American Water Heater 100 Series Instruction manual

Instruction Manual
COMMERCIAL GAS WATER HEATERS
MODELS
BTH-120/150/199/250
SERIES 100 & 101
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www.hotwater.com
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.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED 1012
197727-003
TABLE OF CONTENTS
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6
WATER HEATER INSTALLATION 38
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Supply Gas Line Installation 39
V:QC:+#'!@K@#:#+ 7
Gas Line Leak Testing 40
[@ 7
Purging 40
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TEMPERATURE REGULATION 43
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Insulation Blankets 13
Q+<!+*K
47
INSTALLATION REQUIREMENTS 14
START UP 52
_+
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Prior to Start up 52
Supply Gas Regulator 14
Initial Start Up 52
+
14
!VC 55
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'K 15
LIGHTING THE WATER HEATER 56
!+* 15
Lighting & Operation Labels 56
*:x 15
TROUBLESHOOTING 58
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General 64
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DIAGRAMS 67
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2
SAFE INSTALLATION, USE AND SERVICE
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This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
CAUTION
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GENERAL SAFETY INFORMATION
PRECAUTIONS
HYDROGEN GAS FLAMMABLE
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Explosion Hazard
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Flammable hydrogen gases
may be present.
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Keep all ignition sources away
from faucet when turning on
hot water.
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GROUNDING INSTRUCTIONS
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* * Verify the power to the water heater is turned off before performing any service procedures.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Explosion Hazard
Overheated water can cause
water tank explosion.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
This manual must remain with the
water heater.
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
CAUTION
Improper installation, use and service may result
in property damage.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
4
Do not operate water heater if flood damaged.
Inspect anode rods regularly, replace if damaged.
Install in location with drainage.
Fill tank with water before operation.
Properly sized thermal expansion tanks are required on all
closed water systems.
Refer to this manual for installation and service.
GENERAL SAFETY INFORMATION
Fire or Explosion Hazard
Fire Hazard
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
For continued protection against
risk of fire:
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas
pressure.
Do not install water heater on
carpeted floor.
Do not operate water heater if
flood damaged.
Use only the gas shown on the water heater rating label.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended
periods of non-use.
Fire and Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Use joint compound or Teflon tape
compatible with propane gas.
Leak test before placing the
water heater in operation.
Disconnect gas piping and main
gas shutoff valve before leak
testing.
Install sediment trap in
accordance with NFPA 54.
Breathing Hazard - Carbon Monoxide Gas
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Fire and Explosion Hazard
Install water heater in accordance with
the instruction manual.
Do not use water heater with any gas
other than the gas shown on the rating
label.
Excessive gas pressure to gas valve can
cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
CAUTION
Property Damage Hazard
All water heaters eventually leak.
Do not install without adequate drainage.
Jumping out control circuits or components can
result in property damage, personal injury or death.
Electrical Shock Hazard
Turn off power to the water heater
before performing any service.
Label all wires prior to disconnecting
when performing service. Wiring errors
can cause improper and dangerous
operation.
Verify proper operation after servicing.
Service should only be performed by a qualified service
agent using proper test equipment.
Altering the water heater controls and/or wiring in any way
could result in permanent damage to the controls or water
heater and is not covered under the limited warranty.
Altering the water heater controls and/or wiring in any way
could result in altering the ignition sequence allowing gas to
flow to the main burner before the hot surface igniter is at
ignition temperature causing delayed ignition which can
cause a fire or explosion.
Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the appliance warranty.
Failure to follow these instructions can
result in personal injury or death.
5
INTRODUCTION
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6
FEATURES AND COMPONENTS
BLOWER/BURNER ASSEMBLY DETAIL
BASIC OPERATION
INTAKE AIR
(combustion air)
CONNECTION
3 INCH PVC
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BLOWER
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ASSEMBLY
COMBUSTION
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MAIN
BURNER
(radial design)
INTAKE AIR
(combustion air)
CONNECTION
3 INCH PVC
HOT SURFACE
IGNITER
120,000 & 150,000 Btu/hr MODELS
MAIN
BURNER
(radial design)
COMBUSTION
BLOWER ASSEMBLY
INTAKE AIR
(combustion air)
CONNECTION
3 INCH PVC
HEAT
EXCHANGER
BLOWER
FLANGE
HELICAL
COIL
HOT SURFACE
IGNITER
MAIN
BURNER
(radial design)
FLAME
SENSOR
199,000 & 250,000 Btu/hr MODELS
Figure 2
VENT (exhaust)
OUTLET
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TOP VIEWS
120,000 & 150,000
Btu/hr MODELS
TOP VIEW
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7
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9
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2
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11
4
12
13
3
2
14
FRONT
15
16
1
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Figure 3
BTH 120 & 150 COMPONENTS
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TOP VIEWS (CONT)
199,000 & 250,000
Btu/hr MODELS
TOP VIEW
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4
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FRONT
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Figure 4
BTH 199 & 250 COMPONENTS
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LEFT SIDE
120,000 & 150,000 Btu/hr MODELS
RIGHT SIDE
199,000 & 250,000 Btu/hr MODELS
Figure 5
SIDE VIEWS
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10
INSTALLATION CONSIDERATIONS
ROUGH IN DIMENSIONS
SUPPLY GAS
CONNECTION
INTAKE AIR CONNECTION
3 INCH PVC
WATER OUTLET
HEIGHT
FRONT
I
BACK
T & P VALVE
E
F
B
H
D
CLEANOUT
VENT CONNECTION
3 INCH PVC
(exhaust elbow)
3/4” NPT DRAIN
1 1/2” NPT
WATER INLET
CONDENSATE
DRAIN CONNECTION
1/2 INCH PVC
C
A
G
These designs comply with the current edition of the American National Standard for Gas Water Heaters, Volume III, ANSI Z21.10.3 / CSA 4.3
as an automatic circulating tank water heater, and automatic storage water heaters.
TOP VIEWS
22°
199,000 & 250,000
Btu/hr
MODELS
V
3 I ENT
N
PV CH
C
V
3 I ENT
N
PV CH
C
64°
GA
S
68°
35°
35°
120,000 & 150,000
Btu/hr
MODELS
SUPPLY GAS
CONNECTION
VERTICAL
INTAKE AIR
3 INCH PVC
N
O
UT
E
LV
E
LV
FRONT
CL
EA
N
O
U
T
VA
A
VE
VAL
C
LE
P
V
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VAL
AIN
DR
P
A
&
&
A IN
DR
FRONT
T
*1 1/2” NPT
WATER
OUTLET
T
*1 1/2” NPT
WATER
OUTLET
INTAKE AIR
3 INCH PVC
18°
18°
45°
45°
45°
45°
* Center line of water outlet on top of the water heaters is approximately 7 inches from the front edge of the water heater.
DIMENSIONS
MODEL
SHIP
SHIP
WEIGHT
WEIGHT
A
B
!
