Home

A.O. Smith BTH 120 - 250 Owner's Manual

1. oa TARE VENT ve itae Ae l L ql f I gt mun W TH 250 L EXHAUST VENT t INTAKE VENT TERMINALS lt J pe mm 24 MIN FIGURE 9 IMPORTANT WHEN LOCATING THE TERMINALS ON A SIDEWALL THE FOLLOWING SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE FOLLOWED 1 The intake vent terminal and the exhaust vent terminal must terminate on the same exterior wall and must be located at a minimum of 24 inches from the vertical centerline of the exhaust vent terminal see Figure 9 In colder climates increasing the 24 minimum will reduce possibility of frost over from side winds blowing exhaust vapors to the air intake of the direct the vent 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 INSTALLATION SEQUENCE For installations in the City of Los Angeles California Category IV PVC Pipe such as that manufactured by Brownline Pipe Company must be used as vent pipe material A CAUTION Vent terminals supplied with the heater must be used NOTE BEFORE BEGINNING INS
2. 15 ERROR CODES Possible Cause The following Error Codes are external to the controller 01 Pressure Switch Fail On should be Off 1 No Input Power 1 Apply Power 11 Pressure Switch Fail Off should be On 02 Ignition Fail after 3 attempts 2 Wiring Disconnected 2 Check alll wiring 04 05 Temperature Probe Open 15 Temperature Out of Bounds lt 30 degrade 3 One or more wiring receptacles 3 Reconnect plugs on control 25 Temperature Out of Bounds gt 220 degrees disconnected from control confirm all are fully seated The following Error Codes are internal to the controller 4 LED burned out 4 Ignore or replace control 113 Flame On Should be Off Fail 22 Ignition Relay Fail is On should be Off 112 Ignition Relay Fail is Off should be On NO LOW VOLTAGE Figure 20 101 K2 Failin K1 24V AC LED 102 Main Loop Fail in K2 103 K1 Main Loop Gas Valve Power Supply WDPS Watch Dog Power Supply Keka 106 WDPS Fail to be Off 107 WDPS Fail to be Off switcH SWITCH VALVE VALVE 108 WDPS Fail to be On RLY1 RLY2 116 Gas Valve Relay Fail is should be 117 Gas Valve Relay Fail is On should be Off Checks The ROM Read Only Memory coms 200 CRC Check Sum Error Checks The CPU Central Processing Unit 201 CPU Instruction Test Error ELECTRONICS 202 CPU Instruction Test Error iden 203 CPU Instruction T
3. Recovery capacities are based on heater performance at 94 thermal efficiency 2 FOREWORD These designs comply with the latest version of the American National Standard for Gas Water Heaters Volume III ANSI Z21 10 3 as an automatic circulating tank water heater and automatic storage water heaters Detailed installation diagrams are found in this manual These diagrams will serve to provide the installer with reference for the materials and methods of piping necessary It is highly essential that all water gas piping and wiring be installed as shown on the diagrams Particular attention should be given to the installation of thermometers at the locations indicated on the diagrams as these are necessary for checking the proper functioning of the heater In addition to these instructions the equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made These shall be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made In the absence of local codes the installation must comply with the latest editions of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and the National Electric Code NFPA 70 The former is available from the Canadian Standards Association 8501 East Pleasant Valley Road Cleveland OH 44131 and both documents are available from the National F
4. CONDENSATE NOTE THE CONDENSAT HOSE MUST BE BELOW FIGURE3 WARNING DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE APPLIANCE AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER CLEARANCES 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 Inall installations the minimum combustible clearances from any vent piping shall be 0 Vent piping passing through a combustible wall or ceiling must be continuous run no joints A service clearance of 24 should be maintained from serviceable parts such as relief valves flue baffles flue damper devices thermostats cleanout openings or drain valves Always disconnect electrical power before servicing the unit CEILING REAR WALL FRONT VIEW For removal of top cover TOP VIEW FIGURE 4 ILLUSTRATION OF MINIMUM COMBUSTIBLE CLEARANCES IN AN ALCOVE HARD WATER Where hard water conditions exist water softening or the threshold type of water treatment is recommended This will protect the dishwashers coffee ums water heaters water piping and other equipment See MAINTENANCE section for details of tank cleanout procedure AIR REQUIREMENTS KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE MATERIALS GASOLINE AND
5. 7 Place a bead of caulking not supplied around the gap between the pipe and the wall Place some of the caulking on the back of the plate to hold it against the wall after installation 8 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 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 Figure 10 METAL PLATES MORTAR OR Erne 3 PVC VENT TERMINAL WITH MESH PROTECTIVE SCREEN INSIDE EXHAUST z VENT TERMINAL OUTSIDE BUILDING 3 PVC COUPLING EXHAUST VENT TERMINAL ALL MODELS METAL PLATES MORTAR OR SILICONE 3 PVC 45 ELBOW WIDIVERTER PLATE amp ADAPTER SCREEN INTAKE VENT TERMINAL OUTSIDE 12 MINIMUM BUILDING COUPLING WALL INTAKE VENT TERMINAL BTH 150 amp 199 MODELS ONLY METAL PLATES 3 PVC TEE WITH MESH PROTECTIVE SCREEN INSIDE INTAKE VENT TERMINAL MORTAR OR SILICONE OUTSIDE 12 MINIMUM s PVC WALL COUPLING INTAKE VENT TERMINAL BTH 250 MODELS ONLY WATER HEATER BUILDING METAL PLATES MORTAR OR SILICONE 37 PVC 45 ELBOW WIDIVERTER PLATE amp ADAPTER SCREEN INTAKE VENT TERMINAL WATER OUTSIDE 12 MINIMUM HEATER oy pug BUILDING COUPLING w INTAKE VENT TERMINAL BTH 120 MODELS ONL
6. CONTROL ELECTRONICS ke TEMPERATURE PROBE FAULT Water Temp LED Flashing ELEMENT FIGURE 21 NO INCOMING LINE VOLTAGE Line LED Off This condition accommodates multiple failure modes To more accurately FIGURE 19 determine the cause of failure press the pushbutton on the display board 16 Display Flashes 05 when button is pressed 1 il PRESSURE GAS GAS Possible Cause Remedy atte vite 1 Temperature Probe wiring 1 Repair Wiring open 2 Defective probe 2 Replace probe CONTROL IGNITER ELECTRONICS Display Flashes 15 when button is pressed ELEMENT Possible Cause Remedy 1 No water in tank and tank 1 The symptom does not in freezing conditions reflect a control problem CONTROL BAD All LEDs Flashing FIGURE 23 2 Water in tank above freezing 2 Temperature probe out of tolerance replace temp probe Possible Cause 1 Temp Probe unplugged 1 Check connectors 2 Temp probe wiring damaged 2 Repair wiring Display Flashes 25 when button is pressed 3 Water in tank too hot 3 Normal condition when watertemperature exceeds safety limit Allow water to cool or admit water into tank and manually reset the control Determine cause for overtemp condition Possible Cause 1 Water in tank is low probe 1 Filltank immersed in steam 2 Probe wiring shorted 2 Repair wiring 3
7. THE DISCHARGE LINE SHALL BE INSTALLED TO ALLOW COMPLETE DRAINAGE OF BOTH THE VALVE AND LINE 13 WATER LINE CONNECTIONS This manual provides detailed installation diagrams see back section of this manual for typical methods of application for the water heaters The water heater may be installed by itself or with a separate storage tank When used with a separate storage tank the circulation may be either by gravity or by means of circulating pump When a circulating pump is used it is important to note that the flow rate should be slow so that there will be a minimum of turbulence inside the heater CLOSED SYSTEM caution A closed system will exist if check valve without bypass pressure reducing valve without bypass or a water meter without bypass is installed in the cold water line between the water heater and street main or well Excessive pressure may develop causing premature tank failure or intermittent relief valve operation This type of failure is not covered by the limited warranty An expansion tank or a similar device may be required in the inlet supply line between the appliance and the meter or valve to compensate for the thermal expansion of water under supply pressure If a water heater is installed closed water system check local codes or contact the water supplier or local plumbing inspector on how to control this situation HEATER WIRING IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WIT
8. Why When and How describes tank cleaning methods and materials UNsLIME and the booklet may be obtained through your Smith dealer or distributor The cleanout opening is shown in Figure 25 To clean heater through cleanout opening proceed as follow 1 Turn off water inlet valve the heater electrical disconnect switch and open drain valve Remove outer cover plate from lower side of heater jacket Remove cover from cleanout opening Remove lime scale or sediment using care not to damage the glass lining Inspect cleanout plate gasket If new gasket is required replace with O Smith part no 99038 Install cleanout plate Be sure to draw plate up tight by tightening screws securely Close drain valve open water inlet line and turn on the power burner electrical disconnect switch Check for water leakage Replace outer jacket cover plate ANODE INSPECTION AND REPLACEMENT This water heater is equipped with multiple sacrificial anodes Anodes protect the glass lined tank from corrosion by sacrificing themselves through electrolysis When the anode material is consumed there is no more protection and corrosion of the tank accelerates Inspection of the anode every 6 to 12 months allows you to identify a spent anode and replace it Replace the anode when its diameter is 3 8 of an inch or annually which ever is first Aggressive very hot and softened water causes rapid consumption of the anode requiring frequent
9. above 100 F and or insufficient dilution air itis recommended that CPVC or ABS pipe and fittings MUST USE SUPPLIED VENT TERMINAL be used 4 It is important that condensate not be allowed to buildup in the exhaust vent pipe To prevent this from happening the pipe should be installed with slight 1 8 inch per five feet 5 of pipe maximum downward slope The vent system should be supported every five feet 5 of vertical run and every three feet 3 of horizontal run of vent pipe length NOTE Stress levels in the pipe and fittings can be significantly increased by improper installation If rigid pipe clamps are used to hold the pipe in place or if the pipe cannot move freely through a wall penetration the pipe may be directly stressed or high thermal stresses may be formed when the pipe heats up and expands Install accordingly to minimize such stresses VENT PIPE PREPARATION 1 INITIAL PREPARATION A Make sure the solvent cement you are planning to use is designed for the specific application you are attempting B Know the physical and chemical characteristics and limitations of the PVC PVC cellular core ABS or CPVC piping materials that you are about to use C Know the reputation of your pipe and cement manufacturer and their products 11 D Know your own qualifications or those of your contractor The solvent welding technique of joining PVC PVC cellular core ABS or CPVC pipe is a specialized skill just as an
10. inspections Anodes are available from your distributor or Smith To inspect or replace an anode The anodes on this heater are easily accessible from the top of the heater making replacement simple and quick 1 Turn the heater off per the lighting instructions Connect a hose to the drain valve Locate the hose s discharge an area where hot water will not cause any damage or injury Open the drain valve to flush any sediment out of the bottom of the heater Shut off the cold water supply Make sure all hot water fixtures and circulating pumps are turned off Wait for water flow from the hose to stop Remove the anode using a socket of the appropriate size Sometimes pry bar will be required to loosen the anode plug Do not use an impact wrench Inspect and replace the anode as required Use a pipe tape or sealant when reinstalling the anode Close the drain valve Open a hot water fixture to allow air to escape Open the cold water supply to heater and allow the tank to fill Follow the lighting instructions Check your anode and drain valve for leaks DRAIN VALVE AND ACCESS PANELS The heaters are equipped with a 3 4 drain valve access panel covers the cleanout opening in the tank which is sealed by a gasket and cover figure 25 RELIEF VALVE At least twice a year the temperature and pressure relief valve should be checked to ensure that itis in operating condition To check the relief valve li
