tolerance. 1. Turn off power to the water heater.
TROUBLESHOOTING GUIDELINES These guidelines should be utilized by a qualified service agent.
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COMMERCIAL LIMITED WARRANTY WATER HEATER LIMITED WARRANTY EFFECTIVE WHAT'S NOT COVERED For 3 Years, in the event of a tank leak, we will repair or, at our • Problems caused by improper: gas supply line sizing, gas type, venting, connections, combustion air, voltage, wiring, or fusing For 1 Year, in the event of part failure, we will repair or, at our discretion, replace the defective part. • Failure to follow applicable codes discretion, replace the defective water heater.
500 Tennessee Waltz Parkway, Ashland City, TN 37015 Technical Support: 800-527-1953 • Parts: 800-433-2545 • Fax: 800-644-9306 www.hotwater.com Copyright © 2015 A. O. Smith Corporation. All rights reserved.