D
E
V
G
H
I
STD
ASME
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BTH 120
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BTH 150
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BTH 199
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BTH 250
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Figure 6
11
GAS LINE CONNECTION SIZE
STORAGE CAPACITIES
TABLE 1
† MODEL
BTH 120
BTH 150
BTH 199
BTH 250
TABLE 2
SERIES
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NATURAL GAS
$~/›#
$~/›#
$~/›#
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PROPANE GAS
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MODEL
BTH 120
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60
LITERS
227
BTH 150
BTH 199
BTH 250
100
100
100
379
379
379
GAS PRESSURE REQUIREMENTS
TABLE 3
MODEL
BTH 120
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NATURAL GAS
PROPANE GAS
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NATURAL GAS
PROPANE GAS
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NATURAL GAS
PROPANE GAS
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BTH 150
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BTH 199
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BTH 250
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RECOVERY CAPACITIES
TABLE 4
K
BTH 120
BTH 150
BTH 199
BTH 250
Type of
Gas
Natural
Propane
Natural
Propane
Natural
Propane
Natural
Propane
Input
[
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35
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GPH
LPH
GPH
LPH
GPH
LPH
GPH
LPH
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461
1744
576
2179
767
2904
960
3632
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345
1308
432
1635
575
2178
720
2724
U. S. GALLONS/HR & LITTERS/HR AT TEMPERATURE RISE INDICATED
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276
230
197
173
154
138
126
115
1046
872
747
654
581
523
476
436
345
288
247
216
192
173
157
144
1308
1090
934
817
726
654
594
545
460
384
329
288
256
230
209
192
1743
1452
1245
1089
968
871
792
726
576
480
411
360
320
288
262
240
2179
1816
1557
1362
1211
1090
991
908
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106
402
133
503
177
670
221
838
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99
374
123
467
164
622
206
778
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LOCATING THE WATER HEATER
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All water heaters eventually leak.
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12
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas
pressure.
Use only the gas shown on the water heater rating label.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended
periods of non-use.
Read instruction manual before
installing, using or servicing
water heater.
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/ =
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= **
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) * = * =" " (*)]%
)*
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= *
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 '=*
^ *=
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x * Z
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4” x 3” REDUCER
FIELD SUPPLIED
3” PIPE FIELD
SUPPLIED
NOTE:+
*x=*
*
***"
*
x=
***
EXHAUST ELBOW
VENT CONNECTION
FACTORY INSTALLED
VENT (EXHAUST) CONNECTION
&=?x
B*
**
*&~/?
B
Figure 18
25
&&) $ = = x
&/)$
&]) / = $ x
V
&
]$Œx
/Œx$Œ
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&)/$
V
]$Œ
/Œ x $Œ &
?/*B
&$:
)+)!
*=
+V
&^
4” PIPE FIELD
SUPPLIED
3” PIPE FIELD
SUPPLIED
3” PIPE FACTORY
INSTALLED
INTAKE AIR
Breathing Hazard - Carbon Monoxide Gas
Do not obstruct water heater air intake.
4” x 3” REDUCER
FIELD SUPPLIED
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
INTAKE AIR CONNECTION
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Figure 20
NOTE: ' = ) ! ' ( @ *=
**=*
* *
* [ )
*
120,000 & 150,000
Btu/hr MODELS
COMBUSTION
BLOWER
3” COUPLING OR TEE
FACTORY INSTALLED
INTAKE AIR CONNECTION
INSTALL TEE FITTING AS CLOSE TO WATER HEATER
INTAKE AIR CONNECTION AS POSSIBLE
FACTORY
INTAKE AIR
CONNECTION
INTAKE
AIR
PIPING
FIELD SUPPLIED
3” x 3” x 1/2” TEE
WITH HOSE BARB
FITTING INSTALLED
199,000 & 250,000
Btu/hr MODELS
CONNECT FIELD
SUPPLIED FLEXIBLE
DRAIN HOSE TO BARB
FITTING AND FORM A
LOOP WATER TRAP IN
DRAIN HOSE
INTAKE AIR SCREEN
RUN DRAIN HOSE
TO SUITABLE FLOOR
DRAIN SEPARATELY
FROM OTHER
CONDENSATE DRAINS
3 INCH INTAKE AIR CONNECTIONS
FACTORY INSTALLED
INTAKE AIR SCREEN
(remove for Direct Vent)
INTAKE AIR CONDENSATE TEE INSTALLATION
Figure 19
Figure 21
26
=**
=**
*
]/Œ?&*B*
V
]])*
/?&]]*B
VERTICAL TERMINATION INSTALLATION
& '**?B
NOTE:=*
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=  x = Z
* V
]$V
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*
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NOTE:@=**
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]/]
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=  x = Z
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]$V
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*
*
NOTE: @  =
**
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*]/?*B=
" = & ?$ *B
+V
]/]
/ )=(
=
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‰
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]$V
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% !
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NOTE:[
 +
?B *Z
=
*
V
]$]
^ + Z
=  = Z
=   V
]$" V
]/ V
]]
&)
~=*?B
^”
V
]$ ] ^”
**
x=
x * ]
?*B"V
]$]
&&C
( ) ] '
( ) ] * ~=*?B
VENT TERMINATION
45° ELBOW WITH
RECESSED DEBRIS
SCREEN
INTAKE AIR TERMINATION
45° ELBOW WITH
DOME SHAPED DEBRIS
SCREEN
STANDARD FACTORY SUPPLIED TERMINATIONS
Figure 22
27
2” (5 cm)
MAXIMUM
24 INCHES (61 cm) MINIMUM
48 INCHES (122 cm) IN COLDER CLIMATES
FACTORY SUPPLIED
STANDARD TERMINATION
POINTED DOWN TOWARDS
THE GROUND
FIELD
SUPPLIED
90° ELBOW
FIELD
SUPPLIED
90° ELBOW
NOTE: INTAKE AIR
TERMINATION
SHOWN HERE
FIELD SUPPLIED
PLUMBING
ROOF BOOT
OR FLASHING
INTAKE AIR
TERMINATION
VENT (EXHAUST)
TERMINATION
FACTORY SUPPLIED
STANDARD TERMINATIONS
POINTED DOWNWARD
MAINTAIN 12” (30 cm)
18” (45 cm) FOR CANADA
MINIMUM CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW LEVEL.
MAINTAIN 12” (30 cm)
18” (45 cm) FOR CANADA
MINIMUM CLEARANCE
ABOVE HIGHEST ANTICIPATED
SNOW LEVEL.
FIELD SUPPLIED
PLUMBING
ROOF BOOTS
OR FLASHINGS
VERTICAL TERMINATION - DIRECT VENT
STANDARD TERMINATIONS
FIELD
SUPPLIED
STRAP/SUPPORT
Figure 25
VERTICAL TERMINATION(S) INSTALLATION
INTAKE AIR AND/OR VENT (EXHAUST)
Figure 23
IF LESS THAN
10 FEET (3 m)
24 INCHES (60 cm)
MINIMUM HEIGHT ABOVE
NOTE: VENT
TERMINATION
SHOWN HERE
INTAKE AIR AND/OR VENT
TERMINATION(S) MUST BE A
MINIMUM OF 24 INCES (60 cm)
ABOVE ANY PARAPET, VERTICAL
WALL OR STRUCTURE WITHIN
10 FEET (3 m) HORIZONTALLY.
VERTICAL TERMINATION(S) FLAT ROOF CLEARANCE
INTAKE AIR AND/OR VENT (EXHAUST)
Figure 24
28
% !
/?&*B*$
?&$*B*/?B
SIDEWALL TERMINATION INSTALLATION
& '**?B
NOTE:=*
"V
]]]%
NOTE:[
] ) = ?x
B (
 x
Z
* *" V
/ $" * *
*
 !
?B $ ?^ *B
^?]/&*B
+V
]%
$ ) = ' (
 x
Z
**"
V
/^$%"=*
*
*
*
/ ) = * ' ( *
**
* ]/ ?& *B " *
= " =
*"V
]
NOTE:)*
/ ?&]] *B =*=
*
\ = * x
=***
!