11. Air Blockage 17 PRIOR TO START UP 18 Required Ability 18 OPERATIING INSTRUCTIONS 18 Adjustment Procedure Initial Start Up 18 Lighting Instructions 19 Cathodic Protection 20 Precautions 20 GENERAL INFORMATION 20 Power Burer 20 High Limit 20 High Altitude Installations 2 MAINTENANCE 20 General 20 Maintenance Schedule 72 Flushing 2 Draining 21 Sediment Removal 21 Lime Scale Removal 21 Anode Inspection and Replacement 21 22 Drain Valve and Access Panels 2 Relief Valve 2 Circulating Pump 2 Vent System 2 INSTALLATION DIAGRAMS 23 27 Manifold Kits 28 CHECKLIST AND SERVICE INFORMATION 29 TROUBLE SHOOTING sve 29 30 REPLACEMENT PARTS 30 LIMITED WARRANTY 31 FEATURES IMPORTANT ITIS REQUIRED THAT A QUALIFIED SERVICE TECHNICIAN PERFORM THE INITIAL FIRING OF THE HEATER AT THIS TIME THE USER SHOULD NOT HESITATE TO ASK THE TECHNICIAN ANY QUESTIONS WHICH HE MAY HAVE IN REGARD TO THE OPERATION AND MAINTENANCE OF THE UNIT ACHECKLIST AND SERVICE INFORMATION section are included at the rear of this manual By using this checklist the user may be able to make minor operational adjustments and save himself unnecessary service calls However the user should not attempt repairs which are not listed in this section WATER TEMPERATURE CONTROL DANGER A DANGER THIS WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE THERMOSTAT TO CONTROL WATER TEMPERATURE HOT WATER TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHER AND LAUNDRY USE
12. CAN CAUSE SCALD BURNS RESULTING IN SERIOUS PERSONAL INJURY AND OR DEATH THE TEMPERATURE AT WHICH INJURY OCCURS VARIES WITH THE PERSON S AGE AND TIME OF EXPOSURE THE SLOWER RESPONSE TIME OF DISABLED PERSONS INCREASES THE HAZARDS TO THEM NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER TAP OR TO DRAW THEIR OWN BATH WATER NEVER LEAVE A CHILD OR DISABLED PERSON UNATTENDED INA BATHTUB OR SHOWER THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET TEMPERATURES water temperature is controlled using the Temperature Control Button on the Display at the front of the unit See Figure 1 This control utilizes two temperature probes to determine the tank temperature The primary temperature probe is located at the top of the tank and the other is near the water inlet The temperature may be adjusted from 80 to 180 F The thermostat was adjusted to 120 F 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 SETTING THE WATER HEATER TEMPERATURE 120 F WILL REDUCE THE RISK OF SCALDS Some states require settings at specific lower temperatures Figure 1 shows the app
13. Defective probe 3 Replace probe COMBUSTION AIR BLOCKAGE Figure 24 Pressure Switch LED Flashing ECO SWITCH OPEN Figure 22 ECOLED Flashing PRESSURE GAS GAS SWITCH SWITCH VALVE VALVE RLY2 coms BLOWER CONTROL ELECTRONICS IGNITER ELEMENT ECO SWITCH OPEN ECOLED Flashing FIGURE 22 Possible Cause 1 This indicates the control has 1 Press button the failed on of its internal display board to reset diagnostic self tests control If this error occurs repeatedly replace control CONTROL BAD Figure 23 All LEDs Flashing 1 PRESSURE GAS SWITCH VALVE VALVE RLY2 24VAC mco SWITCH CONTROL EL CTRONICS IGNITER ELEMENT COMBUSTION AIR BLOCKAGE Pressure Switch LED Flashing FIGURE 24 Possible Cause 1 Combustion air blocked 1 Check exhaust piping and flue for obstructions 2 Blower not operating 2 Repair wiring a Check blower wiring b Check blower motor b Replace blower motor 3 Defective air switch 3 Replace air switch 4 Pressure switch jumped out 4 This controller must sense an open contact on the blower proving airflow switch before the blower comes on Check to see if blower proving airflow switch is still connected to the unit 17 PRIOR TO START UP REQUIRED ABILITY INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO TH
14. OR INDIRECT AND WHETHER ARISING IN CONTRACT OR TORT Some states do not allow the exclusion or limitation of the incidental or consequential damage so the above limitations or exclusions may apply to you b This warranty gives you specific legal rights and you may also have other rights which vary from state to state Fill in the following for your own reference Keep it Registration is not a condition of warranty The model and serial number found on the heater s rating plate Date Installed Model No Serial No Dealers Name Phone No Dealer s Address City and State Zip Code FILL IN WARRANTY AND KEEP FOR FUTURE REFERENCE 31 WATER PRODUCTS COMPANY PSD Alsip IL ProductPreservers SMITH WATER PRODUCTS CO INC 5621 W 115TH STREET ALSIP ILLINOIS 60803 PHONE 1 800 433 2545 FAX 1 800 433 2515 WWW HOTWATER COM E MAIL PARTS HOTWATER COM
15. THE ELECTRICITY WHENEVER POSSIBLE OR APPROPRIATE WHILE CHECKING EQUIPMENT A WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING BURNER OPERATIONAL PROBLEMS Refer to TROUBLESHOOTING NOT ENOUGH OR NO HOT WATER Be certain the electrical disconnect switch serving the water heater is in the ON position 2 Check the fuses The electrical disconnect switch usually contains fuses 3 The capacity of the heater may have been exceeded by large demand for hot water Large demands require a recovery period to restore water temperature 4 Colder incoming water temperature will lengthen the time required to heat water to the desired temperature lf the heater was installed when incoming water temperature was warm colder water creates the effect of less hot water 5 Look for hot water wastage and leaking or open hot water faucets 6 Sediment or lime scale may be affecting water heater operation Refer to MAINTENANCE for details 7 The heaters temperature high limit sensor has activated Press the reset button on the thermostat 8 may not be firing at proper rate Check gas pressure Adjust to obtain required manifold pressure 9 fan wheel may be dirty Clean fan wheel with a stiff brush
16. THE OPERATION AND MAINTENANCE OF THE UNIT A CAUTION BEFORE PROCEEDING WITH THE OPERATION OF THE UNIT MAKE SURE HEATER AND SYSTEMARE FILLED WITH WATERANDALL AIR IS EXPELLED FROMHEATER AND PIPING NEVER OPERATE THE HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER TEMPERATURE AND A PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVEOPENING OF THE HEATER DO NOT ATTEMPT TO OPERATE HEATER WITH COLD WATER INLET VALVE CLOSED FILLING 1 Close the heater drain valve 2 Open nearby hot water faucet to permit the air in the system to escape Fully open the cold water inlet pipe valve allowing the heater and piping to be filled 4 Close the hot water faucet as water starts to flow 5 The heater is ready to be operated 3 THE MAIN MANUAL GAS SHUTOFF VALVE MUST HAVE BEEN CLOSED FORAT LEAST FIVE 5 MINUTES THIS WAITING PERIOD IS AN IMPORTANT SAFETY STEP ITS PURPOSE IS TO PERMIT GAS THAT MIGHT HAVE ACCUMULATED IN THE COMBUSTION CHAMBER TO CLEAR IF YOU DETECT GAS AT THE END OF THIS PERIOD DO NOT PROCEED WITH LIGHTING RECOGNIZE THAT GAS ODOR EVEN IF IT SEEMS WEAK MAY INDICATE THE PRESENCE OF ACCUMULATED GAS SOMEPLACE IN THE AREA WITH ARISK OF FIRE OR EXPLOSION SEE THE FRONT PAGE FOR STEPS TOBE TAKEN DO NOT USE THIS HEATER IF ANY PART HAS BEEN UNDER WATER IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE HEATER AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDE
17. drawing combustion air from inside a conventionally constructed building to a confined space such a space shall be provided with two permanent openings ONE IN OR WITHIN 12 INCHES OF THE ENCLOSURE AND ONE IN OR WITHIN 12 INCHES OF THE ENCLOSURE BOTTOM Each opening shall have a free area of at least one square inch per 1000 Btuh of the total input of all appliances the enclosure but not less than 100 square inches If the confined space is within a building of tight construction air for combustion and ventilation must be obtained from outdoors When directly communicating with the outdoors through vertical ducts two permanent openings located in the above manner shall be provided Each opening shall have a free area of not less than one square inch per 4000 Btuh of the total input of all appliances in the enclosure If horizontal ducts are used each opening shall have a free area of not less than one square inch per 2000 Btuh of the total input of all appliances in the enclosure CHEMICAL VAPOR CORROSION AA warnine CORROSION OF THE FLUE WAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS SUCH CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION Spray can propellants cleaning solvents refrigerator and air conditioning refrigerants swimming pool chemicals calcium and sodium chloride waxes and process chemicals are typical compounds which are potentially corrosive PRODUCTS OF T
18. of detecting the temperature of the outlet water supply RELIEF VALVE This heater is equipped with an approved temperature and pressure relief valve ASME ratings cover pressure relief A G A ratings cover release rate with temperature actuation FOR SAFE OPERATION OF THE WATER HEATER THE RELIEF VALVE S MUST NOT BE REMOVED OR PLUGGED In addition to the appliance relief valve each remote storage tank which may be used in conjunction with this appliance shall also be installed with a properly sized rated and approved temperature ANSI and pressure ASME relief valve s This relief valve shall comply with the standard for relief valves and automatic gas shutoff devices for hot water supply systems ANSI 221 22 Your local code authority may have other specific relief valve requirements A WARNING THE PURPOSE OF A RELIEF VALVE IS TO AVOID EXCESSIVE PRESSURE OR TEMPERATURE INTO THE STEAM RANGE WHICH MAY CAUSE SCALDING AT FIXTURES TANK EXPLOSION SYSTEM OR HEATER DAMAGE NO VALVE IS TO BE PLACED BETWEEN THE RELIEF VALVE AND THE TANK ADRAIN LINE MUST BE CONNECTED TO THE RELIEF VALVE TO DIRECT DISCHARGE TO A SAFE LOCATION TO AVOID SCALDING OR WATER DAMAGE THIS LINE MUST NOT REDUCED FROM THE SIZE OF THE VALVE OUTLET AND MUST NOT CONTAIN VALVES OR RESTRICTIONS NOR SHOULD IT BE LOCATED IN FREEZING AREAS DO NOT THREAD OR CAP THE END OF THIS LINE RESTRICTED OR BLOCKED DISCHARGE WILL DEFEAT THE PURPOSE OF THE VALVE AND IS UNSAFE
19. of the plug cock in the circulating line See installation diagrams CIRCULATING PUMP 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 latest version of the National Electric Code ANSI NFPA No 70 Only all bronze circulators are used with commercial water heaters Although circulators are oiled and operated by the manufacturer some circulators must be oiled again before operated Please refer to manufacturer s instructions INSTALLATION INSTRUCTIONS 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 INSULATION BLANKETS Insulation blankets available to the general public for external use on gas water heaters are not approved for use on your Smith water heater The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank water heaters Your Smith water heater meets or exceeds the ASHRAE IES 90 1b 1992 standards with respect to insulation and standby loss requirements making an insulation blanket unnecessary A WARNING Should you choose to apply an insulation blanket to this heater you should follow these instr
20. 10 Condensate hose may be blocked where it connects to the exhaust elbow Verify the condensate drains from the unit without restriction WATER IS TOO HOT Refer to WATER TEMPERATURE CONTROL WATER HEATER MAKES SOUNDS Sediment or lime scale accumulations cause rumbling and pounding noises when the heater is operating sounds are normal however the tank bottom should be cleaned Refer to MAINTENANCE for details Some of the electrical components of the water heater make sounds which are normal Contacts click or snap as the heater starts and stops Transformers often hum WATER LEAKAGE IS SUSPECTED 1 Check to see if the water heater drain valve is tightly closed Also check the cleanout opening for leakage 2 The apparent leakage may be condensation which forms on cool surfaces of the heater and piping 3 If the outlet of the relief valve is leaking it may represent Excessive water pressure Excessive water temperature Faulty relief valve Excessive water pressure is the most common cause of relief valve leakage It is often caused by a closed system If a check valve is in the inlet system it will not permit the expanded hot water volume to equalize pressure with the main The relief valve must release this water or the water heater or plumbing system will be damage d Refer to MAINTENANCE RELIEF VALVE section in this manual When such a condition is encountered local codes or inspecti
21. AT 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 The power burner is equipped with an ignition system which automatically sequences prepurge and ignition senses and ignites main burner flame and sequences burner operation Heater is equipped with an ignition control which locks out after three unsuccessful ignition attempts Familiarize yourself with the sequence of operation of this unit prior to start up Be certain that the water heater is full of water that air is purged from all lines there are no leaks gas and water and all inlet water lines are open The following test equipment should be on hand all test equipment must be acclimated to ambient temperature before calibration and use Two U tube manometers or calibration 0 10 and 0 35 W C pressure gauges Attach gas pressure gauge or manometer to the upstream side of main gas cock and a gas pressure gauge or manometer to the manifold pressure tap see Figure 15 You now ready to begin the burner start up procedure OPERATING INSTRUCTIONS IMPORTANT IT IS RECOMMENDED THAT A QUALIFIED SERVICE TECHNICIAN PERFORM THE INITIAL FIRING OF THE HEATER AT THIS TIME THE USER SHOULD ASK THE TECHNICIAN ANY QUESTIONS IN REGARD TO
22. BOILER TO TANK LOOP ANDIOR HOT WATER LOOP IF USED 23 TWO TEMPERATURE ONE HEATER HIGH TEMPERATURE WITH OR WITHOUT BUILDING RECIRCULATION A DANGER PIPE RELIEF VALVE TO OPEN DRAIN TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES SEE WATER NOTE IF TEMPERED WATER IS TEMPERATURE CONTROL WARNING ON PAGE 4 IF RECIRCULATED RETURN LINE SHOULD BE HIGHER PREHEAT TEMPERATURES ARE NECESSARY CONNECTED AT POINT TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO INSTALL IN ACCORDANCE WITH LOCAL FIXTURES CODES 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 INSTALL THERMAL EXPANSION TANK IF CHECK VALVE OR PRESSURE REDUCING VALVE 18 USED IN SUPPLY VACUUM RELIEF 180 F WATER OUTLET VALVE gt INSTALL PER LOCAL CODES THERMOMETER TEMPERED WATER 12 TO 15 RELIEF VALVE Point A RETURN LINE FROM 1 I 180 CIRCULATING 11 lug 4 LOOP IF USED 0 VALVE e Fn Fanka 4 LINE TEMP SU Um 54 CONTROL CIRCULATING PUMP CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK TEMPERATURE CONTROL CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK TEMPERATURE CONTROL 120vAc DISHWASHER LINE 2 TOGGLE TEMPERATURE NEUTRAL Li SWITCH CONTROL WITH RED
23. COMPONENT OPERATION INTERVAL REQUIRED Tank Sediment Monthly Flushing POWER BURNER Removal The initial start up procedure of the unit is provided on page 18 Tank Lime Scale Semi UN LIME Removal Annually Delimer The sequence of operation of the unit is provided on page 15 It is important to note that the controller has a reset button on the control Anode Inspect Semi Replace as box Figure 1 The reset button is a safety device and would not normally Rods Annually Required be used Relief Valve Inspect Semi HIGH LIMIT Annual The high limit not adjustable is factory set to cutout at 202 F The controller must be manually reset by depressing the reset button on front of the SAE No 20 control when water temperature drops to below 160 F Circulating Oiling Four Months non detergent Pump 1 motor oil TABLE 4 BTH 120 BTH 150 BTH 120 Clean Inlet GAS SUPPLY SPECIFICATIONS Blower Screen and As Required Soft Brush Blower Wheel Natural Gas Max Gas Supply Press W C 14 0 14 0 14 0 Vent System Inspect Every 3 Joints should Nominal Gas Supply Press W C 70 7 0 110 Menthe iis denied Minimal Gas Supply Press W C 50 45 11 0 Manifold Press W C 40 3 5 10 0 1 If furnished with oiling provision 20 FLUSHING 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 h
24. CYCLONE XHE Model BTH 120 250 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 WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Thank you for buying this energy efficient water heater from A O Smith Water Products Company We appreciate your confidence in our products CAUTION TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY PLEASE READ THOROUGHLY BEFORE INSTALLING AND USING THISAPPLIANCE PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FORFUTURE REFERENCE PRINTED IN U S A 2570 1199 WATER PRODUCTS COMPANY ADIVISION OF A O SMITH CORPORATION Mc BEE SOUTH CAROLINA Part No 194119 000 Supersed
25. ERS ARE USED THIS PREVENTS ANY VIBRATIONS FROM BEING TRANSMITTED INTO THE LIVING SPACES A WARNING FLAMMABLE ITEMS PRESSURIZED CONTAINERS OR ANY OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON OR ADJACENT TO THE HEATER OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM WITH THEHEATER When installing the heater consideration must be given to proper location Location selected should be as close to the intake and exhaust termination points as practicable with adequate air supply and as centralized with the piping system as possible THE HEATER MUST NOT BE LOCATED IN AN AREA WHERE IT WILL BE SUBJECT TOFREEZING LOCATE IT NEAR A FLOOR DRAIN THE HEATER SHOULD BE LOCATED IN AN AREA WHERE LEAKAGE FROM THE HEATER OR CONNECTIONS WILL NOT RESULT IN DAMAGE TO THE ADJACENT AREA OR TO LOWER FLOORS OF THESTRUCTURE When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the appliance A WARNING THIS WATER HEATER IS A CONDENSING UNIT AND REQUIRES A DRAINTO BE LOCATED IN CLOSE PROXIMITY TO ALLOW THE CONDENSATE TO DRAIN SAFELY THE CONDENSATE DRAINS FROM THE UNIT AT THE EXHAUST ELBOW LOCATED AT THE BOTTOM OF THE UNIT NOTE IT IS IMPORTANT THAT THE CONDENSATE HOSE NOT BE ELEVATED ABOVE THE EXHAUST ELBOW SEE FIGURE 3 THE CONDENSATE BUILD UP WILL BLOCK THE EXHAUST OUTLET WHICH WILL CAUSE IMPROPER OPERATION EXHAUST ELBOW
26. Gas 11 0 W C if the inlet pressure is not within these limits then adjust the supply pressure accordingly If the inlet pressure falls within the allowable limits then verify that the manifold pressure when the gas is fully open with the heater running is as called outin Table 4 thats for Natural Gas 4 0 W C for BTH 120 amp 250 or 3 5 W C for BTH 150 amp 199 for L P Gas 10 0 W C If the manifold pressure is not correct then adjust accordingly See ADJUSTMENT PROCEDURE in OPERATING INSTRUCTIONS selection page 18 for the manifold pressure adjustment procedure If the inlet and manifold pressures are within the limits specified in step 5 then reset the appliance Verify 24V AC at the gas valve during the three 3 second ignition trial after the igniter reaches operating temperature If 24V AC at the gas valve is not seen during this period the controller must be replaced If there is 24V at the gas valve during the four second ignition trial and the manifold pressure does not increase above 0 W C then verify that the manual gas control valve is in the position see page 20 If the valve is in the position and the previous voltage and gas pressure conditions are met then the gas valve is defective and must be replaced Note that a positive manifold pressure reading of approximately 1 5 W C is normal during the prepurge portion of the ignition cycle due to the location of the gas orific
27. H THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH 105 C WIRE OR ITS EQUIVALENT EXCEPT IN THE BURNER HOUSING IN THIS CASE USE 200 C WIRE THE COMPUTER CONTROL REQUIRES A SOURCE OF STABLE CLEAN ELECTRICITY FOR PROPER OPERATION INSTALLING THE HEATER ON ABRANCH CIRCUIT THAT HAS ELECTRONIC NOISE IS SUBJECT TO FLUCTUATIONS IN VOLTAGE LEVEL OR HAS AN APPLIANCE WHICH GENERATES EMF OF RFI INTERFERENCE CAN CAUSE THE CONTROLLER TO MALFUNCTION A HIGH QUALITY POWER CONDITIONER MUST BE INSTALLED IF THE ABOVE CONDITIONS EXIST MALFUNCTIONS CAUSED BY A POOR ELECTRICAL SUPPLY ARE NOT COVERED UNDER YOUR WARRANTY The controller is wired to the heater as shown in figures 16 amp 17 The model and rating plate provides the electrical information needed to size the complete heater branch supply electrical work must be installed in accordance with the National Electrical Code and local requirements When installed the appliance must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 DO NOT ENERGIZE THE BRANCH CIRCUIT BEFORE THE HEATER TANK IS FILLED WITH WATER NOTE This controller is Polarity Sensitive If the Hot and Neutral Supply Voltage is reversed the controller will not sense flame Verify polarity before connecting the unit DISPLAY WHC1002 INTEGRATED WATER HEATER CONTROL CONNECTION DIAGRAM TEMPERATURE E C
28. HIS SORT SHOULD NOT BE STORED NEAR THE HEATER ALSO AIR WHICH IS BROUGHT IN CONTACT WITH THE HEATER SHOULD NOT CONTAIN ANY OF THESE CHEMICALS IF NECESSARY UNCONTAMINATED AIR SHOULD BE OBTAINED FROM REMOTE OROUTSIDE SOURCES VENTING wanNING THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST BE FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULATION OF FLUE GASES SUCH CONDITIONS CAUSE SOOTING OR RISKS OF FIRE AND ASPHYXIATION Heater must be protected from freezing downdrafts during shutdown periods A 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 VENT PIPE TERMINATION NOTE Before installing venting determine place of vent pipe termination See Figure 6 before proceeding A CAUTION DONOT TERMINATE THE VENTING WHERE NOISE FROM THE EXHAUST OR INTAKE WILL BE OBJECTIONABLE THIS INCLUDES LOCATIONS CLOSE TO OR ACROSS FROM WINDOWS AND DOORS AVOID ANCHORING THE VENT AND INTAKE PIPES DIRECTLY TO FRAMED WALLS FLOORS OR CEILINGS UNLESS RUBBER ISOLATION PIPE HANGERS ARE USED THIS PREVENTS ANY VIBRATIONS FROM BEING TRANSMITTED INTO THE LIVING SPACES DIRECT VENT warnine VENT HOOD S MAY VENT HOOD MUST BE BE EXTREMELY HOT MOUNTED 1 MINIMUM DURING OPERATION ABOVE DOORS AND WINDOWS AIR INTAKE 1 MINIMUM MINIMUM SEE DIRECT VENT AIR INTAKE SECTION PAGE 9 OPTIONAL _ SEE D
29. IMUM CAPACITY OF PIPE IN CUBIC FEET OF GAS PER HOUR Based upon a Pressure Drop of 0 5 inch Water Column and 0 6 Specific Gravity Gas and max gas pressure of 0 5 psig NOMINAL IRON PIPE SIZES INCHES Tae r ar F 1 400 2 100 3 950 6 300 11000 950 770 660 1 460 1 180 990 900 2 750 2 200 1 900 1 680 4 350 3 520 3 000 2 650 7 700 6 250 5 300 4 750 1 520 1 400 1 300 1 220 1 150 2 400 2 250 2 050 1 950 1 850 4 300 3 900 3 700 3 450 3 250 1 020 950 850 800 1 650 1 500 1 370 1 280 2 950 2 650 2 450 2 280 A WARNING THE HEATER IS NOT INTENDED FOR OPERATION AT HIGHER THAN 14 0 WATER COLUMN 1 2 POUND PER SQUARE INCH SUPPLY GAS PRESSURE HIGHER GAS SUPPLY PRESSURES REQUIRE SUPPLEMENTAL REDUCING SERVICE REGULATION EXPOSURE TO HIGHER GAS SUPPLY PRESSURE MAY CAUSE DAMAGE TO THE GAS CONTROLS WHICH COULD RESULT IN FIRE OR EXPLOSION IF OVERPRESSURE HAS OCCURRED SUCH AS THROUGH IMPROPER TESTING OF GAS LINES OR EMERGENCY MALFUNCTION OF THE SUPPLY SYSTEM THE GAS VALVE MUST BE CHECKED FOR SAFE OPERATION MAKE SURE THAT THE OUTSIDE VENTS ON THE SUPPLY REGULATORS AND THE SAFETY VENT VALVES ARE PROTECTED AGAINST BLOCKAGE THESE ARE PARTS OF THE GAS SUPPLY SYSTEM NOT THE HEATER VENT BLOCKAGE MAY OCCUR DURING ICE STORMS IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING FROM CONTAMINANTS IN THE GAS WAYS SUCH FOULING
30. IRECT VENT a PAGES REGULATOR 1 MINIMUM MIN VENT HOOD MUST BE MOUNTED lt usss A MINIMUM 1 MINIMUM AWAY HORIZONTALLY FROM DOORS AND WINDOWS 3 ABOVE ANY OUTSIDE AIR INTAKE WITHIN 10 INTAKE AIR MUST MOUNTED 1 MINIMUM BELOW WINDOWS cas MINIMUM FROM INSIDE CORNER RECOMMENDED NOTE BTH 250 USES TEE ON AIR INTAKE TERMINAL FIGURE 5 DO NOT TERMINATE EXHAUST EXHAUST VENT HOOD MUST BE OVER PUBLIC AREA WHERE LOCATED 1 MINIMUM FROM ANY CONDENSATE OR VAPOR CAN OPENING IN BUILDING CAUSE NUISANCE OR HAZARD A HORIZONTAL VENT WARNING VENT HOOD S MAY BE EXTREMELY HOT DURING OPERATION VENT HOOD MUST BE MOUNTED 1 MINIMUM ABOVE DOORS AND WINDOWS 4 MINIMUM 1 MINIMUM CD ES at EXHAUST VENT HOOD MUST BE MOUNTED EXHAUST MINIMUM AWAY HORIZONTALLY FROM DOORS AND WINDOWS ABOVE ANY OUTSIDE AIR INTAKE WITHIN 10 MINIMUM FROM INSIDE CORNER RECOMMENDED 1 ABOVE GRADE OR ANTICIPATED SNOW LEVEL FIGURE 6 IMPORTANT The vent system must terminate so that proper clearances are maintained as cited in local codes or the latest edition of the National Fuel Gas Code ANSI 2223 1 7 3 4 and 7 8a b as follows 1 Do not terminate the exhaust vent terminal over public area where con