)=*'
( = * *
* =
*
\V
]
VENT (EXHAUST)
TERMINATION
INTAKE AIR
TERMINATION
NOTE: ( * ¢ x
&/”V)*=
x
=
=x
=
x = * = :xx=
*x*
*?&]*B*=
* Ž = *"=*=
"(*)]%
^ !*~=*?B
=+
&+
*?B=?B
~ = * *
? B ?B
&& * " *?B
*=
:
*?B +
V
]%
METAL PLATES
INSTALL INSIDE
AND/OR OUTSIDE
FROM
WATER
HEATER
ELEVATION
INSTALL ON
INCREASE EXPOSED VENT
PIPING UP TO A MAXIMUM
OF 6 INCHES (15.2 cm) FROM
WALL TO HELP PREVENT VAPOR
FROM DISCOLORING THE WALL
SURFACE IN COLDER CLIMATES
FACTORY SUPPLIED
STANDARD TERMINATION
POINTED DOWN
TOWARDS THE GROUND
COUPLING
CENTERLINE
INTERIOR WALL
EXTERIOR WALL
SIDEWALL TERMINATION INSTALLATION
KEEP INTAKE AND VENT
TERMINATION SCREENS
CLEAR OF DEBRIS
INTAKE AIR AND/OR VENT (EXHAUST)
24 INCHES (61 cm) MINIMUM
Figure 27
48 INCHES (122 cm) IN COLDER CLIMATES
&]
?
B
?B
?B
SIDEWALL TERMINATION - DIRECT VENT
STANDARD TERMINATIONS
&$
Figure 26
 ~ = * *
**
"
= * x* \ ~
*
x*\~
>="=
* *
**
* ]/ ?& *B
)*
/?&]]*B+V
]
29
&/ * ?B =?B
&)
?B
[ * * *?B +V
]%
&C
()]'(
)]*
~ = *?B CONCENTRIC TERMINATION INSTALLATION
& ! * *
[>
&]\]**
/*
#
*‰^$]!
*
*=
*
*
] '**
NOTE:C*
*"
*
===
$ *=

x=Z
*
*"V
$
$& * *
*
/ *=
"*•=*
**
*&
?$*B*"=
V
]
NOTE:)Z
&?$*B"
= *" * *
+ ( *
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*

x Z
* *" V
/^ $%" *
*
*
 *
* =
Z
*
*
* * + $] $$**
% !
?&$ *B * / **
NOTE:[
 *
* =
* * * *
* *
*
+K
!*
*$$
^ '* * **Z
= * *
*=
*
CONCENTRIC TERMINATION(S)
MUST BE A MINIMUM OF 10 FEET
(3 m) AWAY FROM ANY PARAPET,
VERTICAL WALL OR
STRUCTURE.
+ V
]^ $& *x*
* **
*
/*
x *
DO NOT  * * *
*
*Ž=*
**
x*
Q +'C\] x / *
* *
? B !
**
*?=B
CONCENTRIC TERMINATION
FLAT ROOF CLEARANCE
& / ) ! * ) $&
Figure 28
30
/=\
*
/›x
$› $ ?&
B!*
4 INCH CONCENTRIC TERMINATION INSTALLATION
INTAKE AIR CONNECTION
3 INCH PVC
3” x 3” x 4”
Y FITTING
INTAKE AIR PIPE
VENT CONNECTION - 3 INCH PVC
VENT PIPE
^ C
'()]*
= *
VENT
VENT CAP
VENT PIPE IS 2 1/2 INCH SDR-26 PIPE
SUPPLIED LENGTH 37 INCHES (94 cm)
MAXIMUM ALLOWABLE LENGTH 73 INCHES (185 cm)
MINIMUM ALLOWABLE LENGTH 25 INCHES (64 cm)
COMBUSTION
AIR
INTAKE AIR PIPE IS 4 INCH SDR-26 PIPE
SUPPLIED LENGTH 24 INCHES (60 cm)
MAXIMUM ALLOWABLE LENGTH 60 INCHES (152 cm)
MINIMUM ALLOWABLE LENGTH 12 INCHES (30 cm)
MAINTAIN 12” (30 cm)
18” (45 cm) FOR CANADA
MINIMUM CLEARANCE
ABOVE HIGHEST ANTICIPATED
SNOW LEVEL. MAXIMUM OF
24” (60 cm) ABOVE ROOF.
ROOF FLASHING
(field supplied)
INTAKE AIR PIPE
Y FITTING ASSEMBLY
STRAP
(field supplied)
NOTE: SECURING STRAP
MUST BE FIELD INSTALLED
TO PREVENT MOVEMENT
OF TERMINATION KIT
VENT CAP
VENT PIPE ASSEMBLY
VENT
PIPE
4 INCH CONCENTRIC TERMINATION KIT
FOUR PIECE KIT - FIELD ASSEMBLY REQUIRED
Figure 29
INTAKE
AIR PIPE
4 INCH CONCENTRIC TERMINATION
VERTICAL INSTALLATION
*/*C
V
]^"V
$V
$&
‰
Figure 30
& !*J*
] +J**
* :
* *
*
$ +
J*
*Z
=
*
/ @ *=J
*
NOTE: SECURING STRAP MUST BE
FIELD INSTALLED TO PREVENT
MOVEMENT OF TERMINATION KIT
IN SIDEWALL.
VENT
PIPE
COMBUSTION
AIR
STRAP
(field supplied)
VENT
+
*
 !*==\
*
]
* * *
=
*~=~=
% )=~=*J
*":
**=*
*J
 $ = * *
31
1 INCH
MAXIMUM
INTAKE
AIR PIPE
4 INCH CONCENTRIC TERMINATION
SIDEWALL INSTALLATION
Figure 31
MULTIPLE CONCENTRIC TERMINATION CLEARANCES
Four Concentric Terminations
*
*=
Z
?B * *
:
*
* Z
& *
x**
V
$/
V
$
NOTE: *
* = =?x
B!
*
*
] V
*x*
*
**
* * x*V
$/
A
*
* V
$] *
*
CONCENTRIC
TERMINATION
CAPS END VIEW
A
+K
!**$$
Close Proximity & Standard Clearance
& *
**
?
B*x*
*]?*B"*
\V
$]"*
x*+V
$%$$
A = 0 - 2 INCHES (0 - 5 cm)
CLOSE PROXIMITY
FOUR CONCENTRIC TERMINATIONS
(THROUGH A ROOF OR SIDEWALL)
] *
* *
**
*]/?&*B"*[\
V
$]"x*?=B
A
CONCENTRIC
TERMINATION CAPS
END VIEW
A
V
$/
CONCENTRIC
TERMINATION
CAPS END VIEW
CLOSE PROXIMITY
STANDARD CLEARANCE
A = 0 - 2 INCHES (0 - 5 cm)
B = 24 INCHES (61 cm)
OR GREATER
A = 0 - 2 INCHES (0 - 5 cm)
CLOSE PROXIMITY
B = 24 INCHES (61 cm)
OR GREATER
FOUR CONCENTRIC TERMINATIONS
TWO CONCENTRIC TERMINATIONS
(THROUGH A ROOF OR SIDEWALL)
(THROUGH A ROOF OR SIDEWALL)
V
$
Figure 32
Groups Of Terminations
Three Concentric Terminations
& *
**
x**V
$$
] ) x* * **
*[V
$$
A
A
B
OR
CONCENTRIC
TERMINATION
CAPS END VIEW
B
& *
*
x*
V
$;
V
$*
* = * *
=
A
B
B
CONCENTRIC
TERMINATION
CAPS END VIEW
A
A
THIRD
TERMINATION
A = 0 - 2 INCHES (0 - 5 cm)
CLOSE PROXIMITY
A = 0 - 2 INCHES (0 - 5 cm)
CLOSE PROXIMITY
B = 24 INCHES (61 cm)
OR GREATER
B = 24 INCHES (61 cm)
OR GREATER BETWEEN
GROUPS OF FOUR
THREE CONCENTRIC TERMINATIONS
EIGHT CONCENTRIC TERMINATIONS
(THROUGH A ROOF OR SIDEWALL)
(THROUGH A ROOF OR SIDEWALL)
V
$
V
$$
32
MULTIPLE CONCENTRIC TERMINATION ARRANGEMENTS
* * *
* SIDEWALL
+ K
! * ! $] * *
NOTE: *
* ***
**
*
Two Concentric Terminations
**x*
V
$% * + V
$] $] * + V
$$ $]
*
ROOF
SIDEWALL
Figure 38
Eight Concentric Terminations
: * * " x*" V
$^ +
V
$$]*
; V
$ $]
**=**
=
ROOF
SIDEWALL
Figure 37
Four Concentric Terminations
V
**x*
V
$ + V
$/ V
$ $] * *
ROOF
Figure 39
33
VENTING ARRANGEMENTS
Power Vent Vertical
Figure 40
Power Vent Horizontal
Figure 41
Direct Vent Vertical
Figure 42
Direct Vent Horizontal
Figure 43
34
VENTING ARRANGEMENTS
Direct Vent Vertical Vent Horizontal Intake
Figure 44
Direct Vent Horizontal Vent Vertical Intake
Figure 45
Direct Vent Vertical Concentric
Figure 46
Direct Vent Horizontal Concentric
Figure 47
35
TERMINATION CLEARANCES SIDEWALL POWER VENT
POWER VENT
(using room air for combustion)
EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION
G
V
D
H
A
v E
L
v
B
FI XE D
CLOSED
V
OPERABLE
F
B
B
C
V
OPERABLE
V
B
FI XE D
CLOSED
M
K
J
A
X
V
X
V
B
V
B
V
X
VENT TERMINAL
AIR SUPPLY INLET
AREA WHERE TERMINAL IS NOT PERMITTED
Figure 48
CANADIAN INSTALLATIONS
A
!="
="" &]?$*B
B
!
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1
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&"[
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US INSTALLATIONS
2
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CANADIAN INSTALLATIONS
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36
2
TERMINATION CLEARANCES SIDEWALL DIRECT VENT
DIRECT VENT
(using outdoor air for combustion)
EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION
G
V
D
H
A
v E
L
v
B
FI XE D
CLOSED
V
OPERABLE
F
B
B
C
V
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V
B
FI XE D
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M
K
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A
X
V
X
V
B
V
B
V
VENT TERMINAL
X
AIR SUPPLY INLET
AREA WHERE TERMINAL IS NOT PERMITTED
Figure 49
CANADIAN INSTALLATIONS
1
A
!="
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?&*B
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~?$B"&]
?$*B
!
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2
CANADIAN INSTALLATIONS
1
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37
WATER HEATER INSTALLATION
&~](!
CONDENSATE DRAIN INSTALLATION
$ DO NOT*="*
) *
* INSTALLATION INSTRUCTIONS
& :
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V
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INSTALLATION NOTES
$ *=
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NOTE: ) * ** *
& * Ž =
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**=
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;>='*
" " / :
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&
[*
=
 :
" +Q]
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CONDENSATE DRAIN
LINE - FIELD INSTALLED
EXHAUST (VENT)
ELBOW
CLEANOUT PLUG SHOULD
FACE TOWARDS THE FRONT
OF THE WATER HEATER FOR
SERVICE ACCESS
FACTORY INSTALLED
CONDENSATE TRAP
DRAIN LINE TO
TERMINATE NO
MORE THAN 6
INCHES (15.2 cm)
ABOVE DRAIN
BUILDING
DRAIN
Figure 50
PVC PIPE NIPPLE
½” NPT
PVC BUSHING
1 ½” SLIP x ½” SLIP
PVC TEE FITTING
1 ½” SLIP x 1 ½” SLIP x ½” NPT
½” PVC 90° ELBOW
CONDENSATE DRAIN
CONNECTION. FIELD
INSTALLED DRAIN
LINE CONNECTS HERE
PVC BUSHING
1 ½” SLIP x 1 ¼” NPT
½” PVC PIPE NIPPLE
PVC PIPE PLUG
1 ¼” NPT
½” PVC 90°
STREET ELBOW
CLEANOUT PIPE
PLUG SHOULD
BE ORIENTED TO
THE FRONT OF THE
WATER HEATER FOR
SERVICE ACCESS
CONDENSATE TRAP DETAIL
Figure 51
38
SUPPLY GAS LINE INSTALLATION
!
*
Z
= = = [
*
Z
*
Z
* * ) *
"*=
*
Fire and Explosion Hazard
GAS LINE SIZING
'=Z
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^=
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"
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++
?!++B
SUPPLY GAS LINE SIZING U. S. UNITS
TABLE 8
Do not use water heater with any gas
other than the gas shown on the rating
label.
Excessive gas pressure to gas valve can
cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
K
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SUPPLY LINE
MAIN GAS
SHUTOFF VALVE
TEE FITTING
SEDIMENT TRAP
PIPE CAP
Figure 52
:
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39
LENGTH
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$~/Œ
&Œ
&&~/Œ
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10
175
360
680
1400
2100
3960
20
120
250
485
950
1460
2750
30
97
200
375
770
1180
2200
40
82
170
320
660
990
1900
50
73
151
285
580
900
1680
60
66
138
260
530
810
1520
70
61
125
240
490
750
1400
80
57
118
220
460
690
1300
90
53
110
205
430
650
1220
100
50
103
195
400
620
1150
125
44
93
175
360
550
1020
150
40
84
160
325
500
950
175
37
77
145
300
460
850
200
35
72
135
280
430
800
SUPPLY GAS LINE SIZING METRIC UNITS
TABLE 9
LENGTH
#@CK;)C@#):+):+?)#!>:+B
IN
INPUT IN kW
METERS
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$~/Œ
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&&~/Œ
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$
51
105
199
410
615
1160
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35
73
142
278
428
805
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28
59
110
225
346
644
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24
50
94
193
290
556
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21
44
83
170
264
492
&$
19
40
76
155
237
445
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18
37
70
143
220
410
]//
17
35
64
135
202
381
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16
32
60
126
190
357
$
15
30
57
117
182
337
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13
27
51
105
161
299
/%
12
25
47
95
146
278
$$
11
23
42
88
135
249
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10
21
40
82
126
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BURNER
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Fire and Explosion Hazard
Use joint compound or Teflon tape
compatible with propane gas.
FIELD INSTALLED
PIPE NIPPLE
Leak test before placing the
water heater in operation.
24 VOLT
GAS VALVE
Disconnect gas piping and main
gas shutoff valve before leak
testing.
SUPPLY GAS LINE CONNECTION
120,000 & 150,000 Btu/hr MODELS
Install sediment trap in
accordance with NFPA 54.
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WATER (POTABLE) HEATING AND SPACE HEATING
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Can result in overheating and
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Can cause serious injury or death.
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TEMPERATURE REGULATION
HIGH TEMPERATURE LIMIT CONTROL (ECO)
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Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
HIGH TEMPERATURE APPLICATIONS
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Operating Set Point
103°F
120°F
Status: Heating
OFF
43
DN
GAS O
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MENU
HELP
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CONTROL SYSTEM OPERATION
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MANUFACTURER / MODEL INFORMATION
Tank Temperature
Operating Set Point
103°F
120°F
UP
Status: Heating
Status Icons
OFF
DN
GAS O
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MENU
HELP
Operational buttons are multi functional. Their current function is defined by
the text that appears directly above each button on the LCD screen.
Figure 56
44
Up & Down buttons:
navigate menus,
adjust user settings
3 Operational buttons:
enter/exit menus,
select menu items,
activate adjustment modes,
confirm/cancel changes.