31. LVE UST BE EQUAL I LINE TMP RELIEF Boosten ADD CHECK VALVE WHEN CIRCULATING LOOP MUST BE IDENTICAL HEATERS FOR MULTIPLE HEATER INSTALLATION SEE MANIFOLD KIT DANGER OO TEMPERATURE SETTING SHOULD NOTEXCEED SAFE TEMPERATURE AT CAUTION IF BUILDING COLD WATER SUPPLY HAS A BACK FLow FIXTURES SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 4 PREVENTER CHECK VALVE OR WATER METER WITH CHECK F HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN PROVISIONS FOR THERMAL EXPANSION OF WATERINTHEHOTWATER ADEQUATE BOOSTER OUTPUT ADD ANTI SCALD VALVE FOR HOT SYSTEM MUST BE PROVIDED WATER SUPPLIED TO FIXTURES 25 TWO TEMPERATURE TWO HEATERS ONE PRE HEATER ONE BOOSTER HEATER WITH OR WITHOUT BUILDING RECIRCULATION Adpancer TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 4 IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES INSTALL THERMAL EXPANSION TANK IF CHECK VALVE OR PRESSURE REDUCING VALVE IS USED IN SUPPLY pRE HEATER COLD WATER SUPPLY MAXIMUM 1 1 2 BOOSTER CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK TEMPERATURE CONTROL 120 CIRCULATING PUMP L2 NEUTRAL WIRING DIAGRAM FOR BOILER TO TANK LOOP ANDIOR HOT WATER LOOP IF USED PRE HEATED WATER PIPE
32. MAY CAUSE IMPROPER OPERATION FIRE OR EXPLOSION IF COPPER SUPPLY LINES ARE USED THEY MUST BE INTERNALLY TINNED AND CERTIFIED FOR GAS SERVICE BEFORE ATTACHING THE GAS LINE BE SURE THAT ALL GAS PIPE IS CLEAN ON THE INSIDE TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS SUPPLY LINE A DIRT LEG SOMETIMES CALLED A SEDIMENT TRAP OR DRIP LEG MUST BE INCORPORATED IN THE PIPING SEE FIG 14 THE DIRT LEG MUST BE READILY ACCESSIBLE AND NOT SUBJECT TO FREEZING CONDITIONS INSTALL IN ACCORDANCE WITH RECOMMENDATIONS OF SERVING GAS SUPPLIERS REFER TO THE NATIONAL FUEL GAS CODE REGULATED GAS SUPPLY MAIN GAS SHUTOFF VALVE DIRT LEG dth PIPE wn FIGURE 14 CONNECTION OF GAS PIPE 1 When connecting gas pipe to unit apply wrench to flange only Note Do not use wrench on gas valve or gas bracket See Figure 15 2 PERFORM THE GAS LEAK TEST ANY TIME WORK IS DONE ON A GAS SYSTEM TO AVOID THE POSSIBILITY OF FIRE OR EXPLOSION WITH PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE Q 1508199 rA LUNE PRESSURE UNE PRESSURE MANIFOLD aDwust UNE PRESSURE oust BTH 120 MANIFOLD PRESSURE Y MANFOLD Pressure FIGURE 15 Gas Leak Testis performed as follows Paint pipe connections upstream of gas control with a rich soap and water solution to test for leaks before operating main burner Bubbles indicate gas leak To stop leak tighten pipe connections A
33. NNECTED AT POINT A 27 MANIFOLD KITS Precision cut type L all copper Smith manifold kits assure 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 Unions shown in piping diagrams are not included in the manifold kits Dimensions shown are for minimum space occupied by the water heaters assemblies Space for the venting system and unit servicing must be added TWO UNIT MANIFOLD KIT PART NO 78692 THREE UNIT MANIFOLD KIT PART NO 78693 2 INLET AND OUTLET 2 INLET AND OUTLET MANIFOLD CONNECTION MANIFOLD CONNECTIONS 8 91 2 INLET AND OUTLET 2 INLET AND OUTLET MANIFOLD CONNECTION MANIFOLD CONNECTIONS FOUR UNIT MANIFOLD KIT PART NO 78694 24 INLET AND OUTLET MANIFOLD CONNECTIONS kus 124 116 2 INLET AND OUTLET MANIFOLD CONNECTIONS g 4 28 CHECKLIST AND SERVICE INFORMATION IMPORTANT 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 BE SURE TO TURN OFF
34. ON OF AVENT SYSTEM WITHA DEVICE OTHER THAN THE SUPPLIED VENT TERMINATIONS WILL AFFECT SYSTEM PERFORMANCE AND RESULT INA SAFETY HAZARD DIRECT VENTING The air intake provided on the unit contains a mesh screen see Figure 7 to prevent large particles from entering the unit 3 45 PVC ELBOW WITH MESH SCREEN RESTRICTOR FIGURE 7 A WARNING WHEN THE UNIT IS TOBE SETUP AS A DIRECT VENT THE MESH SCREEN MUST BE REMOVED THE INLET VENT PIPE MAY THEN BE GLUED TO THE AIR INTAKE see Figure 8 PROVIDED ON THE UNIT REMOVE MESH SCREEN AND RESTRICTOR RING AND DISCARD WHEN DIRECT VENT PIPE IS ADDED EXHAUST FIGURE 8 DIRECT VENT TERMINAL INSTALLATION IMPORTANT THIS UNIT CONSISTS OF TWO VENT TERMINALS AN INTAKE VENT TERMINAL AND AN EXHAUST VENT TERMINAL THE INTAKE VENT TERMINAL IS A 3 45 PVC ELBOW OR 3 PVC TEE FOR BTH 250 WITHA MESH WIRE SCREEN AND THE EXHAUST VENT TERMINAL IS A 3 45 PVC ELBOW WITHA MESH WIRE SCREEN SIDEWALL EXHAUSTVENT INTAKE VENT TERMINAL TERMINAL
35. OTHER FLAMMABLE VAPORS AND LIQUIDS DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATING AIR Awarninc FOR SAFE OPERATION PROVIDE ADEQUATE AIR FOR COMBUSTION AND VENTILATION AN INSUFFICIENT SUPPLY OF AIR WILL CAUSE RECIRCULATION OF COMBUSTION PRODUCTS RESULTING IN CONTAMINATION THAT MAY BE HAZARDOUS TO LIFE SUCH A CONDITION OFTEN WILL RESULT IN A YELLOW LUMINOUS BURNER FLAME CAUSING CARBONING OR SOOTING OF THE COMBUSTION CHAMBER BURNERS AND FLUE TUBES AND CREATES A RISK OF ASPHYXIATION MECHANICAL EXHAUSTING OF ROOM AIR 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 TOBE DRAWN INTO THE ROOM THROUGH THE HEATERS VENTING SYSTEM CAUSING POOR COMBUSTION SOOTING MAY RESULT IN SERIOUS DAMAGE TO THE HEATER AND RISK OF FIRE OREXPLOSION ITCANALSO CREATE ARISK OF ASPHYXIATION UNCONFINED SPACE In buildings of conventional frame brick or stone construction unconfined spaces may provide adequate air for combustion and ventilation If the unconfined space is within a building of tight construction buildings using the following construction weather stripping heavy insulation caulking vapor barrier etc air for combustion and ventilation must be obtained from outdoors The installation instructions for confined spaces in tightly constructed buildings must be followed to ensure adequate air supply CONFINED SPACE When
36. PILOT LIGHT 120 CIRCULATING PUMP L2 NEUTRAL WIRING DIAGRAM FOR BOILER TO TANK LOOP WIRING DIAGRAM FOR 180 LOOP IF USED ANDIOR HOT WATER LOOP IF USED 24 TWO TEMPERATURE TWO HEATERS HIGH TEMPERATURE WITH OR WITHOUT BUILDING RECIRCULATION ALL MANIFOLDING MUST BE EQUAL LENGTH 1 1 2 MAXIMUM PIPE 180 F WATER OUTLET THERMOMETER VACUUM RELIEF VALVE INSTALL PER LOCAL CODES MIXING TEMPERED VALVE WATER WATER SUPPLY INSTALL THERMAL EXPANSION TANK IF CHECK VALVE OR PRESSURE REDUCING VALVE 15 USED IN SUPPLY HEATER ALL MANIFOLDING MUST BE EQUAL LENGTH 117 MAXIMUM PIPE RETURN LINE FROM 180 F WATER 4 CIRCULATING LOOP IF USED 4 cincutatine LINE TEMP CONTROL MUST BE IDENTICAL HEATERS CHECK VALVE TWO TEMPERATURE THREE HEATERS TWO PRE HEATERS ONE BOOSTER HEATER WITH OR WITHOUT BUILDING RECIRCULATION ALL MANIFOLDING MUST BE EQUAL LENGTH 1 1 2 MAXIMUM PIPE THERMOMETER HOT WATER TO FIXTURES THERMOMETER PREHEATED WATER TO BOOSTER RETURN LINE FROM 180 F CIRCULATING i RELIEF PDR INSTALL THERMAL EXPANSION mL VALVE eye TANK IF CHECK VALVE OR PRESSURE REDUCING VALVE ALL MANIFOLDING MUST TAN miia RESSURE REDUCING V EQUAL LENGTH HEATER A VACUUM RELIEF ALL MANIFOLDING es VA
37. PROBE BOARD 20 CONDUCTOR RIBBON CABLE CONTROL BSR BOARD BTH 250 ONLY FIGURE 16 14 TO BLOWER ITEM DESCRIPTION 1 Transformer 2 Control Board 3 Probe 4 Blower Proving Air Switch 5 Low Voltage Cable Assembly 6 Line Voltage Cable Assembly 14 Tubing Pressure 7 Blower Motor Assembly 15 Tubing Pressure 8 Igniter Assembly 16 Connector Tubing 9 Cable To Control Display Board 17 Switch On Off 10 Control Display Board 18 Low Gas Pressure 11 Blocked Outlet Exhaust Switch Switch 12 Lower Temperature Probe 19 Bocked Inlet Switch 13 Wire Assembly Gas Pressure 20 Wire Assembly Air Switch Flow Switch FIGURE 17 OPERATION SEQUENCE OF OPERATION Typical Contro Appliance Operating Sequence 1 When the control is powered it should first display 0 then the input line voltage 120 the calibration setting 12 then the actual water temperature in the tank 2 If the control determines that the actual water temperature inside the tank is below the programmed temperature setpoint less the differential call for heat is activated 3 The control then performs selected system diagnostic checks This includes confirming the proper state of the air switch and ECO limit device 4 If all checks are successfully passed the combustion blower is energized for the pre purge
38. R WATER LIGHT THE UNIT IN ACCORDANCE WITH THE OPERATING INSTRUCTIONS LABEL ATTACHED TO THE HEATER THESE INSTRUCTIONS ARE REPEATED IN THE LIGHTING AND OPERATING LABEL ILLUSTRATION ON PAGE 20 IN THIS MANUAL 18 ADJUSTMENT PROCEDURE INITIAL START UP minimum gas supply pressure of 5 0 W C 4 5 on BTH 150 and 199 for natural gas 11 0 W C for L P Gas is required before making adjustment to the gas control pressure regulator Attempts to adjust the regulator during periods of low gas supply pressure could result in overfiring of the heater when the gas supply pressure retums to normal 1 Check gas line pressure with a manometer 2 Check manifold pressure see Table 4 page 20 using a pressure gauge manometer connected to the manifold pressure tap on the gas control valve Figure15 If full rate adjustment is required remove cover screw from top of the gas control valve Figure 15 Using small screwdriver turn adjusting screw clockwise Y to increase or counterclockwise to decrease gas pressure to obtain 4 0 on BTH 120 and 250 3 5 on BTH 150 and 199 for natural gas 10 0 W C for L P Gas Water Column 3 4 amp Cycle the bumer and off several times to check its operation Check the operation of the limit and operating controls Check the vent system seams and joints and ensure that there is discharge of flue products into the room 6 Check the input rate For appliance installati
39. RELIEF VALVE TO OPEN DRAIN 140 F TO 150 F SHOULD BE MAXIMUM WATER TEMPERATURE MAINTAINED IN THE PRE HEATERS 120 F SHOULD BE THE MINIMUM TEMPERATURE OF WATERIN THE PRE HEATERS CONNECT CIRCULATING LINE FROM FIXTURES IF USED TOCOLD WATER SUPPLY LINE OF PRE HEATER CONNECT CIRCULATING LINE OF 180 F OR BOOSTED WATER IF USED TO INLET WATER LINE TO BOOSTER INSTALL IN ACCORDANCE WITH LOCAL CODES VACUUM RELIEF HOT WATER TO FIXTURES VALVE THERMOMETER INSTALL PER LOCAL CODES OUTLET BOOSTED TEMPERTURE TYPICAL SOOSTER HEATER RELIEF VALVE 11 2 CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK TEMPERATURE CONTROL sav Ac DISHWASHER LINE z TOGGLE TEMPERATURE Li switch CONTROL WITH RED PILOT LIGHT CIRCULATING PUMP WIRING DIAGRAM FOR 180 LOOP IF USED 26 TWO TEMPERATURE ONE HEATER HIGH TEMPERATURE WITH RECIRCULATION OF SANITIZING LOOP CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK TEMPERATURE CONTROL LINE TEMPERATURE CONTROL DISHWASHER re TOGGLE Li SWITCH WITH RED PILOT LIGHT CIRCULATING PUMP VACUUM RELIEF VALVE INSTALL PER LOCAL CODES WIRING DIAGRAM FOR 180 LOOP IF USED SANITIZING LOOP TO VICINITY OF DISHWASHER VACUUM BREAKER MINAL RINSE ERMOMETER CONTROL SOLENOID WATER SUPPLY ARRESTER PRESSURE REDUCING VALVE l DISHWASHER TOGGLE
40. SWITCH NOTE 1 3 4 75 ALL BRONZE LINE TEMPERATURE CIRCULATING PUMP CONTROL NOTE 2 CHECK VALVE A DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 5 IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES 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 PIPE RELIEF VALVE TO OPEN DRAIN INSTALL IN ACCORDANCE WITH LOCAL CODES SUPPLY COLD TEMPERED WATER OUTLET NOTE 4 INSTALL THERMAL EXPANSION TANK IF CHECK VALVE OR PRESSURE REDUCING VALVE 15 USED IN SUPPLY 180 F WATER OUTLET TEMPERATURE AND PRESSURE RELIEF VALVE PLUG cock NOTE 3 NOTE 1 TOGGLE SWITCH CONTROLS 180 F WATER CIRCULATION INSTALL ON OR CLOSE TO DISHWASHER TOGGLE SWITCH MUST BE CLOSED ON DURING THE RINSE OPERATION AND OPEN OFF WHEN DISHWASHER IS NOT OPERATING OR WHEN ON LONG STANDBY NOTE 2 INSTALL LINE TEMPERATURE CONTROL IN AN UNINSULATED TEE BEYOND THE DISHWASHER TAKEOFF IN THE SANITIZING LOOP CONTROL SHOULD SET AT 185 F NOTE 3 ADJUST PLUG COCK SO THE SANITIZING LOOP FLOW RATE DOES NOT CAUSE UNNECESSARY TURBULENCE IN THE TANK NOTE 4 IF TEMPERED WATER IS RECIRCULATED RETURN LINE SHOULD BE CO
41. T AND THE EXHAUST VENTING ARRANGEMENT MUST BE INSTALLED TO RUN DIRECTLY TO THE OUTDOORS AND NOT IN ANY WAY BE CONNECTED TO ANOTHER VENTING SYSTEM I E FURNACE DRYERS OR SPACE HEATERS IT IS CRUCIAL THAT THE VENTING ARRANGEMENT BE KEPT SEPARATE FROM OTHER VENTING SYSTEMS IF THIS WARNING IS IGNORED AND THE SYSTEMIS VENTED INCORRECTLY IT MAY CAUSE IMPROPER OPERATION FIRE EXPLOSION OR ASPHYXIATION 1 Plan the route of the vent system from the vent termination to the planned location of the appliance Layout the total vent system to use the minimum of vent pipe and elbows possible The installer may add up to MAXIMUM OF FIFTY 50 EQUIVALENT feet of pipe to the exhaust venting arrangement This addition of FIFTY 50 EQUIVALENT feet of pipe on both the intake venting arrangement and exhaust venting arrangement must include any 3 inch PVC elbows which equals 5 EQUIVALENT feet of pipe Table 2 VENT LENGTH TABLE Number of 90 Elbows ONE 1 TWO 2 3 Minimum Pipe Feet 7 3 Maximum Pipe Feet 45 40 35 30 4 Maximum Pipe Feet 115 110 105 100 95 90 THREE 3 FOUR 4 FIVE 5 SIX 6 4 inch PVC may be used for a MAXIMUM intake of ONE HUNDRED TWENTY 120 EQUIVALENT FEET and a MAXIMUM exhaust of ONE HUNDRED TWENTY 120 EQUIVALENT FEET The maximum number of 90 elbows with the 4 inch venting is six 6 on the intake and six 6 on the exhaust 90 elbow is equal to f
42. T WATER SYSTEM MUST BE PROVIDED 3 4 78 ALL BRONZE CIRCULATING PUMP STORAGE TANK NOTE CONNECT RETURN LINE FROM HOT WATER CIRCULATING LOOP IF USED TO COLD WATER INLET LINE PIPE OPEN DRAIN COLD WATER SUPPLY CHECK VALVE TANK TEMPERATURE CONTROL INSTALL IN ACCORDANCE WITH LOCAL CODES ONE TEMPERATURE ONE HEATER HORIZONTAL STORAGE TANK FORCED CIRCULATION WITH OR WITHOUT BUILDING RECIRCULATION A DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 4 IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES PIPE TO OPEN DRAIN INSTALL IN ACCORDANCE WITHLOCAL CODES TEP RELIEF VACUUM RELIEF VALVE INSTALL PER LOCAL CODES HOT WATER OUTLET WITH STORAGE TANK ABOVE HEATER PROVIDE HEAT TRAP TO APPROX MID POINT OF HEATER INSTALL THERMAL EXPANSION TANK IF CHECK VALVE OR PRESSURE REDUCING VALVE 1S USED IN SUPPLY STORAGE TANK 2 RISER A RETURN LINE FROM BUILDING CIRCULATING LOOP IF USED TANK TEMPERATURE CONTROL PLUG CHECK VALVE CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK TEMPERATURE CONTROL 3 4 75 ia ALL BRONZE C FUME 120 CIRCULATING PUMP L2 NEUTRAL WIRING DIAGRAM FOR
43. TALLATION OF ANY VENT PIPE READ THE VENT PIPE MANUFACTURER S INSTALLATION INSTRUCTIONS 1 After the points of termination have been determined use the cover plates as templates to mark the holes for the vent pipes to be inserted through the wall BEWARE OF CONCEALED WIRING AND PIPING INSIDE OF WALL 2 Ifthe vent terminals are being installed on the outside of a finished wall it may be easier to mark both the inside and outside wall Align the holes by drilling a hole through the center of the template from the inside through to the outside The template can now be positioned on the outside wall using the drilled holes as a centering point for the template 3 A MASONRY SIDE WALLS Chisel an opening approximately one half inch larger than the marked circle B WOODEN SIDE WALLS Drill a pilot hole approximately one quarter inch outside of the marked circle This pilot hole is used as a starting point for a saws all or sabre saw blade Cut around the marked circle staying approximately one quarter inch outside of the line This will allow the vent pipe to easily slide through the opening The resulting gap will be covered by the vent terminal cover plates Repeat this step on the inside wall if necessary 4 Cut a length of 3 inch PVC pipe about 3 5 inches longer than the wall thickness at the opening 5 Glue the intake vent terminal to the section of the pipe 6 Slide the wall plate over the pipe to stop against intake vent terminal
44. TO SHUT OFF TURN OFF THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE HIGH ALTITUDE INSTALLATIONS A WARNING BTH HEATERS ARE CERTIFIED FOR USE WITHOUT MODIFICATION FOR ALTITUDES UP TO 6500 FEET INSTALLATIONS ABOVE 6500 FEET MAY REQUIRE REPLACEMENT OF THE BURNER ORIFICE CALL THE TECHNICAL CENTER 800 627 1953 FOR REQUIREMENTS Some gas utility companies derate their gas for altitude making it unneccessary to install high altitude orifices the local gas or utlity company to verify BTU content Due to the input rating reduction at high altitudes the output rating of the appliance is also reduced and should be compensated for in the sizing of the equipment for applications MAINTENANCE GENERAL KEEP APPLIANCE AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS SEE WARNING ON PAGE 5 LOCATING THE HEATER Water heater maintenance includes periodic tank flushing and cleaning and removal of lime scale The unit should be inspected and adjusted to maintain proper combustion Refer to the following table A periodic inspection of the venting system should be made Where used the water circulating pump should be oiled MAINTENANCE SCHEDULE Following are the instructions for performing some of the recommended maintenance Unit inspection and adjustment should be performed by a competent technician GENERAL INFORMATION
45. TYPE OF GAS SERVICE TO AVOID RISK OF FIRE OR EXPLOSION PURGE DISCHARGE MUST NOT ENTER CONFINED AREAS OR SPACES WHERE IGNITION CAN OCCUR THE AREA MUST BE WELL VENTILATED AND ALL SOURCES OF IGNITION MUST BE INACTIVATED OR REMOVED GAS METER SIZE CITY GASES ONLY Be sure that 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 the gas meter is too small ask the gas company to install a larger meter having adequate capacity GAS PRESSURE REGULATION Main line gas pressure to the water heater should be between a maximum 14 0 W C and a minimum as shown in Table 4 that is for Natural Gas 5 0 W C for BTH 120 amp 250 or 4 5 W C for BTH 150 amp 199 or for L P Gas 11 0 W C The inlet gas pressure must not exceed the maximum value A service regulator should be installed within ten feet 10 of unit GAS VALVES A WARNING SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE SYSTEM CONNECTIONS The system installation must conform to these instructions and to the local code authority having jurisdiction Good practice requires that all heavy piping be supported THERMOMETERS Not Supplied Thermometers should be obtained and field installed as shown in the installation diagrams Thermometers are installed in the system as a means
46. VENTILATED AREA CONTROLS AND SWITCHES BTH 120 and 250 are provided with four pressure switches Both the BTH 150 and 199 are provided with three pressure switches These switches are essential to the safe and proper operation of the unit All switches are wired in series The controller is set up to shut the unit down whenever there is a failure of any of the switches It is important to understand the purpose of each switch LOW VOLTAGE CABLE ASSEMBLY BLOWER ASSEMBLY BLOCKED INLET PROVING SWITCH USED ON BTH 120 BLOWER PROVING 4 250 ONLY AIR SWITCH Low Gas PRESSURE SWITCH BLOCKED OUTLET PROVING SWITCH _ FIGURE 13 BLOWER PROVER SWITCH SEE FIGURE 13 The Blower Prover Switch is provided on the heater to verify that the fan is operating It is a positive pressure switch whose electrical contacts 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 BLOCKED OUTLET PROVER SWITCH SEE FIGURE 13 The Blocked Outlet Prover Switch is set up to shut the unit off when a build up of positive pressure in the ex
47. Y FIGURE10 PLUMBING VENT ROOF BOOT BOTH PIPES _ 24 MIN ER INTAKE gt 5e VENT ITERMINAL gt lt Be EXHAUST TERMINAL VERTICAL VENT TERMINATION BTH 250 MODELS ONLY A B 12 ABOVE ROOF OR SNOW ACCUMULATION LEVEL FIGURE 11 VERTICAL VENT TERMINAL INSTALLATION IMPORTANT WHEN TERMINATING THROUGH A ROOF THE FOLLOWING SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE FOLLOWED 1 Proper support must be provided for all pipe protruding through the roof 2 The vertical roof terminations should be sealed with a plumbing roof boot or equivalent flashing 3 The intake vent termination and the exhaust vent termination must penetrate the same side of roof 4 The center line of the intake vent termination and the center line of the exhaust vent termination must be no closer than 24 inches 5 The intake vent terminal and the exhaust vent terminal must be oriented facing downward and the same direction The specifications are displayed Figure 11 amp 12 NOTE Exhaust vent terminal is installed using the same procedure INSTALLATION SEQUENCE NOTE BEFORE BEGINNING INSTALLATION OF ANY VENT PIPE READ VENT PIPE PREPARATION SECTION ON PAGE 11 1 After the points of termination have been determined use the cover plates as templates to mark the holes for the vent pipes to be inserted through the roof Drill a pilot hole approximately one quarter inch o
48. be performed 3 Remove top cover 4 Push in gas control knob slightly and turn clockwise to OFF Do not force 5 Replace top cover waRNNG UNDER NO CIRCUMSTANCES SHOULD THEINPUT EXCEED THE SHOWN ON THE HEATER RATING PLATE OVERFIRING COULD RESULTIN DAMAGE SOOTING OF THE HEATER CATHODIC PROTECTION HYDROGEN GAS CAN BE PRODUCED IN AHOT WATER SYSTEM SERVED BY THIS HEATER THAT HAS NOT BEEN USED FOR A LONG PERIOD OF TIME GENERALLY TWO WEEKS OR MORE HYDROGEN GAS 15 EXTREMELY FLAMMABLE To reduce the risk of injury under these conditions itis recommended that a hot water faucet be opened for several minutes before using any electrical appliance connected to the hot water system If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow There should be no smoking open flame near the faucet at the time it is open PRECAUTIONS IF THE UNIT IS EXPOSED TO THE FOLLOWING DO NOT OPERATE HEATER UNTIL ALL CORRECTIVE STEPS HAVE BEEN MADE BY A QUALIFIED SERVICEMAN 1 FLOODING TO OR ABOVE THE LEVEL OF THE BURNER OR CONTROLS 2 EXTERNALFIRING 3 DAMAGE 4 FIRING WITHOUT WATER 5 SOOTING NEVER OPERATE THE HEATER WITHOUT FIRST BEING CERTAIN IT ISFILLED WITH WATER AND A TEMPERATURE AND PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE OPENING OF THE HEATER SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL
49. cycle 5 When the pre purge cycle is complete power is applied to the ignitor element for the ignitor warm up period 6 At the conclusion of the igniter warm up period the gas valve will open allowing gas to enter the burner chamber 7 The igniter will remain on for a short predetermined time period then will be turned off 8 After an additional 2 seconds the control will monitor the flame sense probe to confirm a flame is present If a flame is not verified within this time period the gas valve willimmediately be closed and the blower will continue to run for approximately 10 seconds The control will then retum to step 2 9 If a flame is confirmed the control will enter the heating mode where it will continue heating the tank water until the setpoint temperature plus differential is reached At this point the gas valve is closed and the control enters the post purge cycle 10 The combustion blower will run for the duration of the post purge cycle to purge the system of all combustion gases When the post purge cycle is complete the blower is de energized and will coast to stop 11 The control will now enter the idle state while continuing to monitor the internal tank water temperature and the state of other system devices If the temperature drops below the setpoint value less differential the control will automatically return to step 2 and repeat the entire operating cycle During this idle state if the control det
50. d in the Checklist and Service Information which appears later in this manual ABOVE ALL DO NOT PLUG THE TEMPERATURE AND PRESSURE RELIEF VALVE THIS IS NOT A SOLUTION AND CAN CREATE A HAZARDOUS SITUATION CIRCULATING PUMP The water heating system may include a circulating pump Where used it should be lubricated as directed by the circulator manufacturer VENT SYSTEM Examine the vent system every 3 months Points of inspection are as follows 1 Check for obstructions and or deterioration of vent piping and vent hood Replace immediately where needed 2 Vent pipe and vent hood screen should be cleaned of foreign material and soot The screen is located inside the vent hood outlet and is accessible from the outside of the hood Do not reach inside the vent hood when the heater is in operation Check all vent system connections for leakage and reseal as required using Hi Temp Silicone sealer or equivalent INSTALLATION DIAGRAMS ONE TEMPERATURE ONE HEATER VERTICAL STORAGE TANK FORCED CIRCULATION WITH OR WITHOUT BUILDING RECIRCULATION VACUUM RELIEF VALVE INSTALL PER LOCAL CODES HOT WATER OUTLET RELIEF VALVE CAUTION IF BUILDING COLD THERMOMETER WATER SUPPLY HAS A BACK FLOW PREVENTER CHECK INSTALL THERMAL EXPANSION VALVE OR WATER METER WITH TANK IF CHECK VALVE OR CHECK VALVE PROVISIONS PRESSURE REDUCING VALVE FOR THERMAL EXPANSION OF IS USED IN SUPPLY WATER IN THE HO