STATUS ICONS
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OPERATING STATES
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State
Description
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Menu
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USER SETTINGS & CONTROL SYSTEM MENUS
TEMPERATURES MENU
Operating Set Point And Differential Adjustment
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MANUFACTURER / MODEL INFORMATION
Tank Temperature
Operating Set Point
120°F
120°F
Status: Standby
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Heater Status
Display Settings
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Current Fault
SELECT
BACK
HELP
Temperatures
Operating Set Point
Differential
Tank Temperature
Upper Temperature
Lower Temperature
(Heater Regulated to Tank)
Upper Probe Offset
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0°F
HELP
Temperatures
Operating Set Point
Differential
Tank Temperature
Upper Temperature
Lower Temperature
(Heater Regulated to Tank)
Upper Probe Offset
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120°F
8°F
120°F
122°F
118°F
140°F
8°F
120°F
122°F
118°F
0°F
CANCEL
TEMPERATURES MENU (CONT)
DESCRIPTION/ACTION
DISPLAY
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Temperatures
Operating Set Point
Differential
Tank Temperature
Upper Temperature
Lower Temperature
(Heater Regulated to Tank)
Upper Probe Offset
CHANGE
BACK
140°F
8°F
120°F
122°F
118°F
0°F
HELP
[*K
Temperatures
Differential
Tank Temperature
Upper Temperature
Lower Temperature
(Heater Regulated to Tank)
Upper Probe Offset
Lower Probe Offset
CHANGE
BACK
8°F
120°F
122°F
118°F
0°F
0°F
HELP
{
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HEATER STATUS MENU
DESCRIPTION/ACTION
DISPLAY
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Heater Status
Š Status\
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Top of Menu
Status
ECO Contact
Low Gas PS
Blocked Inlet PS
Blocked Outlet PS
Blower Prover PS
Blower On
Standby
Closed
Closed
Closed
Closed
Open
No
BACK
HELP
[*K
Heater Status
Blower On
Igniter On
Igniter Current
Gas Valve On
Flame Detected
External Input Enable
Ignition Trials
BACK
No
No
No
No
No
No
3
HELP
DISPLAY SETTINGS
DESCRIPTION/ACTION
DISPLAY
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30s
60%
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BACK
HEATER INFORMATION
DESCRIPTION/ACTION
DISPLAY
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{
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Heater Information
Š Elapsed Time\
*
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Elapsed Time
10 day 0 hrs 0 mins
Burner On Time
5 hrs 22 mins
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X.XX
X.XX
Cycle Count
CCB Version
UIM Version
CHANGE
BACK
HELP
CURRENT FAULT
DESCRIPTION/ACTION
DISPLAY
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Blocked Exhaust
Fault occurred 2 mins ago
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The exhaust is blocked or
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condensate hose is draining.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
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ADVANCED
FAULT HISTORY
DESCRIPTION/ACTION
DISPLAY
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Fault History
*
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1:
Blocked Air Intake (A7)
51 mins ago
Blocked Exhaust (A8)
54 mins ago
Low Gas Pressure (A6)
57 mins ago
Blower Prover Failure (AC)
2:
3:
4:
VIEW
BACK
HELP
FAULT OCCURRENCE
DESCRIPTION/ACTION
DISPLAY
+ V
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Fault Occurrence
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Ignition Failure
ECO
Low Gas Pressure
Blocked Intake Air
Blocked Exhaust
Thermostat Input 4
Blower Prover
10
0
10
0
0
0
3
BACK
HELP
RESTORE FACTORY DEFAULTS
DESCRIPTION/ACTION
DISPLAY
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Restore Factory Defaults
{
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YES
50
NO
SERVICE CONTACT INFORMATION
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DESCRIPTION/ACTION
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Service Contact Information
Show Contact Information
Change Contact Name
Change Contact Phone
Current Contact Info:
No
(000) 000-0000
Access Code
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Service Contact Information
Show Contact Information
Change Contact Name
Change Contact Phone
Current Contact Info:
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Access Code
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Current Contact Info:
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(000) 000-0000
Access Code
SELECT
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Current Contact Info:
YOUR COMPANY NAME HERE
(123) 456-7890
Access Code
BACK
51
Yes
HELP
START UP
PRIOR TO START UP
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REQUIRED TEST EQUIPMENT
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FILLING THE WATER HEATER
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SUPPLY GAS LINE PURGING
Fire or Explosion Hazard
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Gas line purging is required with new piping or systems in
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To avoid risk of fire or explosion purge discharge must not
enter into confined areas or spaces where ignition can occur.
The area must be well ventilated and all sources of ignition
must be deactivated or removed.
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Use only the gas shown on the water heater rating label.
Keep ignition sources away from faucets after extended
periods of non-use.
Read instruction manual before
installing, using or servicing
water heater.
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LIGHTING THE WATER HEATER
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MANIFOLD GAS
PRESSURE
TEST PORT
SUPPLY GAS
PRESSURE
TEST PORT
GAS
VALVE
MANIFOLD GAS
PRESSURE REGULATOR
COVER SCREW
SUPPLY GAS
PRESSURE TAP
1/8’ NPT PLUG
ON
OFF
INLET
MANIFOLD GAS
PRESSURE TAP
1/8’ NPT PLUG
COMBUSTION
BLOWER
CONNECTION
COMBUSTION
AIR INLET
OUTLET
VENTURI
ON/OFF
SWITCH
GAS VALVE / VENTURI ASSEMBLY TOP VIEW
199,000 & 250,000 Btu/hr MODELS
GAS VALVE TOP VIEW
120,000 & 150,000 Btu/hr MODELS
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MANIFOLD GAS
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SUPPLY GAS
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GAS VALVE TOP DETAIL VIEW
199,000 & 250,000 Btu/hr MODELS
LOW GAS
PRESSURE
SWITCH
Figure 60
GAS VALVE
OUTLET
SUPPLY GAS
CONNECTION
GAS
VALVE
1/8” NPT
TEE FITTING
SUPPLY GAS
PRESSURE TAP
1/8’ NPT PLUG
BOTTOM OF TEE
MANIFOLD GAS
PRESSURE TAP
1/8’ NPT PLUG
GAS VALVE SIDE VIEW
120,000 & 150,000 Btu/hr MODELS
LOW GAS
PRESSURE
SWITCH
Figure 58
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53
COMBUSTION
AIR INLET
VENTURI
GAS VALVE / VENTURI ASSEMBLY SIDE VIEW
199,000 & 250,000 Btu/hr MODELS
Figure 61
SUPPLY GAS PRESSURE ADJUSTMENT
Breathing Hazard - Carbon Monoxide Gas
Fire and Explosion Hazard
Under no circumstances should
the input exceed the rate shown
on the water heater’s rating label.
Do not use water heater with any gas
other than the gas shown on the rating
label.
Excessive gas pressure to gas valve can
cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
Overfiring could result in damage to
the water heater and sooting.
Gas and carbon monoxide detectors
are available.
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water heater’s rating label.
Overfiring could result in fire or
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Gas and carbon monoxide detectors are
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CHECKING THE FIRING RATE
HIGH ALTITUDE INSTALLATIONS
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Under no circumstances should the
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Overfiring could result in fire or
explosion.
Gas and carbon monoxide detectors are
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the input exceed the rate shown
on the water heater’s rating label.
Overfiring could result in damage to
the water heater and sooting.
x H = Btu/hr
Gas and carbon monoxide detectors
are available.
Example:
3600
12.6
Breathing Hazard - Carbon Monoxide Gas
x 1050 = 300,000 Btu/hr (87.9 kW)
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
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LIGHTING THE WATER HEATER
LIGHTING & OPERATION LABELS
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BTH 120 AND 150 MODELS ONLY
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING
IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION
MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
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.
telephone. Follow the gas supplier’s instructions.
%
B. 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.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob 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 fire
or explosion.