51. d recommendation The best option when the noise is a concern is to locate the exhaust as far away from any occupied spaces as practical Ifnoise becomes more than one can tolerate a dampening mufflers available through our Product Service Division See REPLACEMENT PARTS segment below GAS FAILS TO SHUT OFF Check for defective gas valve or thermostat If operation is incorrect replace REPLACEMENT PARTS Replacement parts may be ordered through A O Smith dealers authorized servicers or distributors Refer to the Yellow Pages for where to call or contact the Smith Water Products Company 5621 W 115th Street Alsip IL 60482 1 800 433 2545 When ordering parts be sure to state the quantity part number and description of the items including the complete model and serial number as it appears on the product Refer to the parts list for more information Model 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 Smith water heater of equivalent size and current model at the warrantor s option Some government agencies are requiring ener
52. densate or vapor can cause nuisance or hazard 2 For direct vent the venting system shall terminate at least 1 foot below 1 foot horizontally from or 1 foot above any door window or gravity air inlet into building 3 For horizontal the venting system shall terminate 4 foot below 4 foot horizontally from 1 foot above any door window or gravity air inlet into building 4 The manufacturer also recommends the vent system terminations not be installed closer than 3 feet from an inside comer of an L shaped structure And not less than 1 foot above grade or anticipated snow level 5 The vent termination shall not be mounted directly above or within 3 feet horizontally from an oil tank vent or gas meter to avoid potential freeze up from condensation 6 The vent shall terminate a minimum of 1 level to prevent blockage of vent termination above expected snowfall Plan the vent system layout so that proper clearances are maintained from plumbing and wiring Vent pipes serving power vented appliances are classified by building codes as Vent connectors Required clearances from combustible materials must be provided in accordance with information in this manual under LOCATION OF HEATER and CLEARANCES and with National Fuel Gas Code and local Codes IMPORTANT Plan the layout of the vent system backwards from the vent termination to the appliance A WARNING USE ONLY THE VENT TERMINALS SUPPLIED WITH THIS UNIT TERMINATI
53. drop below 160 F before the controller can be reset Continued manual resetting of high limit control preceded by higher than usual water temperature is evidence of high limit switch operation The following are possible reasons for high limit switch operation A malfunction in the thermostatic controls would allow the gas valve to remain open causing water temperature to exceed the thermostat setting The water temperature would continue to rise until high limit switch operation Contact your dealer or servicer if continued high limit switch operation occurs DISHWASHING MACHINE REQUIREMENT All dishwashing machines meeting the National Sanitation Foundation requirements are designed to operate with water flow pressures between 15 and 25 pounds per square inch Flow pressures above 25 pounds per square inch or below 15 pounds per square inch will result in improperly sanitized dishes Where pressures are high a water pressure reducing or flow regulating control valve should be used in the 180 F line to the dishwashing machine and should be adjusted to deliver water between these limits The National Sanitation Foundation also recommends circulation of 180 F water Where this is done the circulation should be very gentle so that it does not cause any unnecessary turbulence inside the water heater The circulation should be just enough to provide 180 F water at the point of take off to the dishwashing machine Adjust flow by means
54. e MOTOR RUNS BURNER LIGHTS MOMENTARILY THEN LOCKS OUT Reset the appliance two more times to ensure that all of the air has been purged from the gas line if the burner lights momentarily but does not sustain ignition verify that 30 the inlet pressure is not greater than 14 0 W C or lower than the minimal gas supply pressure as shown in Table 4 that is for Natural Gas 5 0 W C for BTH 120 amp 250 or 4 5 W C for BTH 150 amp 199 or for L P Gas 11 0 W C pressure Also the manifold pressure should rise during the three 3 second trial for ignition to the manifold pressure value for the individual unit listed Table 4 that is for Natural Gas 4 0 W C for BTH 120 amp 250 or 3 5 W C for BTH 150 amp 199 or for L P Gas 10 0 W C If the manifold pressure is not correct then adjust accordingly See ADJUSTMENT PROCEDURE in OPERATING INSTRUCTIONS section page 18 for the manifold pressure adjustment procedure Check for the reversed polarity in the supply wiring This controller is polarity sensitive If the hot and neutral supply wires are reversed the controller will not sense flame Reverse the supply wires and try to fire the unit NOTE Always tum off and disconnect main supply wiring before servicing the unit 4 Check connecting wire to the flame sensor Verify that the flame sensor has not been damaged in any way Verify that the air supply is adequate The air inlet screen or blower wheel ma
55. eater electrical disconnect switch DRAINING The heater must be drained if it is to be shut down and exposed to freezing temperatures Maintenance and service procedures may also require draining the heater 1 Turn off the heater electrical disconnect switch Close the cold water inlet valve to heater Open a nearby hot water faucet to vent the system Open the heater drain valve Ifthe heater is being drained for an extended shutdown it is suggested the drain valve be left open during this period Follow FILLING instructions when restoring hot water service SEDIMENT REMOVAL Waterborne impurities consist of the particles of soil and sand which settle out and form a layer of sediment on the bottom of the tank For convenience sediment removal and lime scale removal should be performed at the same time LIME SCALE REMOVAL The amount of calcium carbonate lime released from water is in direct proportion to water temperature and usage The higher the water temperature or water usage the more lime deposits are dropped out of the water This is the lime scale which forms in pipes heaters and on cooking utensils Lime accumulation not only reduces the life of the equipment but also reduces efficiency of the heater and increases fuel consumption The usage of water softening equipment greatly reduces the hardness of the water However this equipment does not always remove alll of the hardness lime For this reason it i
56. ecified input rate is achieved f the manual gas valve to OFF Replace the pressure regulator cover screw Remove the pressure gauge or manometer from the manifold pressure tap Replace the set screw in the manifold pressure tap If the gas pressure regulator cannot be adjusted to give the full input rating with sufficient gas pressure at the valve check to ensure the unit is equipped with the correct orifice FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire 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 BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions If you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control knob Never use tools If the kn
57. ects an improper operating state for external devices such as the ECO switch vent switch pressure switch etc the appropriate LED s on the Display Board will be illuminated indicating the nature of the fault SELF DIAGNOSTIC CONTROLLER This controller is designed for ignition lockout after three consecutive failed attempts to light If lockout occurs the display lights will match Figure 18 Along with this a numeric message will appear in the display The following list of ERROR CODES illustrates possible numeric failures e k x lt Va RYT RYA PRESSURE GAS SWITCH SWITCH CONTROL ELECTRONICS IGNITER ELEMENT FIGURE 18 GAS VALVE LED FLASHING This condition results from a failure to establish burner ignition after three successive trials In such cases 1 Investigate the possible cause and remedy any observations 2 Momentarily depress the button on the display panel to reset the lockout condition 3 Confirm proper appliance operation Possible Cause Check wire and connection at bumer Check connections Replace igniter Replace flame probe on gas supply Replace gas valve Replace gas valve Replace control Adjust bumer Clean bumer 1 Bumer ground wire broken or corroded Connectors unplugged Igniter broken Flame probe faulty Gas shut off Clogged gas valve Faulty gas valve Defective control Burner improperly adjusted Dirty bumer
58. es P Ns 192968 000 193329 000 19331 1 000 ROUGH IN DIMENSIONS OPTIONAL WATER OUTLET 1 1 2 IN TOP OF UNIT CLEANOUT CYCLONE XHE BTH 120 250 GAS VALVE BTH 120 1 2 150 199 amp 250 WATER OUTLET 1 112 NPT 75 50 55 50 120 ONLY 27 75 O D HEIGHT TO WATER OUTLET AND GAS VALVE INLET IN BACK 64 50 44 50 120 ONLY WATER INLET 11 2 NPT EXHAUST VENT Table 1 RECOVERY CAPACITIES NATURAL GAS L P Model BTU Aporok TEMPERATURE RISE DEGREES F GALLONS PER HOUR Input Gallon Capacity 30 40 50 60 70 80 go 100 110 120 130 140 BTH 120 125 000 Nat 60 475 356 285 237 203 178 158 142 129 119 no 102 BTH 120 120 000 L P 60 456 342 274 228 195 171 152 137 124 105 98 BTH 150 150 000 Nat 100 570 427 342 285 244 214 190 171 155 142 132 122 BTH 150 150 000 L P 100 570 427 342 285 244 214 190 1 4 155 142 132 122 BTH 199 199 900 Nat 100 759 569 456 325 285 253 228 207 190 175 163 BTH 199 199 900 L P 100 759 569 456 325 285 253 228 207 190 175 163 BTH 250 240 000Nat 100 912 684 547 456 391 342 304 274 248 228 210 195
59. est Error ELEMENT Checks the RAM Random Acess Memory 205 RAM Test Fail NO LOW VOLTAGE 24V AC LED Off SW Check to see what the Last State it was in FIGURE 20 ie Fails if it can from the wrong place 125 State Error 426 State Error NOTE The transformer is of Class II variety and has an internal non 428 State Error replaceable fuse If blown a problem may exist with the control which is 427 State Error affecting the transformer In such cases the control should be replaced as 129 State Error well 131 State Error 132 State Error Possible Cause These State Numbers are not used 230 Executed State 3 Not Implimented h s 1 Transformer wiring problem 1 Repair Wiring 240 Executed State 4 Not Implimented h s 210 Executed State 10 Not Implimented h s 2 Defective Transformer 2 Replace Transformer 213 Executed State 13 Not Implimented h s 214 Executed State 14 Not Implimented h s 3 LED burned out 3 Ignore replace control 216 Executed State 16 Not Implimented h s FAULT CONDITIONS TEMPERATURE PROBE FAULT Figure 21 Water Temp LED Flashing The controller is set up to provide additional status indicators under Fault Conditons The following figures are possible Fault Conditions NO INCOMING LINE VOLTAGE Figure 19 Line LED Off oo 0 0 ECO PRESSURE GAS GAS SWITCH SWITCH VALVE VALVE RLY RLY2 24V AG CONTROL ELECTRONICS IGNITER ELEMENT