“WHAT TO DO IF YOU SMELL GAS”
%
Do not try to light any appliance.
%
Do not touch any electrical switch; do not use any telephone
in your building.
%
Immediately call your gas supplier from a neighbor’s
If you cannot reach your gas supplier, call the fire
department.
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
1.
7. Turn on all electrical power to the appliance.
STOP! Read the safety information above on this
label.
8. Set thermostat to desired setting.
2. Set thermostat to lowest setting.
9. If the appliance will not operate, follow the instructions
“To Turn Off Gas To Appliance” and call your service
technician or gas supplier.
3. Turn off all electrical power to the appliance.
F
L
O
W
4. This appliance is equipped with an ignition device which
automatically lights the burner. Do not try to light the
burner by hand.
REG
ADJUST
On/Off Switch
ON
6. Move “Off/On” switch to the “On” position.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electrical power to the appliance if service is to be performed.
3. MOve “Off/On” switch to the “Off” position. Do not force.
56
OFF
5. Move “Off/On” switch to the “Off” position.
Wait five (5) minutes to clear out any gas. If you then
smell gas,
STOP! Follow “B” in the safety information
above on
this label. If you don’t smell gas, go on to
the next step.
LIGHTING THE WATER HEATER
LIGHTING & OPERATION LABELS
x•=*
*
BTH 199 AND 250 MODELS ONLY
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING
IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION
MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES
A. This appliance does not have a pilot. It is equipped with
an ignition device which automatically lights the burner.
Do not try to light the burner by hand.
telephone. Follow the gas supplier’s instructions.
?
B. 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.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob 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 fire
or explosion.
“WHAT TO DO IF YOU SMELL GAS”
?
Do not try to light any appliance.
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Do not touch any electrical switch; do not use any telephone
in your building.
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Immediately call your gas supplier from a neighbor’s
If you cannot reach your gas supplier, call the fire
department.
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
5. This appliance is equipped with an ignition device which
automatically lights the burner.
DO NOT TRY TO LIGHT THE BURNER BY HAND.
MODEL INFORMATION
Tank Temperature
Operating Set Point
103°F
120°F
UP
Status: Heating
6. Wait five (5) minutes to clear out any gas. If you then
smell gas,
STOP! Follow “B” in the safety information
above on
this label. If you don’t smell gas, go on to
the next step.
OFF
DN
GAS O
N
MENU
HELP
7. Turn on all electrical power to the appliance.
8. Set the ON/OFF switch on the control panel to
the “ON” position.
9. Set thermostat to desired setting.
CAUTION: Hotter water increases the risk of
scald injury. Consult the instruction
manual before changing temperature.
ON/OFF SWITCH
1.
STOP! Read the safety information above on this
label.
2. Set the ON/OFF switch on the control panel to
the “ON” position.
10. If the appliance will not operate, follow the instructions
“TO TURN OFF GAS TO APPLIANCE” and call your service
technician or gas supplier.
WARNING: TURN OFF ALL ELECTRICAL
POWER BEFORE SERVICING.
3. Set the thermostat to the lowest setting.
4. Set the ON/OFF switch on the control panel to the
“Off” position.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Set the ON/OFF switch on the control panel to the “OFF” position.
3. Turn off all electrical power to the appliance if service is to be performed.
57
TROUBLESHOOTING
INSTALLATION CHECKLIST
SEQUENCE OF OPERATION
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SEQUENCE OF OPERATION FLOW CHART
If tank temperature drops below Operating Set Point minus
Differential setting a heating cycle is activated
Control System performs diagnostic checks
Normal State of all pressure switches and ECO are checked
Blower Prover pressure switch verified open
All other pressure switches and ECO are verified closed
NO
Control System Locks Out
Displays Fault Msg
Combustion Blower is energized
Pre-Purge cycle
Blower Prover switch contacts confirmed
closed by control system
NO
Control System Locks Out
“Blower Prover Open”
Fault Msg is displayed
Igniter is energized for warm up period
Does Control System sense minimum
Igniter amps?
NO
Control System Locks Out
“Low Igniter Current”
Fault Msg is displayed
24 Volt Gas Valve is energized
gas flows to Main Burner
2.0 minimum AC amps
Is flame sensed at the Main Burner ?
(control system monitors the flame sensor)
YES
NO
Water is heated to
set point
24 Volt Gas Valve
de-energized
24 Volt Gas Valve
de-energized
30 second
Inter-Purge cycle
30 second
Post-Purge cycle
Retries up to
two more times
Water heater goes
into standby mode
Control System
Locks Out
“Ignition Failure”
Fault Msg is
displayed
Figure 62
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OPERATIONAL PROBLEMS
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
MOMENTARY IGNITION
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CAUTION
Burn Hazard
The combustion chamber and burner sleeve
and housing become very hot during operation.
Do not reach into the burner housing or
combustion chamber if the water heater
is still hot.
Allow the water heater to cool and always use
gloves when handling the main burner.
INSTALLATION ERRORS
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NOT ENOUGH OR NO HOT WATER
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ROUGH STARTING, ROUGH OPERATION
Fire and Explosion Hazard
Do not use water heater with any gas
other than the gas shown on the rating
label.
Excessive gas pressure to gas valve can
cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
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ALERT CONDITIONS
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DIAGNOSTIC CHECKS
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Turn off power to the water heater
before performing any service.
Label all wires prior to disconnecting
when performing service. Wiring errors
can cause improper and dangerous
operation.
Verify proper operation after servicing.
Failure to follow these instructions can
result in personal injury or death.
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Jumping out control circuits or components can
result in property damage, personal injury or death.
C * * * * *=
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Service should only be performed by a qualified service
agent using proper test equipment.
FAULT AND ALERT CONDITIONS
Altering the water heater controls and/or wiring in any way
could result in permanent damage to the controls or water
heater and is not covered under the limited warranty.
Altering the water heater controls and/or wiring in any way
could result in altering the ignition sequence allowing gas to
flow to the main burner before the hot surface igniter is at
ignition temperature causing delayed ignition which can
cause a fire or explosion.
FAULT CONDITIONS
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Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the appliance warranty.
FAULT AND ALERT MESSAGES
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DISPLAYED FAULT/ALERT MESSAGE
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AC Reversed
Fault occurred 2 mins ago
Power supply to water heater
has reversed polarity.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
Ignition Failure
Fault occurred 2 mins ago
The water heater has failed to
ignite the burner.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
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ADVANCED
Low Gas Pressure
Fault occurred 2 mins ago
The supply gas pressure to the
water heater is low.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
Low Igniter Current
Fault occurred 2 mins ago
Igniter current is low.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
Blocked Exhaust
Fault occurred 2 mins ago
The exhaust is blocked or
restricted. Ensure
condensate hose is draining.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
62
BACK
ADVANCED
FAULT AND ALERT MESSAGES (CONT)
!
*=
Z
=
POSSIBLE CAUSES - CHECK/REPAIR
DISPLAYED FAULT/ALERT MESSAGE
Š *[=+
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Blower Prover Failure
Fault occurred 2 mins ago
The blower prover switch is
closed out of sequence.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
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**
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[\+Z
@
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Š ;[=+\
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BACK
ADVANCED
Blower Prover Open
Fault occurred 2 mins ago
The blower prover switch remains
open after the blower has been
energized.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
Š *[)+
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BACK
ADVANCED
Blocked Air Intake
Fault occurred 2 mins ago
The combustion air intake is
restricted.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
Energy Cut Out (ECO)
Fault occurred 2 mins ago
Tank temperature is excessive.
The water heater has been
disabled.
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
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63
BACK
ADVANCED
Alert:
No Anode Voltage
Alert occurred 2 mins ago
No voltage detected from
Powered Anode(s).