60. ft the lever at the end of the valve several times The valve should seat properly and operate freely If water does not flow remove and inspect for obstructions or corrosion Replace with a new valve of the recommended size as necessary Inspection of the valve should be performed at least every three years Do not attempt to repair the valve as this could result in improper operation and a tank explosion In areas with poor water conditions it may be necessary to inspect the T amp P valve more often than every three years 22 A CAUTION BEFORE MANUALLY OPERATING THE VALVE MAKE SURE THAT A DRAIN LINE HAS BEEN ATTACHED TO THE VALVE TO DIRECT THE DISCHARGE OPEN DRAIN FAILURE TO TAKE THIS PRECAUTION COULD MEAN CONTACT WITH EXTREMELY HOT WATER PASSING OUT THE VALVE DURING THIS CHECKING OPERATION 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 Thermal expansion is the normal response of water when it is heated In a closed system thermal expansion will cause the system pressure to build until the relief valve actuation pressure is equaled Then the relief valve will open allowing some water to escape slightly lowering the pressure Contact your water supplier or local plumbing inspector on how to control this situation Two common corrections are liste
61. fter piping connections are checked turn on main burner With main bumer in operation paint pipe joints including flanges pilot gas tubing connections and control inlet and outlet with rich soap and water solution Bubbles indicate gas leak To stop leak tighten flange screws joints and pipe connections Replace part if leak can t be stopped To prevent damage care must be taken not to apply too much torque when attaching gas supply pipe to gas valve inlet Apply joint compounds pipe dope sparingly and only to the male threads of pipe joints Do not apply compound to the first two threads Use compounds resistant to the action of liquefied petroleum gases DISCONNECT THE APPLIANCE AND ITS MANUAL GAS SHUTOFF VALVE FROMTHE GAS SUPPLY PIPING SYSTEM DURING ANY SUPPLY PRESSURE TESTING EXCEEDING 1 2 PSIG GAS SUPPLY LINE MUST BE CAPPED WHEN DISCONNECTED FROM THE HEATER FOR TEST PRESSURES OF 1 2PSIG OR LESS THE APPLIANCE NEED NOT BE DISCONNECTED BUT MUST BE ISOLATED FROM THE SUPPLY PRESSURE TEST BY CLOSING THE MANUAL GAS SHUTOFF VALVE BEFORE PLACING THE HEATER IN OPERATION CHECK FOR GAS LEAKAGE USE SOAP AND WATER SOLUTION OR OTHER MATERIAL ACCEPTABLE FOR THE PURPOSE OF LOCATING GAS LEAKS DO NOT USE MATCHES CANDLES FLAME OR OTHER SOURCES OF IGNITIONFOR THIS PURPOSE PURGING Gas line purging is required with new piping or systems in which air has entered A CAUTION PURGING SHOULD BE PERFORMED BY PERSONS EXPERIENCED IN THIS
62. gy efficient standards for water heaters In the event regulations prohibit sale of a model of equivalent size and construction Smith will provide a model which complies with the regulations of your area in which case the consumer will be charged the difference in price between the like replacement and the energy efficient model required The warranty on the replacement water heater will be limited to the unexpired term of the original warranty 2 ALLOTHER PARTS If within ONE year after initial installation of this water heater any part or portion shall prove upon examination by the warrantor to be defective in material or workmanship the warrantor will repair or replace such part or portion at its option 3 CONDITIONS AND EXCEPTIONS This warranty shall apply only when the water heater is installed in accordance with local plumbing and building codes ordinances and regulations the printed instructions provided with it and good industry practices In addition a temperature and pressure relief valve certified by A G A and approved by the American Society of Mechanical Engineers must have been installed This warranty shall apply only when the heater is used 1 at temperatures not exceeding the maximum setting of its thermostat 2 at water pressure not exceeding the working pressure shown on the heater 3 when operated free of the damaging effects of uncontrolled water hammer 4 when filled with potable water free to circ
63. haust vent pipe occurs This switch is a positive pressure switch that requires an increase in pressure to change the electrical contacts from normally closed to open When this switch prevents the unit from igniting most likely the exhaust is blocked by some means Check to see if the condensate is allowed to flow freely from the exhaust elbow and for obstructions in the exhaust venting and exhaust vent terminal Also verify that there is no more than fifty equivalent feet of three inch PVC vent pipe on the exhaust BLOCKED INLET PROVER SWITCH SEE FIGURE 13 The Blocked Inlet Prover Switch is set up to shut the unit off when a build up of negative pressure in the intake vent pipe occurs This switch is a negative pressure switch that requires an increase in negative pressure to change the electrical contacts from normally closed to open The switch is connected to the pressure tap on the PVC flange connected to the inlet of the blower When this switch prevents the unit from igniting most likely the intake is blocked by some means Check to see if there is no more than fifty equivalent feet of three inch PVC vent pipe on the intake Also verify that the intake and intake vent terminal is free of obstructions that may prevent air from entering the unit LOW GAS PRESSURE SWITCH SEE FIGURE 13 The Low Gas Switch LGS is a single pole normally open pressure switch that will close its contacts when a rising pressure of 5 0 in W C is encounte
64. ire Protection Association 1 Park Quincy 02269 TABLE OF CONTENTS ROUGH IN DIMENSIONS FOREWORD FEATURES Water Temperature Control High Limit Switch Dishwashing Machine Requirement Circulating Pump INSTALLATION INSTRUCTIONS Required Ability Insulation Blankets Locating The Heater Clearances Hard Water Air Requirements Mechanical Exhausting of Room Air Unconfined Space Confined Space Chemical Vapor Corrosion VENTING Vent Pipe Termination Direct Venting Direct Vent Terminal installation Sidewall Installation Sequence Vertical Vent Terminal Installation Installation Sequence Installation of Vent System 10 11 Vent Pipe Preparation CONTROLS AND SWITCHES 11 42 Blower Prover Switch Blocked Outlet Switch 12 Blocked Inlet Prover Switch 2 Low Gas Pressure Switch 12 On Off Switch 12 Hot Surface Igniter 12 GAS PIPING 12 Connection of Gas Pipe 13 Purging 13 Gas Meter Size City Gases Only 13 Pressure Regulation 13 Gas Valves 13 SYSTEM CONNECTIONS 13 Thermometers 5 13 Relief Valve 13 PAGE Water Line Connections 14 Heater Wiring 14 OPERATION 15 Sequence of Operation 15 Self Diagnostic Controller 15 Gas Value LEDs Flashing 15 Error Codes 16 Fault Conditions 16 Incoming Line Voltage 16 Low Voltage 6 Temperature Probe Fault 16 E C O Switch Open 17 Control Bad 17 Combustion
65. ive 5 equivalent feet of pipe One 1 90 elbow is equal to two 2 45 elbows Any venting configuration using less than 50 equivalent feet should use 3 inch venting See Table 2 The 3 inch venting terminals provided must be used with the 4 inch venting by adding 4x3 reducing couplings at the venting terminals A reducing coupling is also needed immediately after the condensate elbow exhaust and immediately before the 3 inch blower adapter intake if direct venting is installed See Table 2 IMPORTANT When multiple units are direct vented through wall 3 inch or 4 inch venting all intake vent terminals should be no lower than the highest exhaust vent terminal NOTE This unit can be vented using only PVC Class 160 ASTM D 2241 Schedule 40 ASTM D 1785 or Cellular Core Schedule 40 DWV ASTM F 891 Schedule 40 CPVC ASTM F 411 or ABS ASTM D 2661 pipe The fittings other than the TERMINATIONS should be equivalent to PVC DWV fittings meeting ASTM D 2665 Use CPVC fittings ASTM F 438 for CPVC pipe and ABS fittings ASTM 0 2661 3311 for ABS pipe If CPVC or ABS pipe and fittings are used then the proper cement must be used for all joints including joining the pipe to the Termination PVC Material PVC Materials should use ASTM D 2564 Grade Cement CPVC Materials should use ASTM F 493 Grade Cement and ABS Materials should use ASTM D 2235 Grade Cement NOTE for Water Heaters in locations with high ambient temperatures
66. luding the warranty of merchantability imposed on the sale of this heater under state law are limited to one 1 year duration forthe heater or any of its parts Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you 6 CLAIM PROCEDURE Any claim under the warranty should be initiated with the dealer who sold the boiler or with any other dealer handling the warrantor s products If this is not practicable the owner should contact U S Customers Canadian Customers Smith Corporation Smith Enterprises Ltd 5621 W 115th Street Box 310 768 Erie Street Alsip IL 60803 Stratford Ontario NSA 6T3 Telephone 1 800 323 2636 Telephone 519 271 5800 The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by the warrantor b Dealer replacements are made subject to in warranty validation by warrantor 7 DISCLAIMERS NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE HEATER OR THE INSTALLATION OPERATION REPAIR OR REPLACEMENT OF THE BOILER THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE LOSS OF USE OF THE UNIT INCONVENIENCE LOSS OR DAMAGE TO PERSONAL PROPERTY OR OTHER CONSEQUENTIAL DAMAGE THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE ANY PERSONS OR PROPERTY WHETHER DIRECT
67. ob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS 9 2 Set the thermostat to lowest setting above on this label 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand STOP Read the safety information 5 Remove top cover 6 Push in control knob slightly and turn clockwise to OFF 7 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety above on this label If you don t smell gas go on to next step Turn on all electric power to the appliance Turn gas control knob counterclockwise to ON Replace top cover Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to
68. on agency should be consulted to determine which system is acceptable in your area See CLOSED SYSTEM section in this manual also TROUBLE SHOOTING Awwarninc 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 VOLT OHM METER AND A MICROAMMETER DO NOT ATTEMPT TO TROUBLESHOOT OR REPAIR SMITHEQUIPMENT ALTERING THE CONTROLLER AND OR CONTROLLER WIRING IN ANY WAY COULD RESULT IN INTERNAL DAMAGE TO THE MODULE CIRCUITS POSSIBLY ALTERING THE IGNITION SEQUENCE ALLOWING GAS VALVES TO OPEN BEFORE THE HOT SURFACE IGNITER IS UP TO IGNITION TEMPERATURE NOTE ANY BYPASS OR ALTERATION OF THE UNITS SAFETIES WILL RESULT IN VOIDING THE APPLIANCE WARRANTY Before performing any troubleshooting familiarize yourself with the particular appliance Refer to the SEQUENCE OF OPERATION and the connection diagram located on page 15 before continuing Make sure the appliance is connected to 120V AC power supply manual gas valve is in the ON position and all electrical connections are secure before continuing to troubleshoot this appliance A CAUTION THE WATER HEATER IS POLARITY SENSITIVE BEFORE APPLYING ELECTRICITY TO THIS HEATER BE CERTAIN THAT SUPPLY HEATED WIRE TO GROUND CHECK INDICATES ZERO VOLTAGE 29 1 2 MOTOR WILL NOT RUN Confirm 120V AC to the controller Also to verify c
69. on locations with elevations above 2000 feet refer to HIGH ALTITUDE INSTALLATIONS section of this manual a Attach a pressure gauge manometer to the manifold pressure tap Figure 16 and refer to Table 4 page 20 for correct pressure Use this formula to clock the meter Be sure other gas consuming appliances are not operating during this interval 3600 T X H Btuh Should it be necessary to adjust the gas pressure to the burner to obtain the full input rate the steps below should be followed T Time in seconds to burn 1 cubic foot of gas With a stopwatch read the gas meter and measure the amount of time required for the heater to consume 1 cubic foot of gas H Heating value of gas in Btu s per cubic foot of gas Btuh Actual heater input rate in Btuh EXAMPLE Using BTH 199 900 heater T 18 9 seconds H 1050 Btuft3 BTUH 3600 18 9 1050 199 900 Btuh For high altitude installations compare result to the derated input required for the elevation at the installation location c Remove the pressure regulator cover screw Figure 16 and adjust the pressure by turning the adjusting screw with a small screwdriver Do not exceed 4 0 on BTH 120 and 250 3 5 on BTH 150 and 199 Water Column A Clockwise to increase gas pressure and input rate Y NCounterclockwise to decrease gas pressure and input rate d Clock the meter as in step b above e Repeat steps c and d until the sp