Call a service professional:
Your Company Name Here
(press [DOWN] for more....)
CHANGE
BACK
ADVANCED
MAINTENANCE
GENERAL
MAINTENANCE SCHEDULE
™ * *
*"**=Z
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TABLE 14
*

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PRECAUTIONS
COMPONENT
Tank
Tank
C
<(=
(+*
OPERATION
+*
C*=
;*+
C*=
)
!
Test Operation
INTERVAL
REQUIRED
+*
V
+*
UN-LIME®
Annually
+*
)
Annually
!+
Deposits
Test
*
+!
C~C
DRAINING AND FLUSHING
CAUTION
)**

=  * * *
+ V
!* % *
Do not operate the water heater if it has
been exposed to or exhibits the following:
Flooding at or above the level of the burner or controls.
External damage.
Firing without water.
Sooting.
Do not operate the water heater until all corrective steps
have been made by a qualified service agent.
Burn harzard.
Hot water discharge.
#= *
\
C(===
+ *
\
C (= &
Keep hands clear of drain
valve discharge.
+
=
"
K_+
==+V
]$^
To drain the water heater storage tank:
& ] K_+
(=
x
$ :
==
/ @
!==*
Z
 !==
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 ! == ^ !
+/
&)
x
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
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{
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C=
* * " * * *
•
**
To Flush the tank perform the following steps:
& ] :
==
$ @ / ! == * Z
Explosion Hazard
Overheated water can cause
water tank explosion.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
64
:

V
**
 @==
% V
*=*

TANK
CLEANOUT
OPENING
CLEANOUT
ACCESS PANEL
CLEANOUT
GASKET
 !==
*
^ C*=
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&&
+)+Q]
&]*=
FILLING THE WATER HEATER
CLEANOUT
COVER
Figure 63
+V>]
SEDIMENT REMOVAL
MANUAL LIME SCALE REMOVAL
*
***
NOTE:!
*
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>==*=
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LIME SCALE REMOVAL
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65
TABLE 15
TEMPERATURE-PRESSURE
RELIEF VALVE
UN-LIME® PROFESSIONAL DELIMER
Part Number
Description
9005416105
/\&?B
9005417105
1 - 5 gallon
POWERED ANODE RODS
" \ " = *
Z
* ?]B * * ) *
NOTE:V
/ C*= * $~/›#
*
' * **"
• * C*= * ! V
]
DRAIN VALVE AND ACCESS PANELS
=*
Z
==" V
!* % = *
Z
* * *=+V
$
DISCHARGE PIPE
V
/
) *
\
C (= " * *
x
NOTE::x=
***
*
\
C (= :x= * * ›* x›
›*›+*:x!
+*&*
\
C(=
*x
*
\
C(=
*=*x
=
**
x*
*
DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF
VALVE OPENING. THIS CAN CAUSE PROPERTY DAMAGE,
SERIOUS INJURY OR DEATH.
TEMPERATURE-PRESSURE RELIEF VALVE TEST
Explosion Hazard
Burn hazard.
Hot water discharge.
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
Keep clear of TemperaturePressure Relief Valve
discharge outlet.
Properly sized temperaturepressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
) ** *
\
C (=
=*
*
\
C(="
*
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*
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C (= " ?]B *"
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66
Can cause serious injury or death.
VENT SYSTEM
:x*=*
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~==*
C**
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]]^
NOTE:'=
$ !=*
DIAGRAMS
CCB - CENTRAL CONTROL BOARD LAYOUT
CCB (CENTRAL CONTROL BOARD)
1
1
1
2
2
2
1
3
3
4
2
4
4
J3
5
J2
J4
J5
J1
J6
Spare
Retries
OPEN
Yes
Tstat
1
Use
Type
12
9
6
3
14
11
8
5
2
13
10
7
4
1
3
2 3 4
1 Retry
Ext
Input
15
No
Vent
Spare
S1 DIPSWITCH
J7
4
3
2
1
J9
J13
J10
1
3
2
4
J11
1
5
2
6
J15
3
7
1
4
8
2
J16
S1 DIPSWITCH DETAIL
Yes
Type
Tstat
Spare
OPEN
Use
2 3 4
Ext
Input
3
Retries
1
1 Retry
No
Vent
Spare
Dipswitch Operation:
Along one side of the dipswitch array there are numbers, 1-4. On the other side of the dipswitch
is the word “OPEN.” The dipswitches are rocker type switches, if one side of the rocker is down the
other side will be up. Pressing a rocker down on the side of the array labeled “OPEN,” opens the switch.
Pressing a rocker down on the side of the array labeled with the numbers 1-4 closes the dipswitch.
CHANGING NUMBER OF IGNITION TRIALS BEFORE LOCK OUT
NOTE: Always turn off power to the water heater before changing dipswitch settings.
Set dipswitch #4 to the open position for 1 trial for ignition before Ignition Failure lock out. Set dipswitch
#4 to the closed position for 3 trials for ignition before Ignition Failure lock out.
Figure 65
67
BTH 120 & 150 WIRING DIAGRAM
24 VAC
GAS VALVE
LOW GAS
PRESSURE SWITCH
BLOCKED
AIR INTAKE
BLOWER
PROVER
BLOCKED
EXHAUST
1
J5 J4
UIM
J16
J6
13
2
15
4
14
5
10
6
7
8
11
ENABLE/DISABLE CIRCUIT
JUMPER WIRE BETWEEN PINS
8 AND 11 ON J6 PLUG
HOT SURFACE IGNITER
1 BLACK
2 WHITE
FLAME SENSOR
RED
1 RED (ECO)
3 BLACK
UPPER TEMPERATURE PROBE
4 RED (ECO)
1 BLACK
ANODE 1
2 BLACK
LOWER TEMPERATURE PROBE
1 GREEN
2 BLUE
ANODE 2
120 VAC 1 Ø POWER
1 BLACK
1
2
2 WHITE
COMBUSTION
BLOWER
1 2 RED
J3
2 GREEN
3 WHITE
GREEN
GREEN
GREEN
GREEN
1 BLACK120 VAC HOT
BLACK
RED
J1
WHITE
3 WHITE 120 VAC NEUTRAL
ON/OFF
SWITCH
4 YEL 24 VAC
4 YEL 24 VAC
GROUND STRIP
TRANSFORMER
50VA
BURNER GROUND
(BURNER BOLT)
INSIDE CCB
ENCLOSURE
Figure 66
68
JUNCTION
BOX
USER INTERFACE MODULE
J13
J2
J7
J15 J10
CCB (CENTRAL CONTROL BOARD)
2 BLACK
WHITE
BLACK
GROUND
N
L
120 VAC NEUTRAL
120 VAC HOT
BTH 199 & 250 WIRING DIAGRAM
24 VAC
GAS VALVE
LOW GAS
PRESSURE SWITCH
BLOCKED
AIR INTAKE
BLOWER
PROVER
BLOCKED
EXHAUST
1
J5 J4
UIM
J16
J6
13
2
15
4
14
5
10
6
7
8
11
ENABLE/DISABLE CIRCUIT
JUMPER WIRE BETWEEN PINS
8 AND 11 ON J6 PLUG
HOT SURFACE IGNITER
1 BLACK
2 WHITE
FLAME SENSOR
RED
1 RED (ECO)
3 BLACK
UPPER TEMPERATURE PROBE
4 RED (ECO)
1 BLACK
ANODE 1
2 BLACK
LOWER TEMPERATURE PROBE
1 GREEN
2 BLUE
PWM (pulse width modulation)
SPEED INSTRUCTION SIGNAL
WIRES FROM CCB TO BLOWER
MOTOR VFD (variable frequency drive).
ANODE 2
NOTE: COMBUSTION BLOWER
ASSEMBLY CONSISTS OF
MOTOR, BLOWER AND INTEGRAL
VFD (variable frequency drive).
3 WHITE/GREEN
7 WHITE/BLUE
8 WHITE/BROWN
1 4 5
120 VAC 1 Ø POWER
1 BLACK
1
2
2 WHITE
COMBUSTION
BLOWER
1 2 RED
J3
2 GREEN
3 WHITE
GREEN
GREEN
GREEN
GREEN
1 BLACK120 VAC HOT
BLACK
RED
J1
WHITE
3 WHITE 120 VAC NEUTRAL
ON/OFF
SWITCH
4 YEL 24 VAC
4 YEL 24 VAC
GROUND STRIP
TRANSFORMER
50VA
BURNER GROUND
(BURNER BOLT)
INSIDE CCB
ENCLOSURE
Figure 67
69
JUNCTION
BOX
USER INTERFACE MODULE
J1 3
J2
J7
J15 J10
CCB (CENTRAL CONTROL BOARD)
2 BLACK
WHITE
BLACK
GROUND
N
L
120 VAC NEUTRAL
120 VAC HOT
CIRCULATION PUMP WIRING DIAGRAMS
CIRCULATING PUMP WIRING DIAGRAM
STORAGE TANK OR BUILDING RECIRCULATION
FIELD SUPPLIED TEMPERATURE CONTROL
INSTALLED IN THE STORAGE TANK
OR CIRCULATING LOOP RETURN LINE
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH WATER HEATER AS
THIS MAY CAUSE ELECTRICAL LINE
NOISE AND LEAD TO ERRATIC CONTROL
SYSTEM OPERATION.
L1 HOT
120 VAC
POWER
CIRC
PUMP
MOTOR
L2 NEUTRAL
Figure 68
CIRCULATING PUMP WIRING DIAGRAM
DISHWASHER LOOP WITH TOGGLE SWITCH
DISHWASHER
TOGGLE
SWITCH
FIELD SUPPLIED TEMPERATURE
CONTROL INSTALLED IN THE
CIRCULATING LOOP RETURN LINE
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH WATER HEATER AS
THIS MAY CAUSE ELECTRICAL LINE
NOISE AND LEAD TO ERRATIC CONTROL
SYSTEM OPERATION.
L1 HOT
120 VAC
POWER
CIRC
PUMP
MOTOR
L2 NEUTRAL
Figure 69
70
71
FINISHED FLOOR
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
ONE WATER HEATER, SINGLE TEMPERATURE
WITH BUILDING RECIRCULATION
$ +*
\
C(=&
] +'K&
& +Kx(=&
[=‰
WATER PIPING DIAGRAMS
PIPE T&P TO
OPEN DRAIN
HOT WATER OUTLET
EXPANSION
TANK
COLD
WATER
SUPPLY
LINE TEMPERATURE
CONTROL
HOT WATER
RETURN
WATER FLOW SWITCH
TANK OR LINE TEMPERATURE
CONTROL
DRAIN
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
% ) * **V
V
^%
 )
*
V
%
+;!/]
/ +!+**:x&
72
EXPANSION
TANK
COLD WATER
SUPPLY
TEMPERED WATER
RETURN
LINE TEMPERATURE
CONTROL
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HOT WATER
RETURN
ONE WATER HEATER, TWO TEMPERATURE
WITH HIGH TEMPERAURE LOOP RECIRCULATION
WITH BUILDING RECIRCULATION
$ +*
\
C(=&
] +'K&
& +Kx(=&
[=‰
WATER PIPING DIAGRAMS
TEMPERED
WATER
TO FIXTURES
LINE TEMPERATURE
CONTROL
12” TO 15”
MINIMUM
HOT
COLD
MIXING VALVE
HOT WATER
OUTLET
WATER FLOW SWITCH
DRAIN
PIPE T&P TO
OPEN DRAIN
TEMPERATURE GAGE
CHECK VALVE
MIXING VALVE
FULL PORT BALL VALVE
TANK OR LINE TEMPERATURE
CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
% ) * **V
V
^%
 )
*
V
%
+;!/]
/ +!+**:x&
73
HOT WATER
OUTLET
ALT. COLD WATER
CONNECTION
TANK TEMPERATURE
CONTROL
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
LINE TEMPERATURE
CONTROL
WATER FLOW SWITCH
TANK OR LINE TEMPERATURE
CONTROL
DRAIN
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
% ) * **V
V
^%
 )
*
V
%
+;!/]
/ +!+**:x&
NOTE:
The water heater’s Operating Set Point should be set 5° higher than the Tank Temperature Control in the auxiliary storage tank.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
ONE WATER HEATER, SINGLE TEMPERATURE
WITH VERTICAL STORAGE TANK FORCED RECIRCULATION
WITH BUILDING RECIRCULATION
$ +*
\
C(=&
] +'K&
& +Kx(=&
[=‰
WATER PIPING DIAGRAMS
AOS
STORAGE TANK
74
AOS
STORAGE TANK
ALTERNATE TANK
TEMPERATURE
CONTROL LOCATION
TANK TEMPERATURE
CONTROL
HOT WATER
OUTLET
EXPANSION
TANK
WATER FLOW SWITCH
DRAIN
COLD WATER
SUPPLY
HOT WATER
RETURN
LINE TEMPERATURE
CONTROL
TEMPERATURE GAGE
CHECK VALVE
MIXING VALVE
FULL PORT BALL VALVE
TANK OR LINE TEMPERATURE
CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
% ) * **V
V
^%
 )
*
V
%
+;!/]
/ +!+**:x&
NOTE:
The water heater’s Operating Set Point should be set 5° higher than the Tank Temperature Control in the auxiliary storage tank.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
ONE WATER HEATER, SINGLE TEMPERATURE
WITH HORIZONTAL STORAGE TANK FORCED RECIRCULATION
WITH BUILDING RECIRCULATION
$ +*
\
C(=&
] +'K&
& +Kx(=&
[=‰
WATER PIPING DIAGRAMS
75
FINISHED
FLOOR
HOT WATER
OUTLET
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
PIPE T&P TO
OPEN DRAIN
TWO WATER HEATERS, SINGLE TEMPERATURE
WITH BUILDING RECIRCULATION
$ +*
\
C(=&
] +'K&
& +Kx(=&
[=‰
WATER PIPING DIAGRAMS
PIPE T&P TO
OPEN DRAIN
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
LINE TEMPERATURE
CONTROL
WATER FLOW SWITCH
TANK OR LINE TEMPERATURE
CONTROL
DRAIN
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
% ) * **V
V
^%
 )
*
V
%
+;!/]
/ +!+**:x&
76
FINISHED
FLOOR
HOT WATER
OUTLET
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
THREE WATER HEATERS, SINGLE TEMPERATURE
WITH BUILDING RECIRCULATION
$ +*
\
C(=&
] +'K&
& +Kx(=&
[=‰
WATER PIPING DIAGRAMS
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
LINE TEMPERATURE
CONTROL
WATER FLOW SWITCH
TANK OR LINE TEMPERATURE
CONTROL
DRAIN
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
% ) * **V
V
^%
 )
*
V
%
+;!/]
/ +!+**:x&
77
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
HOT WATER
OUTLET
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
FOUR WATER HEATERS, SINGLE TEMPERATURE
WITH BUILDING RECIRCULATION
$ +*
\
C(=&
] +'K&
& +Kx(=&
[=‰
WATER PIPING DIAGRAMS
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
LINE TEMPERATURE
CONTROL
WATER FLOW SWITCH
TANK OR LINE TEMPERATURE
CONTROL
DRAIN
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
% ) * **V
V
^%
 )
*
V
%
+;!/]
/ +!+**:x&
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