70. orrect polarity check for 120 V AC between hot supply and ground If there is no voltage check for a loose connection where it connects to the controller If there is 120 volts to the controller check for loose connections or a locked rotor If the rotor cannot be freed the motor and blower assembly must be replaced MOTOR RUNS PREPURGE TIME ELAPSES BUT MAIN FLAME NOT ESTABLISHED Check to see if main manual gas valve is open Check for a loose connection at the transformer or a defective transformer Check for a loose connection at the gas valve Check for open pressure switches or open reset button Check for blockage in the intake and exhaust venting or at the vent hoods If no blockage is found check vinyl tubing for cuts or crimps If this tubing is damaged it must be replaced If these steps do not eliminate the problem replace the pressure switches Check to see if there is resistance across the igniter terminal with an OHM meter If there is no continuity the igniter is broken and should be replaced If the igniter appears to function properly then verify that the inlet pressure is 14 0 W C maximum The gas valve supplied on this appliance is not designed to open against a higher pressure At this time also check that the inlet pressure is not lower than the minimal gas supply pressure as shown in Table 4 that is for Natural Gas 5 0 W C for BTH 120 amp 250 or 4 5 W C for BTH 150 amp 199 or for L P
71. red The contacts will open when the pressure falls below the fixed set point of 5 0 in W C The LGS monitors the gas supply pressure to the heater If the gas supply falls below 5 0 in W C the main burner is extinguished if heater is running or the heater will not start up ON OFF SWITCH The ON OFF Switch is a single pole single throw rocker switch This switch provides 120V from the line source to the heater THE WATER HEATER IS POLARITY SENSITIVE BEFORE APPLYING ELECTRICITY TO THIS HEATER BE CERTAIN THAT SUPPLY NEUTRAL WIRE GROUND CHECK INDICATES ZERO VOLTAGE HOT SURFACE IGNITER The Hot Surface Igniter is a device that ignites the main bumer by high temperature gt 1800 F When 120VAC is applied to the igniter sufficient heat is generated to ignite the main bumer Although improvements have been made to strengthen the igniter itis still fragile and care must be taken when handling the igniter to prevent breakage GAS PIPING Contact your local gas service company to ensure that adequate gas service is available and to review applicable installation codes for your area Size the main gas line in accordance with Table 3 The figures shown are for straight lengths of pipe at 0 5 in W C pressure drop which is considered normal for low pressure systems Note that fittings such as elbows and tees will add to the pipe pressure drop DO NOT USE FLEXIBLE GAS PIPING 12 TABLE 3 MAX
72. roximate time to burn relationship for normal adult skin Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the thermostat setting by up to 20 F you experience this type of use you should consider using lower temperature settings to reduce scald hazards DISPLAY BOARD TEMPERATURE ADJUSTMENT BUTTON RESET BUTTON Time to Produce 2nd amp 3rd Degree Bums Adult Skin Nearly instantaneous Nearly instantaneous About 1 2 second About 1 1 2 seconds Less than 5 seconds About 30 seconds More than 5 minutes Temperature Setting 180 F 170 F 160 F 150 F 140 F 130 F 120 F FIGURE 1 Valves for reducing point of use temperature by mixing cold and hot water are available see Figure 2 Also available are inexpensive devices that attach to faucets to limit hot water temperatures Contact a licensed plumber or the local plumbing authority HOT WATER TEMPERED WATER OUTLET T MIXING VALVE TO TANK INLET FIGURE 2 HIGH LIMIT SWITCH The top immersion well of the dual bulb controller also contains the high limit energy cutoff sensor The high limit switch interrupts the main burner gas flow should the water temperature reach approximately 202 F Should the high limit switch activate it must be manually reset by depressing the Temperature Adjustment Button Reset Button the display board The water temperature must
73. s recommended that a regular schedule for deliming be maintained The depth of lime buildup should be measured periodically Heaters will have about 3 of lime buildup when the level of lime has reached the bottom of the cleanout opening or about 1 of lime buildup if it has reached the drain valve opening A schedule for deliming should be set up based on the amount of time it would take for a 1 buildup of lime Example 1 Initial inspection shows 1 2 of lime accumulation Therefore the heater can be delimed once a year Example 2 Initial inspection shows 2 of lime accumulation Therefore the heater should be delimed every months Sediment and lime scale removal may be accomplished through the cleanout opening furnished on the heater see Figure 25 The heater must be drained see DRAINING before removing cleanout cover on tank 21 CLEANOUT ACCESS PANEL See TANK CLEANOUT OPENING CLEANOUT GASKET CLEANOUT COVER FIGURE 25 To dissolve and remove the more stubborn mineral deposits Smith UN LIME Professional Delimer should be used Smith UN LIME Professional Delimer is an easy to handle patented food grade acid formulated specifically for lime scale removal from all types of water using equipment Available in 1 gallon part no 4763 and 5 gallon part no 4813 sizes Hydrochloric base acids are not recommended for use glass lined tanks Smith Form No 4800 entitled
74. uctions Failure to follow these instructions can result in fire asphyxiation serious personal injury or death Do not apply insulation to the top or the upper 15 of the water heater as this will interfere with safe operation Do not cover the temperature amp pressure relief valve Do not cover the instruction manual Keep it on the side of the water heater or nearby for future reference Do obtain new labels from Smith for placement on the blanket directly over the existing labels LOCATING THE HEATER A WARNING THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH AS GAS WATER HEATERS IN ROOMS GARAGES OR OTHER AREAS WHERE GASOLINE OTHER FLAMMABLE LIQUIDS OR ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED OPERATED OR REPAIRED FLAMMABLE VAPORS ARE HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE IGNITED BY THE HEATER S IGNITER OR MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION SOME LOCAL CODES PERMIT OPERATION OF GAS APPLIANCES IF INSTALLED 18 INCHES OR MORE ABOVE THE FLOOR THIS MAY REDUCE THE RISK IF LOCATION IN SUCH AN AREA CANNOT BE AVOIDED THE HEATER SHALL BE LOCATED OR PROTECTED SOIT IS NOT SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE DO NOT LOCATE THE HEATER WHERE NOISE FROM THE EXHAUST OR INTAKE WILL BE OBJECTIONABLE THIS INCLUDES LOCATIONS CLOSE TO OR ACROSS FROM WINDOWS AND DOORS AVOID ANCHORING THE VENT AND INTAKE PIPES DIRECTLY TO FRAMED WALLS FLOORS OF CEILINGS UNLESS RUBBER ISOLATION PIPE HANG
75. ulate at all times 5 a non corrosive and non contaminated atmosphere 6 with factory approved anode s installed 7 in the United States its territories or possessions and Canada b Any accident to the boiler any misuse abuse including freezing or alteration of it any operation of it in a modified form or any attempt to repair tank leaks will void this warranty This warranty is void if a device acting as backflow prevention device check valves etc is installed the cold water supply the heater is connected to unless an effective method of controlling thermal expansion is also installed at the heater s and operational at all times The relieve valve installed on the heater is not an acceptable method 4 SERVICE AND REPAIR EXPENSES Under the limited warranty the warrantor will provide only a replacement water heater or part thereof The owner is responsible for all other costs Such costs may include but are not limited to a Labor charges for service removal repair or reinstallation of the water heater or any component part b Shipping delivery handling and administrative charges for forwarding the new heater or replacement part from the nearest distributor and returning the claimed defective heater or part to such distributor c cost necessary or incidental for any material and or permits required for installation of the replacement 5 _ LIMITATIONS ON IMPLIED WARRANTIES Implied warranties inc
76. utside of the marked circle This pilot hole is used as a starting point for a saws all 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 Suspend the pipe through the center of the hole using proper support Slide root boot or equivalent flashing over pipe and secure roof boot equivalent flashing to roof Seal around flashing Terminate intake terminal and exhaust vent terminal facing down as shown in Figure 12 10 BTH 120 ONLY EXHAUST VENT TERMINAL INTAKE VENT TERMINAL FLASHING rapa 12 ABOVE AVERAGE SNOWFALL 12 ABOVE AVERAGE SNOWFALL NOTE Intake Vent Terminal wall or Vertical Vent installations are required for Direct Vent units BTH 150 and 199 EXHAUST VENT TERMINAL INTAKE VENT TERMINAL FLASHING FLASHING 12 ABOVE AVERAGE SNOWFALL 12 ABOVE AVERAGE SNOWFALL NOTE Intake Vent Terminal wall or Vertical Vent installations are required for Direct Vent units BTH 250 ONLY EXHAUST VENT TERMINAL INTAKE VENT TERMINAL FLASHING FLASHING 12 ABOVE AVERAGE SNOWFALL 12 ABOVE AVERAGE SNOWFALL NOTE Intake Vent Terminal wall or Vertical Vent installations are required for Direct Vent units FIGURE 12 INSTALLATION OF VENT SYSTEM A WARNING THE OPTIONAL INTAKE VENTING ARRANGEMEN
77. y be restricted Also check the installation for proper ventilation See AIR REQUIREMENTS Check the venting system for the correct sizing excess or insufficient See VENTING Check for a maximum inlet pressure of 14 0 W C and the manifold pressure as listed Table 4 that is for Natural Gas 4 0 W C for BTH 120 amp 250 or 3 5 W C for BTH 150 amp 199 or for L P Gas 10 0 W C Please note that the manifold pressure listed is the maximum value for the manifold pressure Do not set the manifold pressure higher than the value shown for your heater in Table 4 Overfiring the heater will result in rough ignition and or noisy operation Confirm that the air inlet screen see Figures 7 amp 8 is free of obstructions A CAUTION Do not reach into the burner housing or combustion chamber if the heater is still hot Allow the heater to cool and always use gloves as the combustion chamber and the bumer sleeve and housing can become very hot after operation Overfiring is a dangerous condition that must be corrected immediately NOISY BURNER OPERATION The exhaust of this unit produces some noise This noise may be objectionable if the exhaust terminal is located too close to the opening of an occupied space The noise may also be objectionable if the exhaust is located in the confined space between two buildings such as an alley or walkway Since everyone s perception and tolerance for background noise varies there is no standar
78. y other pipe fitting technique Closely supervise the installation and inspect the finished job before start up Contact the manufacturer supplier or competent consulting agency if you have any questions about the application or installation of PVC PVC cellular core ABS or CPVC pipe Take the time and effort to do a professional job Shortcuts will only cause you problems and delays in start up The majority of failures in these systems are the result of shortcuts and or improper joining techniques 2 SELECTION OF MATERIALS PRIMER 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 cellular core ABS or CPVC surfaces A chemical cleaner such as MEK may be used CEMENT The cement should be a bodied cement of approximately 500 to 1600 centipoise viscosity containing 10 20 by weight virgin PVC material solvated with tetrahydrofuran THF Small quantities of dimethyl formamide DMF may be included to act as a retarding agent to extend curing time Select the proper cement Schedule 40 cement should be used for Schedule 40 pipe Never use all purpose cements commercial glues and adhesives or ABS cement to join PVC or CPVC pipe and fittings SAFETY PRECAUTION PRIMERS CEMENTSARE EXTREMELY FLAMMABLE AND MUST STORED USED NEAR HEAT OR OPEN FLAME ALSO USE ONLY INA WELL

A.O. Smith BTH 120 - 250 Owner's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents