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instruction manual commercial gas water heaters
500 Tennessee Waltz Parkway
Ashland City, TN 37015
models Btr 120 - 400(a)
Btrc 120 - 400(a) series 118/119
installation - operation - serVice
- maintenance - limited warranty
Low Lead Content
WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
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.
We appreciate your confidence in our products.
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 0812 197283-004
taBle of contents
SAFe INSTALLATION, USe AND SeRVICe ........................................ 3
APPROVALS .......................................................................................... 3
GENERAl sAfETy INfoRmATIoN
.................................................4-5
Precautions ....................................................................................... 5
Grounding Instructions ...................................................................... 5
Hydrogen Gas flammable
................................................................ 5
INTRoDUCTIoN
................................................................................... 6
Abbreviations Used ........................................................................... 6
Qualifications .................................................................................... 6
Preparing for the Installation
............................................................. 6 fEATUREs AND ComPoNENTs
........................................................ 7
The Eliminator (self Cleaning system)
............................................. 7
High Limit Switch ............................................................................... 7 electronic Ignition Control ................................................................. 7
Automatic Flue Damper .................................................................... 7
Uncrating ........................................................................................... 7
INsTAllATIoN CoNsIDERATIoNs
............................................... 8-12
Rough In Dimensions
........................................................................ 8
Locating The Water Heater ............................................................. 10
Clearances ...................................................................................... 10
NSF Leg Kit ......................................................................................11
Insulation Blanket
.............................................................................11
Hard Water
.......................................................................................11
Circulation Pumps .......................................................................11-12
High Altitude Installations
............................................................... 12
INsTAllATIoN REqUIREmENTs
..................................................... 13
Gas supply systems
....................................................................... 13 supply Gas Regulator
..................................................................... 13
Power supply
.................................................................................. 13
Water Temperature Control and Mixing Valves .............................. 13
Dishwashing Machines ................................................................... 14
Closed Water systems
.................................................................... 14
Thermal Expansion
......................................................................... 14
Temperature-Pressure Relief Valve........................................... 14-15
Contaminated Air
............................................................................ 15
Air Requirements
............................................................................ 15
Unconfined Space ........................................................................... 16
Confined Space ............................................................................... 16
VeNTING INSTALLATION .................................................................. 16
Venting ............................................................................................ 16
Vent Reducer .................................................................................. 16 multiple Heater manifold
................................................................. 17
Fresh Air Opening for Confined Spaces ......................................... 17 outdoor Air Through Two openings
............................................... 17 outdoor Air Through one opening
................................................ 17
Outdoor Air Through Two Horizontal Ducts .................................... 17
Outdoor Air Through Two Vertical Ducts ........................................ 18
Air From Other Indoor Spaces ........................................................ 18
Technical Data Venting ..............................................................19-20
Mechanical Venting ......................................................................... 21
WATER HEATER INsTAllATIoN
................................................. 21-24
Water Line Connections .................................................................. 21
T&P Valve Discharge Pipe .............................................................. 21
Installation Diagrams - Top Inlet/outlet Usage
............................... 22
Heater Wiring
.................................................................................. 23
Gas Piping
....................................................................................... 24
Gas line leak Testing
.................................................................... 24
Purging
............................................................................................ 24 oPERATIoN
........................................................................................ 25
Prior to start Up
.............................................................................. 25 sEqUENCE of oPERATIoN
............................................................ 25
Sequence of Operation Flow Chart ................................................ 26 lighting & operation labels
...................................................... 27-28
Adjustments
..................................................................................... 29
Checking Venting ............................................................................ 29
Checking the Input .......................................................................... 29 mAINTENANCE
................................................................................... 31
Venting System ............................................................................... 31
Remote storage Tank Temperature Control
................................... 31
Temperature-Pressure Relief Valve Test ........................................ 31
Anode Rod Inspection................................................................ 31-32
Draining and flushing
..................................................................... 32
Recommended Procedure for Periodic Removal or Lime Deposits from the Tank Type Commercial Water Heaters ............................ 32
DeLiming Solvents .......................................................................... 33
Tank Cleanout Procedure ............................................................... 33
Deliming Using flo-Jug method
................................................33-34
Pilot Burner
...................................................................................... 34 main Burner
..................................................................................... 35
Gas Control Valve ........................................................................... 35
SeRVICe ............................................................................................. 35 electrical Servicing ......................................................................... 35
TRoUBlEsHooTING
......................................................................... 36
Ignition module
................................................................................ 36 flue Damper
.................................................................................... 36 effikal RVGP-KSF Series Flue Damper Trouble Shooting Guide ........ 37
Troubleshooting Checklist ............................................................... 38 foR yoUR INfoRmATIoN
................................................................ 39 start up Conditions
......................................................................... 39 operational Conditions
................................................................... 39
WATER PIPING DIAGRAms
..........................................................40-54
MANIFOLD KITS ................................................................................. 55
NoTEs
............................................................................................56-58
WARRANTy
........................................................................................ 59
2
safe installation, use and serVice
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
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
WARNING
CAUTION
CAUTION
DANGER indicates an imminently hazardous situation which, if not avoided, will result in injury or death.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in injury or death.
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.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and how to avoid the risk of injury.
The California Safe Drinking Water and Toxic enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.
This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This water heater can cause low level exposure to some of the substances listed in the Act.
approVals
Low Lead Content
note:
ASMe construction is optional on the water heaters covered in this manual.
3
general safety information
Fire or Explosion Hazard
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.
Fire Hazard
For continued protection against risk of fire:
Do not install water heater on carpeted floor.
Do not operate water heater if flood damaged.
Fire and Explosion Hazard
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.
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.
CAUTION
Property Damage Hazard
•
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
•
•
•
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.
Failure to follow these instructions can result in personal injury or death.
4
Jumping out control circuits or components can result in property damage, personal injury or death.
•
•
• 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 water heater warranty.
general safety information
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.
Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death.
Children, the elderly and the physically or mentally disabled are at highest risk for scald injury.
Feel water before bathing or showering.
Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at fixtures.
Explosion Hazard
Overheated water can cause water tank explosion.
Properly sized temperature and pressure relief valve must be installed in the opening provided.
CAUTION
Improper installation, use and service may result in property damage.
•
•
•
•
• Do not operate water heater if flood damaged.
Inspect and 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.
Verify the power to the water heater is turned off before performing any service procedures.
general safety information
precautions hydrogen gas flammaBle
Do NoT UsE THIs WATER HEATER If ANy PART HAs BEEN
UNDeR WATeR. Immediately call a qualified service agency to inspect the water heater and to make a determination on what steps should be taken next.
Explosion Hazard
If the unit is exposed to the following, do not operate heater until all corrective steps have been made by a qualified service agency.
1. external fire.
2. Damage.
3. Firing without water.
Flammable hydrogen gases may be present.
Keep all ignition sources away from faucet when turning on hot water.
grounding instructions
This water heater must be grounded in accordance with the
National electrical Code and/or local codes. These must be followed in all cases.
This water heater must be connected to a grounded, permanent wiring system; or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the water heater, see Figure 20.
5
Hydrogen gas can be produced in a hot water system served by this water heater that has not been used for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To reduce the risk of injury under these conditions, it is recommended that a hot water faucet served by this water heater 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 OR OPeN FLAMe NeAR THe
FAUCeT AT THe TIMe IT IS OPeN.
introduction
Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service.
aBBreViations used
Abbreviations found in this Instruction Manual include :
• ANSI - American National Standards Institute
• ASMe - American Society of Mechanical engineers
• AHRI - Air-Conditioning, Heating and Refrigeration Institute
• NeC - National electrical Code
• NFPA - National Fire Protection Association
• Ul - Underwriters laboratory
• CSA - Canadian Standards Association
Qualifications
Qualified installer or serVice agency
Installation and service of this water heater requires ability equivalent to that of a Qualified Agency (as defined by ANSI below) in the field involved. Installation skills such as plumbing, air supply, venting, gas supply and electrical supply are required in addition to electrical testing skills when performing service.
ansi Z223.1 2006 sec. 3.3.83:
“Qualified Agency” - “Any individual, firm, corporation or company that either in person or through a representative is engaged in and is responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair or servicing of appliances and equipment; that is experienced in such work; that is familiar with all precautions required; and that has complied with all the requirements of the authority having jurisdiction.”
If you are not qualified (as defined by ANSI above) and licensed or certified as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the procedures described in this manual. If you do not understand the instructions given in this manual do not attempt to perform any procedures outlined in this manual.
preparing for the installation
1. Read the “General Safety” section, page 4-5 of this manual first and then the entire manual carefully. If you don’t follow the safety rules, the water heater will not operate properly.
It could cause DeATH, SeRIOUS bODILY INJURY AND/OR
PROPeRTY DAMAGe.
This manual contains instructions for the installation, operation, and maintenance of the gas-fired water heater. It also contains warnings throughout the manual that you must read and be aware of. All warnings and all instructions are essential to the proper operation of the water heater and your safety. Since we cannot put everything on the first few pages, ReAD THe eNTIRe mANUAl BEfoRE ATTEmPTING To INsTAll oR oPERATE
THe WATeR HeATeR.
2. The installation must conform with these instructions and the local code authority having jurisdiction. In the absence of local codes, the installation must comply with the current editions of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or CAN/
CSA-b149.1 the Natural Gas and Propane Installation Code.
All documents are available from the Canadian Standards
Association, 8501 east Pleasant Valley Road, Cleveland, OH
44131. NFPA documents are also available from the National
Fire Protection Association, 1 batterymarch Park, Quincy, MA
02269.
3. If after reading this manual you have any questions or do not understand any portion of the instructions, call the local gas utility or the manufacturer whose name appears on the rating plate.
4. Carefully plan the place where you are going to put the water heater. Correct combustion, vent action, and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and fires.
examine the location to ensure the water heater complies with the “Locating the New Water Heater” section in this manual.
5. For California installation this water heater must be braced, anchored, or strapped to avoid falling or moving during an earthquake. See instructions for correct installation procedures. Instructions may be obtained from California
Office of the State Architect, 400 P Street, Sacramento,
CA 95814.
6. Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5.00.
6
features and components
the eliminator (self-cleaning system)
These units include The eliminator (Self-Cleaning System) installed in the front water inlet, See Figure 1. The eliminator inlet tube can only be used in the front water inlet connection. Do not install the eliminator inlet tube in either the top or back inlet water connection.
The eliminator must be oriented correctly for proper function. There is a marked range on pipe nipple portion of the Eliminator, that must be aligned with top of inlet spud. A label above the jacket hole has an arrow that will point to marked portion of pipe nipple if the orientation is correct. If the arrow does not point within the marked range on pipe nipple, adjust the pipe nipple to correct. A pipe union is supplied with the eliminator to reduce probability of misaligning the eliminator accidentally while tightening the connection to inlet water supply line. Improper orientation of the eliminator can cause poor performance of heater and can significantly reduce outlet water temperatures during heavy draws.
burns during each running cycle. The main burner and pilot gases are cut off during the OFF cycle. Pilot gas ignition is proven by the pilot sensor. Main burner ignition will not occur if the pilot sensor does not first sense pilot ignition.
ignition module figure 3.
note: the eliminator may have 1, 3 or 7 cross tubes.
figure 1.
high limit switch
The digital thermostat (Figure 2) contains the high limit (energy cutout) switch. The high limit switch interrupts main burner gas flow should the water temperature reach 203°F (95°C).
In the event of high limit switch operation, the water heater cannot be restarted unless the water temperature is reduced to approximately
120°F (49°C). The high limit reset button on the front of the control then needs to be depressed.
Continued manual resetting of high limit control, preceded by higher than usual water temperature is evidence of high limit switch operation.
The following is a possible reason for high limit switch operation:
• A malfunction in the thermostatic controls would allow the gas control 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 service agent if continued high limit switch operation occurs.
automatic flue damper
All units are equipped with an automatic flue damper that reduces heat loss during the OFF cycles. The automatic flue damper drive assembly is a field replaceable part and may be obtained by contacting A. O. Smith Corporation at 500 Tennessee Waltz
Parkway, Ashland City, TN 37015, 1-800-433-2545. In Canada, contact A.O. Smith enterprises LTD., P.O. box, 310 - 768 erie
Street, Stratford, Ontario, Canada N5A 6T3, 1-800-265-8520.
each automatic flue damper drive assembly is equipped with a
“Service Switch”, as shown in Figure 4
The “Service Switch” has 2 positions: AUTOMATIC OPeRATION and HOLD OPeN DAMPeR. For normal operation the switch should be in the AUTOMATIC OPeRATION position.
If there is a problem with the damper the “Service Switch” can be placed in the HOLD OPeN DAMPeR position. When the switch is placed in the HOLD OPeN DAMPeR position the damper disc will rotate to the open position and the heater may be used until vent assembly is repaired or replaced. DO NOT turn the damper disc manually; damage will occur to the drive assembly if operated manually. Refer to TeSTING DAMPeR OPeRATION section of this manual for additional information.
digital thermostat figure 2.
flue damper figure 4.
uncrating electronic ignition control
each heater is equipped with a Honeywell ignition module. The solid state ignition control ignites the pilot burner gas by creating a spark at the pilot assembly. See Figure 3. Pilot gas is ignited and
7
The heater is shipped with the flue damper already installed. The wiring conduit runs from the thermostat to the damper drive cover.
before turning unit on, check to make sure the wiring conduit is securely plugged into damper drive.
rough in dimensions
installation considerations
models Btr(c) 120 through 500 see models Below
* bTR(C) - 120 Models are approved for 5” (13 cm) venting using a 6” (15 cm) to 5” (13 cm) reducer.
figure 5.
taBle 1a . Btr models 120 through 400a moDEl
BTR120
BTR154
BTR180
BTR197
BTR198
BTR199
BTR 200
BTR 250
BTR 251
BTR 275
BTR 305
BTR 365
BTR 400
INPUT
RATE bTU/Hr.
120,000 bTU/Hr.
35 Kw/Hr
154,000 BTU/Hr
45 Kw/Hr
180,000 BTU/Hr
53 Kw/Hr
199,000 BTU/Hr
58 kW/Hr
199,000 bTU/Hr.
58 Kw/Hr
199,000 BTU/Hr
58 kW/Hr
199,000 BTU/Hr
58 kW/Hr
250,000 BTU/Hr
72 kW/Hr
251,000 BTU/Hr
73 kW/Hr
275,000 BTU/Hr
80 kW/Hr
305,000 BTU/Hr
89 kW/Hr
365,000 BTU/Hr
107kW/Hr
390,000 BTU/Hr
114kW/Hr
APPRoX
TANK
CAP.
71 Gal
268 l
81 Gal
307 l
81Gal
307 l
100 Gal
379 l
100 Gal
379 l
81 Gal
307 l
100 Gal
379 l
100 Gal
379 l
65 Gal
246 l
100 Gal
379 l
65 Gal
246 l
85 Gal
322 l
100 Gal
379 l
A
69.75”
177 cm
73.00”
185 cm
67.50”
171 cm
75.00”
192 cm
75.00”
192 cm
67.50”
171 cm
72.00”
183 cm
72.00”
183 cm
75.00”
191 cm
72.00”
183 cm
75.00”
191 cm
79.50”
202 cm
75.50”
192 cm
B C
59.50”
151 cm
66.50”
169 cm
62.00”
157 cm
70.00”
178 cm
70.00”
178 cm
62.00”
157 cm
65.13”
165 cm
65.13”
165 cm
65.75”
167 cm
65.13”
165 cm
65.75”
167 cm
70.25”
178 cm
67.50”
171 cm
4.50”
12 cm
4.50”
12 cm
4.50”
12 cm
4.50”
12 cm
4.25”
11 cm
4.25”
11 cm
4.50”
12 cm
4.50”
12 cm
4.50”
12 cm
4.50”
12 cm
4.50”
12 cm
4.50”
12 cm
4.50”
12 cm
D
50.87”
129 cm
57.87”
147 cm
53.62”
136 cm
61.62”
157 cm
61.62”
157 cm
53.62”
136 cm
55.87”
142 cm
55.87”
142 cm
57.25”
145 cm
55.87”
142 cm
57.25”
145 cm
62.50”
159 cm
58.25”
148 cm
E f
21”
53 cm
21”
53 cm
23”
58 cm
23”
58 cm
19”
48 cm
19”
48 cm
21”
53 cm
21”
53 cm
NA
NA
23”
58 cm
NA
NA
23”
58 cm
23”
58 cm
19.69”
50 cm
19.69”
50 cm
20.50”
52 cm
20.50”
52 cm
20.50”
52 cm
20.50”
52 cm
19.75”
50 cm
19.75”
50 cm
20.00”
51 cm
19.75”
50 cm
20.00”
51 cm
22.50”
57 cm
26.75”
68 cm
GAs
INlET
G
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
3/4”
3/4”
3/4”
3/4”
H
51.88”
132 cm
59.00”
150 cm
54.62”
139 cm
62.62”
159 cm
61.50”
150 cm
54.62”
139 cm
56.38”
143 cm
56.38”
143 cm
58.75
149 cm
56.38”
143 cm
58.75
149 cm
63.00
160 cm
59.00”
150 cm
VeNT
DIA
I
6”
15 cm
6”
15 cm
6”
15 cm
8”
20 cm
6”
15 cm
6”
15 cm
6”
15 cm
6”
15 cm
8”
20 cm
8”
20 cm
8”
20 cm
8”
20 cm
8”
20 cm
J
27.75”
71 cm
27.75”
71 cm
27.75”
71 cm
27.75”
71 cm
27.75”
71 cm
27.75”
71 cm
30.25”
77 cm
30.25”
77 cm
27.75”
70 cm
30.25”
77 cm
27.75”
70 cm
27.75”
70 cm
30.25”
77 cm
CoNNECTIoNs
INlET oUTlET
ToP fRoNT bACK ToP fRoNT bACK
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
NA
NA
1.50”
1.50”
NA
NA
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
2.00”
2.00”
2.00”
2.00”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
2.00”
2.00”
1.50”
1.50”
1.50”
1.50”
2.00”
2.00”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
2.00”
2.00”
1.50”
1.50”
2.00”
2.00”
2.00”
2.00”
1.50”
1.50”
2.00”
2.00”
1.50”
1.50”
1.50”
1.50”
2.00”
2.00”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
NA
NA
1.50”
1.50”
NA
NA
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
2.00”
2.00”
2.00”
2.00”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1 .50”
2.00”
2.00”
1.50”
1.50”
1.50”
1.50”
2.00”
2.00”
2.00”
2.00”
1.50”
1.50”
2.00”
2.00”
2.00”
2.00”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
2.00”
2.00”
1.50”
1.50”
1.50”
1.50”
2.00”
2.00”
630 lbs
286 Kg
630 lbs
286 Kg
750lbs
341 Kg
630 lbs
286 Kg
750 lbs
341 Kg
725 lbs
329 Kg
760 lbs
345 Kg
Approximate ship. Weight
STD.
400 lbs
182 Kg
470 lbs
21 3 Kg
AsmE
NA
NA
NA
NA
NA
NA
470 lbs
21 3 Kg
603 lbs
273 Kg
603 lbs
273 Kg
470 lbs
21 3 Kg
NA
NA
NA
NA
NA
NA
725 lbs
329 Kg
725 lbs
329 Kg
862 lbs
391 Kg
725 lbs
329 Kg
862 lbs
391 Kg
833 lbs
379 Kg
874 lbs
396 Kg taBle 1B. Btrc models 120 through 400/a moDEl
BTRC120
BTRC154
BTRC180
BTRC197
BTRC199
BTRC200
BTRC250
BTRC251
BTRC275
BTRC305
BTRC365
BTRC400
INPUT
RATE bTU/Hr.
120,000 bTU/Hr.
35 Kw/Hr
154,000 BTU/Hr
45 Kw/Hr
180,000 BTU/Hr
53 Kw/Hr
199,000 BTU/Hr
58 kW/Hr
199,000 BTU/Hr
58 kW/Hr
199,000 BTU/Hr
58 kW/Hr
250,000 BTU/Hr
72 kW/Hr
251,000 BTU/Hr
73 kW/Hr
275,000 BTU/Hr
80 kW/Hr
305,000 BTU/Hr
89 kW/Hr
365,000 BTU/Hr
107kW/Hr
390,000 BTU/Hr
114kW/Hr
APPROX.
TANK
CAP.
71 Gal
268 l
81 Gal
307 l
76 Gal
288 l
94 Gal
356 l
76 Gal
288 l
100 Gal
379 l
100 Gal
379 l
65 Gal
246 l
100 Gal
379 l
65 Gal
246 l
65 Gal
246 l
100 Gal
379 l
A
69.75”
177 cm
73.00”
185 cm
70.50”
179 cm
81.50”
207 cm
70.50”
179 cm
72.00”
183 cm
72.00”
183 cm
75.00”
191 cm
72.00”
183 cm
75.00”
191 cm
75.00”
191 cm
75.50”
192 cm
B
4.25”
11 cm
4.50”
12 cm
4.50”
12 cm
4.50”
12 cm
4.25”
11 cm
4.25”
11 cm
4.25”
11 cm
4.25”
11 cm
4.50”
12 cm
4.50”
12 cm
4.50”
12 cm
4.50”
12 cm
C
59.50”
151 cm
66.50”
169 cm
63.75”
162 cm
74.75”
190 cm
63.75”
162 cm
65.13”
165 cm
65.13”
165 cm
65.75”
167 cm
65.13”
165 cm
65.75”
167 cm
65.75”
167 cm
67.50”
171 cm
D
50.87”
129 cm
57.87”
147 cm
55.13”
140 cm
66.13”
168 cm
55.13”
140 cm
55.87”
142 cm
55.87”
142 cm
57.25”
145 cm
55.87”
142 cm
57.25”
145 cm
57.25”
145 cm
58.25”
148 cm
E f
19”
48 cm
19”
48 cm
19”
48 cm
19”
48 cm
19”
48 cm
23”
58 cm
23”
58 cm
NA
NA
23”
58 cm
NA
NA
NA
NA
23”
58 cm
19.69”
50 cm
19.69”
50 cm
17.75”
45 cm
17.75”
45 cm
17.75”
45 cm
19.75”
50 cm
19.75”
50 cm
20.00”
51 cm
19.75”
50 cm
20.00”
51 cm
20.00”
51 cm
26.75”
68 cm
GAs
INlET
G
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
3/4”
3/4”
3/4”
3/4”
H
51.88”
132 cm
59.00”
150 cm
56.50”
144 cm
67.50”
171 cm
56.50”
144 cm
56.38”
143 cm
56.38”
143 cm
58.8 149 cm
56.38”
143 cm
58.8 149 cm
58.8
149cm
59.00”
150 cm
VeNT
DIA
I
6”
15 cm
6”
15 cm
8”
20 cm
8”
20 cm
6”
15 cm
6”
15 cm
6”
15 cm
6”
15 cm
8”
20 cm
8”
20 cm
8”
20 cm
8”
20 cm
J
27.75”
71 cm
27.75”
71 cm
27.75”
71 cm
27.75”
71 cm
27.75”
71 cm
30.25”
77 cm
30.25”
77 cm
27.75”
70 cm
30.25”
77 cm
27.75”
70 cm
27.75”
70 cm
30.25”
77 cm
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
ToP
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
NA
NA
1.50”
1.50”
NA
NA
NA
NA
1.50”
1.50”
INlET
CoNNECTIoNs oUTlET
Approximate ship. Weight
1.50”
2.00”
2.00”
2.00”
2.00”
1.50”
1.50”
2.00”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
2.00”
1 .50”
1 .50”
1 .50”
1.50”
2.00”
2.00” fRoNT bACK
ToP fRoNT bACK STD.
1.50” 1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
2.00”
2.00”
2.00”
2.00”
1.50”
1.50”
2.00”
2.00”
1.50”
1.50”
1.50”
1.50”
2.00”
2.00”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
NA
NA
1.50”
1.50”
NA
NA
NA
NA
1 .50”
1 .50”
1.50”
1.50”
1.50”
1 .50”
1 .50”
1.50”
1.50”
1.50”
1.50”
1.50”
2.00”
2.00”
2.00”
2.00”
1.50”
1.50”
2.00”
2.00”
1.50”
1.50”
1.50”
1.50”
2.00”
2.00”
400 lBs
182 Kg
470 lBs
213Kq
470 lBs
213Kq
603 lBs
273 Kg
470 lBs
213Kq
630 Ibs
286 Kg
630 Ibs
286 Kg
750 Ibs
341 Kg
630 Ibs
286 Kg
750 Ibs
341 Kg
750 Ibs
341 Kg
760 Ibs
345 Kg
1.50”
1.50”
2.00”
2.00”
2.00”
2.00”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
1.50”
2.00”
2.00”
1.50”
1.50”
1.50”
1.50”
2.00”
2.00”
AsmE
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
725 Ibs
329 Kg
725 Ibs
329 Kg
862 Ibs
391 Kg
725 Ibs
329 Kg
862 Ibs
391 Kg
862 Ibs
391 Kg
874 Ibs
396 Kg
8
installation considerations
moDEl
BTR
120
BTR
154
BTR
180
BTR
197
BTR
198
BTR
199
BTR
200
BTR
250
BTR
251
BTR
275
BTR
305
BTR
365
BTR
400
INPUT
RATE
BTUH
120,000 BTUH
35 Kw/Hr
154,000 BTUH
45 Kw/Hr
180,000 BTUH
53 Kw/Hr
199,000 BTUH
58 Kw/Hr
199,000 BTUH
58 Kw/Hr
199,000 BTUH
58 Kw/Hr
199,000 BTUH
58 Kw/Hr
250,000 BTUH
73 Kw/Hr
251, 000 BTUH
73 Kw/Hr
275,000 BTUH
80 Kw/Hr
305,000 BTUH
89 Kw/Hr
365,000
107 Kw/Hr
390,000 BTUH 1
14 Kw/Hr
APPROX.
GAL.
CAP.
71 Gal
268 l
81 Gal
306 l
81 Gal
306l
100 Gal
379 l
100 Gal
379l
81 Gal
306 l
100 Gal
379 l
100 Gal
379 l
65 Gal
246 l
100 Gal
379 l
65 Gal
246 l
85 Gal
322 l
100 Gal
379 l eFF.
%
80
80
80
80
80
80
80
80
80
80
80
80
80 taBle 2. heater performance data Btr models
2434
643
2434
614
2324
643
2434
808
3059
811
3071
889
3365
ReCOVeRY RATING CAPACITIeS (GPH AND LPH)
30° F 40° F 50° F 60° F 70° F 80° F 90° F 100° F 110° F 120° F 130° F 140° F
17° C 22° C 28° C 33° C 39° C 44° C 50° C 56° C 61° C 67° C 72° C 78° C
388 291 233 194 166 145 129 116 106 97 90 83
1469
498
1885
1102
373
1412
882
299
1132
734
249
943
628
213
806
549
187
708
488
166
628
439
149
564
401
136
515
367
124
469
341
115
435
314
107
405
579
2192
643
434
1643
482
347
1314
386
289
1094
322
248
939
276
217
821
241
193
731
214
174
659
193
158
598
175
145
549
161
134
507
148
124
469
132
986
3732
1180
4466
1825
482
1825
461
1745
482
1825
606
2294
608
2303
667
2524
739
2799
885
3349
1461
386
1461
368
1393
386
1461
485
1835
487
1843
533
2019
592
2239
708
2680
1219
322
1219
307
1162
322
1219
404
1529
406
1536
444
1682
493
1866
590
2233
1045
276
1045
263
996
276
1045
346
1311
348
1316
381
1442
423
1599
506
1914
912
241
912
230
871
241
912
303
1147
304
1152
333
1262
370
1399
442
1675
810
214
810
205
776
214
810
269
1020
270
1024
296
1122
329
1244
393
1489
731
193
731
184
697
193
731
242
918
243
921
267
1009
296
1120
354
1340
662
175
662
167
632
175
662
220
834
221
838
242
918
269
1018
322
1218
609
161
609
154
583
161
609
202
765
203
768
222
841
246
933
295
1116
560
148
560
142
538
148
560
186
706
187
709
205
776
228
861
272
1031
211
800
253
957
500
132
500
132
500
132
500
173
655
174
658
190
721
1293
4894
970
3671
776
2936
646
2447
554
2097
485
1835
431
1631
388
1468
353
1335
323
1224
298
1129
277
1049 moDEl
BTRC
120
BTRC
154
BTRC
180
BTRC
197
BTRC
199
BTRC
200
BTRC
250
BTRC
251
BTRC
275
BTRC
305
BTRC
365
BTRC
400 model
All models
All models
INPUT RATE
BTUH
120,000 BTUH
35 Kw/Hr
154,000 BTUH
45 Kw/Hr
180,000 BTUH
53 Kw/Hr
199,000 BTUH
58 Kw/Hr
199,000 BTUH
58 Kw/Hr
199,000 BTUH
58 Kw/Hr
250,000 BTUH
73 Kw/Hr
251, 000 BTUH
73 Kw/Hr
275,000 BTUH
80 Kw/Hr
305,000 BTUH
89 Kw/Hr
360,000 BTUH
105 Kw/Hr
390,000 BTUH
114 Kw/Hr
Type of Gas
Natural
Propane taBle 3. heater performance data Btrc models
APPROX.
GAL.
CAP.
71 Gal
268 l
81 Gal
306 l
76 Gal
288l
94 Gal
356 l
76 Gal
288 l
100 Gal
379 l
100 Gal
379 l
65 Gal
246 l
100 Gal
379 l
65 Gal
246 l
65 Gal
246 l
100 Gal
379 l eFF.
%
80
80
80
80
80
80
80
80
80
80
80
80
ReCOVeRY RATING CAPACITIeS (GPH AND LPH)
30° F 40° F 50° F 60° F 70° F 80° F 90° F 100° F 110° F 120° F 130° F 140° F
17° C 22° C 28° C 33° C 39° C 44° C 50° C 56° C 61° C 67° C 72° C 78° C
388 291 233 194 166 145 129 116 106 97 90 83
1469
498
1885
579
2192
643
2434
614
2324
643
2434
808
3059
811
1102
373
1412
434
1643
482
1825
461
1745
482
1825
606
2294
608
882
299
1132
347
1314
386
1461
368
1393
386
1461
485
1835
487
734
249
943
289
1094
322
1219
307
1162
322
1219
404
1529
406
628
213
806
248
939
276
1045
263
996
276
1045
346
1311
348
549
187
708
217
821
241
912
230
871
241
912
303
1147
304
488
166
628
193
731
214
810
205
776
214
810
269
1020
270
439
149
564
174
659
193
731
184
697
193
731
242
918
243
401
136
515
158
598
175
662
167
632
175
662
220
834
221
367
124
469
145
549
161
609
154
583
161
609
202
765
203
341
115
435
134
507
148
560
142
538
148
560
186
706
187
314
107
405
124
469
132
500
132
500
132
500
173
655
174
3071
889
3365
986
3732
1164
4405
2303
667
2524
739
2799
873
3304
1843
533
2019
592
2239
698
2643
1536
444
1682
493
1866
582
2202
1316
381
1442
423
1599
499
1888
1152
333
1262
370
1399
436
1652
1024
296
1122
329
1244
388
1468
921
267
1009
296
1120
349
1321
838
242
918
269
1018
317
1201
768
222
841
246
933
291
1101
709
205
776
228
861
269
1016
658
190
721
211
800
249
944
1293
4894
970
3671
776
2936
646
2447
554
2097
485
1835
431
1631
388
1468
353
1335
323
1224
298
1129
277
1049 taBle 4. gas and electrical characteristics
Gas supply Pressure minimum
4.5" W.C. (1.12 kPa)
11.0" W.C. (2.74kPa) maximum
14" W.C. (3.48 kPa)
14" W.C. (3.48kPa)
Gas manifold Pressure
3.5" W.C. (0.87 kPa)
10.0" W.C. (2.49 kPa)
Volts/Hz
120/60
120/60
Amperes
<5
<5
9
installation considerations
locating the water heater
CAUTION
Property Damage Hazard
•
All water heaters eventually leak.
•
Do not install without adequate drainage.
When installing the heater, consideration must be given to proper location. Location selected should be as close to the stack or chimney as practicable, with adequate air supply and as centralized with the piping system as possible.
Flammable items, pressurized containers or any other potential fire hazardous articles must never be placed on or adjacent to the heater. Open containers or flammable material should not be stored or used in the same room with the heater.
The heater must not be located in an area where it will be subject to freezing.
Locate it near a floor drain. The heater should be located in an area where leakage from heater or connections will not result in damage to adjacent area or to lower floors of the structure.
When such locations cannot be avoided, a suitable metal drain pan should be installed under heater. Such pans should be fabricated with sides at least 2” deep, with length and width at least 2” greater than diameter of heater and must be piped to an adequate drain. Pan must not restrict combustion air flow.
Fire or Explosion Hazard
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.
clearances
These heaters are approved for installation on combustible flooring in an alcove when the minimum clearance from combustion or non-combustible construction are followed as indicated in Figure 6 and Table 5.
In all installations the minimum combustible clearances from draft hood surface or vent piping shall be 6” (152mm). Vent piping passing through a combustible wall or ceiling must be a continuous run
(no joints) and retain 6” (152mm) clearance unless an approved reducing thimble is used.
A service clearance of 24” (610mm) should be maintained from serviceable parts, such as relief valves, baffles, thermostats, cleanout openings or drain valves.
taBle 5. installation clearances
Read instruction manual before installing, using or servicing water heater.
a
(right side)
B
(leftside) c
(Back) d
(ceiling)
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 in such areas if they are installed 18” or more above the floor. This may reduce the risk if location in such an area cannot be avoided.
Do not install this water heater directly on a carpeted floor. A fire hazard may result. Instead the water heater must be placed on a metal or wood panel extending beyond the full width and depth by at least 3 inches in any direction. If the heater is installed in a carpeted alcove, the entire floor shall be covered by the panel. Also, see the
DRAINING requirements in MAINTeNANCe Section.
The heater shall be located or protected so it is not subject to physical damage by a moving vehicle.
198
*199
200
250
120
154
*180
*197
251
275
305
**365
400
1” (2.54 cm)
1” (2.54 cm)
1” (2.54 cm)
1” (2.54 cm)
1” (2.54 cm)
1” (2. 54 cm)
1” (2. 54 cm)
2” (5.08 cm)
2” (5.08 cm)
2” (5.08 cm)
2” (5.08 cm)
3” (7.75 cm)
3” (7.75 cm)
1” (2.54 cm)
1” (2.54 cm)
1” (2.54 cm)
1” (2. 54 cm)
1” (2. 54 cm)
1” (2. 54 cm)
1” (2. 54 cm)
2” (5.08 cm)
2” (5.08 cm)
2” (5.08 cm)
2” (5.08 cm)
3” (7.75 cm)
3” (7.75 cm)
1” (2.54 cm)
1” (2.54 cm)
1” (2.54 cm)
1” (2.54 cm)
1” (2.54 cm)
1” (2. 54 cm)
1” (2. 54 cm)
2” (5.08 cm)
2” (5.08 cm)
2” (5.08 cm)
2” (5.08 cm)
3” (7.75 cm)
3” (7.75 cm)
12” (30.48 cm)
12” (30.48 cm)
12” (30.48 cm)
12” (30.48 cm)
12” (30.48 cm)
12” (30.48 cm)
12” (30.48 cm)
12” (30.48 cm)
12” (30.48 cm)
12” (30.48 cm)
12” (30.48 cm)
12” (30.48 cm)
12” (30.48 cm)
* The bTRC version has a 2” (5.08cm) to sides and rear clearance.
** The bTRC version has a 4” (10.16cm) to sides and rear clearance.
10
insulation Blanket nsf leg kit
figure 6.
The NSF Leg Kit (part number 9003425205) is needed only for applications that must conform to NSF/ANSI Standard 5.
Installation of the NSF leg kit will increase the height of the unit and all connection points by 3 inches. See Figure 7.
Follow these steps to install the Leg Kit:
1. Unit needs to be lifted in a way not to damage unit or laid on it’s side to access the bottom of the legs.
2. Slide leg extension under leg and the bolt up through the bottom hole located in the bottom of the leg.
3. Once in place, screw nut down and secure.
4. Front of leg should line up with front of leg extension as shown to make sure weight of unit is distributed through the leg extension.
Breathing Hazard - Carbon Monoxide Gas
Do not obstruct water heater air intake with insulating blanket.
Gas and carbon monoxide detectors are available.
Install water heater in accordance with the instruction manual.
Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.
Insulation blankets are available to the general public for external use on gas water heaters but are not necessary with these products. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. The water heaters covered by this manual meet or exceed the energy
Policy Act standards with respect to insulation and standby heat loss requirements, making an insulation blanket unnecessary.
Should you choose to apply an insulation blanket to this heater, you should follow these instructions. See the Features and Components section of this manual for identification of components mentioned below. Failure to follow these instructions can restrict the air flow required for proper combustion, potentially resulting in fire, asphyxiation, serious personal injury or death.
• do not apply insulation to the top of the water heater, as this will interfere with safe operation of the draft hood.
• do not cover the gas control valve, thermostat or the
Temperature-Pressure Relief Valve.
• do not allow insulation to come within 2” (5 cm) of the burners, to prevent blockage of combustion air flow to the burners.
• do not allow insulation to come within 9 inches (23 cm) of floor, (within 2 inches (5 cm) of bottom cover) to prevent blockage of combustion air flow to the burners..
• do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.
• do obtain new warning and instruction labels from the manufacturer for placement on the blanket directly over the existing labels.
• do inspect the insulation blanket frequently to make certain it does not sag, thereby obstructing combustion air flow.
Where hard water conditions exist, water softening or the threshold type of water treatment is recommended. This will protect the dishwashers, coffee urns, water heaters, water piping and other equipment.
See the Maintenance Section in this manual for sediment and lime scale removal procedures.
figure 7.
11
A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the water heater. See Water Piping Diagrams in this manual for installation location of circulating pumps.
See the Circulation Pump Wiring Diagrams in this manual for electrical hookup information. Install in accordance with the current edition of the National electrical Code, NFPA 70 or the
Canadian electrical Code, CSA C22.1.
All-bronze circulating pumps are recommended for used with commercial water heaters.
Some circulating pumps are manufactured with sealed bearings and do not require further lubrication. Some circulating pumps
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
L2 NEUTRAL
120 VAC
POWER
CIRC
PUMP
MOTOR must be periodically oiled. Refer to the pump manufacturer’s instructions for lubrication requirements.
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
L2 NEUTRAL
120 VAC
POWER figure 8.
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
L2 NEUTRAL
120 VAC
POWER figure 9.
high altitude installations
CIRC
PUMP
MOTOR
CIRC
PUMP
MOTOR
Fire and Explosion Hazard
Under no circumstances should the input exceed the rate shown on the water heater’s rating label.
Overfiring could result in fire or explosion.
Gas and carbon monoxide detectors are available.
CIRCULATING PUMP WIRING DIAGRAM
Breathing Hazard - Carbon Monoxide Gas
DISHWASHER
TOGGLE
SWITCH
Under no circumstances should the input exceed the rate shown on the water heater’s rating label.
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.
Overfiring could result in damage to the water heater and sooting.
L1 HOT Gas and carbon monoxide detectors are available.
Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.
L2 NEUTRAL
Installations above 2000 feet (610 meters) require replacement of burner orifices in accordance with current edition of the National fuel Gas Code (ANsI z 223.1). For
Canadian installations consult Canadian Installations Code
CAN/CsA B
149.1. Failure to replace orifices will result in improper and inefficient operation of the water heater resulting in the production of increased levels of carbon monoxide gas in excess of safe limits which could result in serious personal injury or death.
You should contact your gas supplier for any specific changes which may be required in your area.
As the elevation above sea level is increased, there is less oxygen per cubic foot of air. Therefore, the heater input rate should be reduced at high altitudes for satisfactory operation with the reduced oxygen supply. Failure to make this reduction would result in an over firing of the heater causing sooting, poor combustion and/or unsatisfactory heater performance.
Ratings specified by manufacturers for most appliances apply for elevations up to 2000 feet (610m). For elevations above
2000 feet (610), ratings must be reduced at the rate of 4% for each 1000 feet (305m) above sea level. For example, if a heater is rated at 78,000 btuh (22.9 Kwh) at sea level, to rate the heater at 4000 feet (1219m), you subtract 4 (once for each thousand feet) x.04 (4% input reduction) x 78,000 (original rating) from the original rating.
Therefore, to calculate the input rating at 4,000 feet (1219m):
4 x .04 x 78,000 = 12,480 btuh (3.7 Kwh), 78,000 (22.9 Kwh) -
12,480 (3.7 Kwh) = 65,520 btuh (19.2 Kwh). At 6000 feet (1829m) the correct input rating should be 59,280 btuh (17.4 Kwh).
12
installation reQuirements
gas supply systems
low pressure building gas supply systems are defined as those systems that cannot under any circumstances exceed 14”
W.C. (1/2 PSI Gauge). These systems do not require pressure regulation. Measurements should be taken to insure that gas pressures are stable and fall within the requirements stated on the water heater rating plate. Readings should be taken with all gas burning equipment off (static pressure) and with all gas burning equipment running at maximum rate (dynamic pressure).
The gas supply pressure must be stable within 1.5” W.C. from static to dynamic pressure to provide good performance.
Pressure drops that exceed 1.5” W.C. may cause rough starting, noisy combustion or nuisance outages. Increases or spikes in static pressure during off cycles may cause failure to ignite or in severe cases damage to appliance gas valves. If your low pressure system does NoT meet these requirements, the installer is responsible for the corrections.
High Pressure building supply systems use pressures that exceed 14” W.C. (1/2 PSI Gauge). These systems must use field supplied regulators to lower the gas pressure to less than 14”
W.C. (1/2 PSI Gauge). Water heaters require gas regulators that are properly sized for the water heater input and deliver the rating plate specified pressures. Gas supply systems where pressure exceeds 5 PSI often require multiple regulators to achieve desired pressures. Systems in excess of 5 PSI building pressure should be designed by gas delivery professionals for best performance.
Water heaters connected to gas supply systems that exceed 14”
W.C. (1/2 PSI Gauge) at any time must be equipped with a gas supply regulator.
All models require a minimum gas supply pressure of 4.5" W.C. for natural gas and 11.0" W.C. for propane gas. The minimum supply pressure is measured while gas is flowing (dynamic pressure).
The supply pressure should never fall below 4.5" W.C. for natural gas and 11.0" W.C. for propane gas. The supply pressure should be measured with all gas fired appliances connected to the common main firing at full capacity. If the supply pressure drops more than 1.5” W.C. as gas begins to flow to the water heater then the supply gas system including the gas line and/or the gas regulator may be restricted or undersized. See Supply Gas
Regulator section and Gas Piping section of this manual. The gas valve on all models has a maximum gas supply pressure limit of
14” W.C. The maximum supply pressure is measured while gas is not flowing (static pressure).
supply gas regulator
The maximum allowable gas supply pressure for this water heater is 14 inches W.C. (3.48 kPa). Install a positive lock-up gas pressure regulator in the gas supply line if inlet gas pressure can exceed 14 inches W.C. (3.48 kPa) at any time. Regulators must be sized/used according to manufacturer’s specifications.
If a positive lock-up regulator is required follow these instructions:
1. Positive lock-up gas pressure regulators must be rated at or above
the input btu/hr rating of the water heater they supply.
2. Positive lock-up gas pressure regulator(s) should be installed no closer
than 3 equivalent feet (1 meter) and no farther than 8 equivalent
feet (2.4 meters) from water heater’s inlet gas connection.
3. After installing the positive lock-up gas pressure regulator(s) an
initial nominal supply pressure setting of 7.0” W.C. while the water
heater is operating is recommended and will generally provide good
water heater operation. Some addition adjustment maybe required
later to maintain a steady gas supply pressure.
4. When installing multiple water heaters in the same gas supply
system it is recommended that individual positive lock-up gas
pressure regulators be installed at each unit.
power supply
The water heaters covered in this manual require a 120 VAC,
1Ø (single phase), 60Hz, 15 amp power supply and must also be electrically grounded in accordance with local codes or, in the absence of local codes, with the National electrical Code, ANSI/
NFPA 70 or the Canadian electrical Code, CSA C22.1.
water temperature control and mixing ValVes
Water heated to a temperature which will satisfy clothes washing, dish washing, and other sanitizing needs can scald and cause permanent injury upon contact. Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the water heater’s temperature setting by up to 20°F (11°C).
some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm and the physically/mentally disabled. Table 6 shows approximate time-to-burn relationship for normal adult skin. If anyone using hot water provided by the water heater being installed fits into one of these groups or if there is a local code or state law requiring a certain water temperature at the point of use, then special precautions must be taken.
In addition to using the lowest possible temperature setting that satisfies the demand of the application a Mixing Valve should be installed at the water heater (see figure 10) or at the hot water taps to further reduce system water temperature.
Mixing valves are available at plumbing supply stores. Consult a
Qualified Installer or Service Agency. Follow mixing valve manufacturer’s instructions for installation of the valves.
Water Temperature °F
Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death.
Children, the elderly and the physically or mentally disabled are at highest risk for scald injury.
Feel water before bathing or showering.
Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at fixtures.
taBle 6.
Time for 1st Degree Burn
(Less Severe burns)
Time for Permanent Burns
2nd & 3rd Degree
(Most Severe burns)
110
116
116
(normal shower temp.)
(pain threshold)
35 minutes 45 minutes
122 1 minute 5 minutes
131
140
149
154
5 seconds
2 seconds
1 second instantaneous
25 seconds
5 seconds
2 seconds
1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978)
13
HOT WATER
OUTLET
12” TO 15”
(30-38 cm)
TEMPERED WATER
OUTLET
A properly sized thermal expansion tank must be installed on all closed systems to control the harmful effects of thermal expansion. Contact a local plumbing service agency to have a thermal expansion tank installed.
See Water Line Connections on page 21 and the Water Piping
Diagrams beginning on page 40.
temperature-pressure relief ValVe
COLD
WATER
INLET
CHECK
VALVE
CHECK
VALVE
MIXING
VALVE
TO TANK
INLET
Explosion Hazard
Temperature-Pressure Relief Valve must comply with ANSI Z21.22-
CSA 4.4 and ASME code.
figure 10.
Properly sized temperaturepressure relief valve must be installed in opening provided.
dishwashing machines
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 (103 kPa and 173 kPa). Flow pressures above 25 pounds per square inch
(173 kPa), or below 15 pounds per square inch (103 kPa), 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 (82°C) line to the dishwashing machine and should be adjusted to deliver water pressure between these limits.
The National Sanitation Foundation also recommends circulation of 180°F (82°C) water. The circulation flow rate should be just enough to provide 180°F (82°C) water at the point of take-off to the dishwashing machine.
Adjust flow by throttling a full port ball valve installed in the circulating line on the outlet side of the pump. Never throttle flow on the suction side of a pump. See Water Piping Diagrams in this manual.
note: These water heaters meet the Nsf standard 5 for sanitary installations when used with the leg kit part number
9003425205.
closed water systems
Water supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure reducing valves, check valves, and back flow preventers. Devices such as these cause the water system to be a closed system.
thermal expansion
As water is heated, it expands (thermal expansion). In a closed system the volume of water will grow when it is heated. As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent Temperature-Pressure Relief Valve operation: water discharged from the valve due to excessive pressure build up. This condition is not covered under the limited warranty. The Temperature-Pressure Relief Valve is not intended for the constant relief of thermal expansion.
Can result in overheating and excessive tank pressure.
Can cause serious injury or death.
This water heater is provided with a properly rated/sized and certified combination Temperature-Pressure Relief Valve (T&P valve) by the manufacturer. The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for
Pressure Relief Valves for Hot Water Supply Systems, ANSI Z21.22
• CSA 4.4, and the code requirements of ASMe.
If replaced, the new T&P valve must meet the requirements of local codes, but not less than a combination Temperature-
Pressure Relief Valve rated/sized and certified as indicated in the above paragraph. The new valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (150 psi = 1,035 kPa) and a discharge capacity not less than the water heater btu/hr or kW input rate as shown on the water heater’s model rating label.
NOTe: In addition to the factory installed Temperature-Pressure
Relief Valve on the water heater, each remote storage tank that may be installed and piped to a water heating appliance must also have its own properly sized, rated and approved Temperature-
Pressure Relief Valve installed. Call the toll free technical support phone number listed on the back cover of this manual for technical assistance in sizing a Temperature-Pressure Relief
Valve for remote storage tanks.
for safe operation of the water heater, the Temperature-Pressure
Relief Valve must not be removed from its designated opening nor plugged. The Temperature-Pressure Relief Valve must be installed directly into the fitting of the water heater designed for the pressure relief valve . Install discharge piping so that any discharge will exit the pipe within 6 inches (15.2 cm) above an adequate floor drain, or external to the building. In cold climates it is recommended that it be terminated at an adequate drain inside the building. be certain that no contact is made with any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstances. excessive length, over 30 feet (9.14 m), or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve.
14
No valve or other obstruction is to be placed between the
Temperature-Pressure Relief Valve and the tank. Do not connect discharge piping directly to the drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in adequate quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water flow may cause property damage.
CAUTION
Water Damage Hazard
•
Temperature-Pressure Relief Valve discharge pipe must terminate at adequate drain.
contaminated air
Breathing Hazard - Carbon Monoxide Gas
Install water heater in accordance with the Instruction Manual and NFPA 54 or
CAN/CSA-B149.1.
To avoid injury, combustion and ventilation air must be taken from outdoors.
Do not place chemical vapor emitting products near water heater.
Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.
t&p Valve discharge pipe requirements:
• shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both the Temperature-Pressure Relief Valve and the discharge pipe.
• Must terminate a maximum of six inches above a floor drain or external to the building. In cold climates, it is recommended that the discharge pipe be terminated at an adequate drain inside the building.
• Shall not have any valve or other obstruction between the pressure relief valve and the drain.
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.
Combustion air that is contaminated can greatly diminish the life span of the water heater and water heater components such as hot surface igniters and burners. Propellants of aerosol sprays, beauty shop supplies, water softener chemicals and chemicals used in dry cleaning processes that are present in the combustion, ventilation or ambient air can cause such damage.
Do not store products of this sort near the water heater. Air which is brought in contact with the water heater should not contain any of these chemicals. If necessary, uncontaminated air should be obtained from remote or outdoor sources. The limited warranty is voided when failure of water heater is due to a corrosive atmosphere. (See limited warranty for complete terms and conditions).
air reQuirements
Burn hazard.
Hot water discharge.
Breathing Hazard - Carbon Monoxide Gas
Keep clear of Temperature-
Pressure Relief Valve discharge outlet.
Install water heater in accordance with the Instruction Manual and NFPA 54 or
CAN/CSA-B149.1.
To avoid injury, combustion and ventilation air must be taken from outdoors.
Do not place chemical vapor emitting products near water heater.
The Temperature-Pressure Relief Valve must be manually operated at least twice a year. Caution should be taken to ensure that (1) no one is in front of or around the outlet of the Temperature-Pressure
Relief Valve discharge line, and (2) the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot. If after manually operating the valve, it fails to completely reset and continues to release water, immediately close the cold water inlet to the water heater, follow the draining instructions in this manual, and replace the Temperature-
Pressure Relief Valve with a properly rated/sized new one.
note:
The purpose of a Temperature-Pressure Relief Valve is to prevent excessive temperatures and pressures in the storage tank.
The T&P valve is not intended for the constant relief of thermal expansion. A properly sized thermal expansion tank must be installed on all closed systems to control thermal expansion, see
Closed Water Systems and Thermal expansion on page 14.
If you do not understand these instructions or have any questions regarding the Temperature-Pressure Relief Valve call the toll free number listed on the back cover of this manual for technical assistance.
15
Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.
For safe operation an adequate supply of fresh uncontaminated air for combustion and ventilation must be provided.
An insufficient supply of air can 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 sooting of the combustion chamber, burners and flue tubes and creates a risk of asphyxiation.
Do not install the water heater in a confined space unless an adequate supply of air for combustion and ventilation is brought in to that space using the methods described in the Confined
Space section that follows.
Never obstruct the flow of ventilation air. If you have any doubts or questions at all, call your gas supplier. Failure to provide the proper amount of combustion air can result in a fire or explosion and cause property damage, serious bodily injury or death.
unconfined space
An Unconfined Space is one whose volume IS NOT LeSS THAN
50 cubic feet per 1,000 btu/hr (4.8 cubic meters per kW) of the total input rating of all appliances installed in the space. Rooms communicating directly with the space, in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconfined space.
makeup air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers and fireplaces shall also be considered in determining the adequacy of a space to provide combustion, ventilation and dilution air.
unusually tight construction
In unconfined spaces in buildings, infiltration may be adequate to provide air for combustion, ventilation and dilution of flue gases. However, in buildings of unusually tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.) additional air must be provided using the methods described in the Confined Space section that follows.
confined space
A Confined Space is one whose volume is less than 50 cubic feet per 1,000 btu/hr (4.8 cubic meters per kW) of the total input rating of all appliances installed in the space.
Openings must be installed to provide fresh air for combustion, ventilation and dilution in confined spaces. The required size for the openings is dependent on the method used to provide fresh air to the confined space and the total btu/hr input rating of all appliances installed in the space.
direct Vent appliances
Appliances installed in a Direct Vent configuration that derive all air for combustion from the outdoor atmosphere through sealed intake air piping are not factored in the total appliance input btu/ hr calculations used to determine the size of openings providing fresh air into confined spaces.
exhaust fans
Where exhaust fans are installed, additional air shall be provided to replace the exhausted air. When an exhaust fan is installed in the same space with a water heater, sufficient openings to provide fresh air must be provided that accommodate the requirements for all appliances in the room and the exhaust fan.
Undersized openings will cause air to be drawn into the room through the water heater’s vent system causing poor combustion.
Sooting, serious damage to the water heater and the risk of fire or explosion may result. It can also create a risk of asphyxiation.
louVers and grilles
The free areas of the fresh air openings in the instructions that follow do not take in to account the presence of louvers, grilles or screens in the openings.
The required size of openings for combustion, ventilation and dilution air shall be based on the “net free area” of each opening.
Where the free area through a design of louver or grille or screen is known, it shall be used in calculating the size of opening required to provide the free area specified. Where the louver and grille design and free area are not known, it shall be assumed that wood louvers will have 25% free area and metal louvers and grilles will have 75% free area. Non motorized louvers and grilles shall be fixed in the open position.
Venting installation
Venting
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.
Remove all soot or other obstructions from the chimney that will retard a free draft.
Type b venting is recommended with these heaters. For typical venting application see TeCHNICAL DATA VeNTING on pages 19 and 20.
This water heater must be vented in compliance with all local codes, the current revision of the National Fuel Gas Code (ANSI-Z223.1) and with the Category I Venting Tables.
If any part of the vent system are exposed to ambient temperatures below 40°F it must be insulated to prevent condensation.
• Do not connect the heater to a common vent or chimney with solid fuel burning equipment. This practice is prohibited by many local building codes as is the practice of venting gas fired equipment to the duct work of ventilation systems.
• Where a separate vent connection is not available and the vent pipe from the heater must be connected to a common vent with an oil burning furnace, the vent pipe should enter the smaller common vent or chimney at a point above the large vent pipe.
Vent reducer
Model bTR 120 is shipped with a 6" to 5" flue outlet adapter. Models bTR 250, 251 and 275 are shipped with a 8" to 6" flue outlet adapter.
each adapter fits on top of the installed flue damper. Use only vent reducers supplied with the unit. The venting must comply with the current editions of the NATIONAL FUeL GAS CODe, ANSI Z223.1/
NfPA 54 or NATURAl GAs AND PRoPANE INsTAllATIoN CoDE
CAN/CSA-b149.1
figure 11.
figure 12.
16
multiple heater manifold
figure 13 and tables on pages 19 and 20 should be used for horizontally manifolding two or more heaters.
outdoor air through one opening
figure 13.
fresh air openings for confined spaces
The following instructions shall be used to calculate the size, number and placement of openings providing fresh air for combustion, ventilation and dilution in confined spaces. The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only. DO NOT refer to these illustrations for the purpose of vent installation. See Venting Installation on page 16 for complete venting installation instructions.
figure 15.
Alternatively a single permanent opening, commencing within 12 inches (300 mm) of the top of the enclosure, shall be provided.
See Figure 14. The water heater shall have clearances of at least 1 inch (25 mm) from the sides and back and 6 inches (l50 mm) from the front of the water heater. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of the following:
1. 1 square inch per 3000 btu/hr (733 mm
2 per kW) of the total input rating of all appliances located in the enclosure, and
2. Not less than the sum of the areas of all vent connectors in the space.
outdoor air through two horiZontal ducts outdoor air through two openings
figure 16.
figure 14.
The confined space shall be provided with two permanent openings, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The openings shall communicate directly with the outdoors. See Figure 14.
each opening shall have a minimum free area of 1 square inch per 4,000 Btu/hr (550 mm 2 per kW) of the aggregate input rating of all appliances installed in the enclosure. each opening shall not be less than 100 square inches (645 cm
2
).
17
The confined space shall be provided with two permanent horizontal ducts, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The horizontal ducts shall communicate directly with the outdoors. See Figure 16.
each duct opening shall have a minimum free area of 1 square inch per 2,000 btu/hr (1100 mm
2 per kW) of the aggregate input rating of all appliances installed in the enclosure.
When ducts are used, they shall be of the same cross sectional area as the free area of the openings to which they connect.
The minimum dimension of rectangular air ducts shall be not less than 3 inches.
outdoor air through two Vertical ducts
The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only.
do not
refer to these illustrations for the purpose of vent installation. See Venting Installation on page 14 for complete venting installation instructions.
When ducts are used, they shall be of the same cross sectional area as the free area of the openings to which they connect.
The minimum dimension of rectangular air ducts shall be not less than 3 inches.
air from other indoor spaces
figure 17.
The confined space shall be provided with two permanent vertical ducts, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The vertical ducts shall communicate directly with the outdoors. See Figure 17.
each duct opening shall have a minimum free area of 1 square inch per 4,000 btu/hr (550 mm
2 per kW) of the aggregate input rating of all appliances installed in the enclosure. figure 18.
The confined space shall be provided with two permanent openings, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. See Figure 18.
each opening shall communicate directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an Unconfined Space.
each opening shall have a minimum free area of 1 square inch per 1,000 Btu/hr (2200 mm 2 per kW) of the aggregate input rating of all appliances installed in the enclosure. each opening shall not be less than 100 square inches (645 cm
2
).
18
taBle 7. technical data Venting
type B gas Vent multiple gas fired tank-type heaters
When venting multiple tank type heaters using Type b vent pipe, follow the installation diagram (figure 13) and tables below which give sizing and data based upon NFPA 54/ANSI
Z223. 1992. model Btr(c)-120 input: 120,000 Btuh total Vent height (feet) draft hood: 5” 6 8 input Btuh
120,000
120,000
120,000 rise
1 Ft.
2 Ft.
3 Ft.
7
6
6
7
6
6 number of heaters combined input in thousands of Btuh
10
7
6
6
15
Vent Connector Diameter (inches)
6
6
6
20
6
6
6
30
6
6
5 manifold and common Vent diameter (in inches)
2
3
4
240
360
480
10
10
12
8
10
12 model Btr(c)-154 input: 154,000 Btuh total Vent height (feet)
8
10
12
7
10
10
7
8
10
7
8
10 draft hood: 6” input Btuh
154,000
154,000
6 8 10 15 20 30 rise Vent connector diameter (in inches)
1 Ft.
2 Ft.
3 Ft.
8
7
7
8
7
7
7
7
7
7
7
6
7
7
6
7
6
6 numbers of heaters
2
3
4
154,000 combined input in thousands of Btuh
308
462
616 manifold and common Vent diameter (in inches)
10
12
14
10
12
14
10
12
12
8
10
12
8
10
12
7
10
10
50
50
6
7
8
7
8
1
6
6
5
7
6
6 model Btr(c)-180, 197, 198, 199, 200 input: 180,000, 199,000 Btuh total Vent height (feet) draft hood: 6” number of heaters
2
3
4 input Btuh
180,000
199,000
180,000
199,000
180,000
199,000 combined input in thousands of Btuh
360
398
540
597
720
796
6
10
12
14
14
14
16
8
10
10
12
14
14
14
10
10
10
12
12
14
14
15
10
10
12
12
12
14
20
8
10
10
12
12
12
30 rise Vent connector diameter (in inches)
1 Ft.
8 8 8 8 8 7
8 8 8 8
2 Ft.
8 8 7 7 7 7
8 8 8 8 7 7
3 Ft.
7 7 7 7 7 7
8 8 7 7 7 7 manifold & common Vent diameter
8
8
10
10
12
12
50
7
8
10
10
10
12
7
6
7
7
8
7
7
8
10
7
7
8
100
7
6
6
7
7
7
100
6
5
5
10
10
10
7
7
8
100
7
6
6
19
20
mechanical Venting
single unit installation
When mechanical venting of these heaters is desired, the following kits are available.
models 120 through the 200/A
A. O. Smith part number 9005381205 models 250/A through the 400/A
A. O. Smith part number 9003434205
Where an approved power venter is to be installed to operate in conjunction with the water heater thermostat, the following codes must be adhered to. Field wiring should conform to the current edition of the National electrical Code NFPA 70.
For Canadian installations the electrical connections and grounding shall be done in accordance with the current edition of the Canadian electrical Code CSA C22.1 and/or local codes.
Vent installation
Seal all joints between the power venter and the vent termination. This is to prevent leakage of exhaust products into the room(s) due to positive pressure of blower.
The “Sequence of Operation” description will be the same with mechanical venting except;
When the water heater thermostat calls for heat:
Thermostat contacts “Close” and the power venter blower
(120 VAC) is energized. Sufficient draft must be established for the “Draft Prover Switch (N.O.)” to “Close”. When the draft prover switch “Closes” the relay coil of the flue damper is energized.
multiple unit installation
For multiple unit installations, contact A. O. Smith, Technical
Support Center at 1-800-527-1953.
water heater installation
water line connections
The water piping installation must conform to these instructions and to all local code authority having jurisdiction. Good practice requires that all heavy piping be supported.
Read and observe all requirements in the following sections before installation of the water piping begins:
1. Water Temperature Control and Mixing Valves on page 13.
2. Dishwashing Machines on page 14.
3. Temperature-Pressure Relief Valve on page 14-15.
4. Closed Systems and Thermal expansion on page 14.
5. for multiple water heater installations see Water Piping
Diagrams beginning on page 40.
water (potaBle) heating and space heating
1. All piping components connected to this unit for space heating applications shall be suitable for use with potable water.
2. Toxic chemicals, such as those used for boiler treatment, shall NeVeR be introduced into this system.
3. This unit may NeVeR be connected to any existing heating system or component(s) previously used with a non-potable water heating appliance.
4. When the system requires water for space heating at temperatures higher than required for domestic water purposes, a tempering valve must be installed. Please refer to installation diagrams beginning on page 40 of this manual for suggested piping arrangements.
5. These water heaters cannot be used in space heating applications only water piping diagrams
This manual provides detailed water piping diagrams for typical methods of application for the water heaters, see Water Piping
Diagrams beginning on page 40.
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. Adjust flow by throttling a full port ball valve installed in the circulating line on the outlet side of the pump. Never throttle flow on the suction side of a pump. See the Water Piping Diagrams beginning on page 40.
note:
In addition to the factory installed Temperature-Pressure
Relief Valve (T&P valve) on the water heater, each remote storage tank that may be installed and piped to a water heating appliance must also have its own properly sized, rated and approved Temperature-Pressure Relief Valve installed.
Call the toll free technical support phone number listed on the back cover of this manual for further assistance in sizing a T&P valve for remote storage tanks.
t&p ValVe discharge pipe
Explosion Hazard
Temperature-Pressure Relief Valve must comply with ANSI Z21.22-
CSA 4.4 and ASME code.
Properly sized temperaturepressure relief valve must be installed in opening provided.
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 of detecting the temperature of the outlet water supply.
Can result in overheating and excessive tank pressure.
Can cause serious injury or death.
21
This water heater is provided with a properly rated/sized and certified combination temperature - pressure (T&P) relief valve by the manufacturer. See Temperature-Pressure Relief Valve on pages
14-15 for information on replacement and other requirements.
CAUTION
Water Damage Hazard
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both
Temperature-Pressure Relief Valve and the discharge pipe.
• Must terminate a maximum of six inches above a floor drain or external to the building. In cold climates, it is recommended that the discharge pipe be terminated at an adequate drain inside the building.
• Shall not have any valve or other obstruction between the relief valve and the drain.
•
Temperature-Pressure Relief Valve discharge pipe must terminate at adequate drain.
Install a discharge pipe between the T&P valve discharge opening and a suitable floor drain. Do not connect discharge piping directly to the drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in adequate quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water flow may cause property damage.
t&p ValVe discharge pipe reQuirements:
• shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
installation diagrams - top inlet/outlet usage
Use of the top inlet water connection requires an inlet dip tube
(refer to figure 19). The tube is supplied in the heater. Follow caution labels if applying heat to this fitting. Do not allow pipe dope to contact the plastic tube during installation.
tuBe inlet installation figure 19.
22
heater wiring
All electrical work must be installed in accordance with the current edition of the National electrical Code ANSI/NFPA No. 70 or Canadian electrical
Code CSA C22.1 and must conform to all local code authority having jurisdiction. AN eLeCTRICAL GROUND IS ReQUIReD TO ReDUCe RISK OF eLeCTRICAL SHOCK OR POSSIbLe eLeCTROCUTION.
If any of the original wire as supplied with the water heater must be
replaced, use only type 105°C thermoplastic or equivalent 250
0 C type f must be used for the flame sensor and igniter leads.
The controls of this water heater are polarity sensitive. be certain to properly wire the hot and neutral connections.
1 3
4 2
DAMPER
DRIVE
Y
BLK
11E79
LINE
IN
ON/OFF
SWITCH
X
R LOWER
PROBE
4
3
2
1
W
BLK
BLK
W
120 vac
NEUTRAL
PV
MV/PV
UPPER
PROBE/ECO
W
PV
MV
TH TR
PROPANE
GAS
VALVE
MV
R
BLK
BL
LEGEND:
W--WHITE
BLK--BLACK
BL--BLUE
R--RED
Y--YELLOW
W
HONEYWELL IGNITION
Y
C
P
M
NATURAL
GAS
VALVE
BL
FACTORY WIRED
BY INSTALLER
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED MUST BE REPLACED, USE ONLY TYPE 105 O
THERMOPLASTIC OR EQUIVALENT. FLAME SENSOR IGNITION CABLE MUST BE 250 O
C
C TYPE F.
197287-000 REV 02 figure 20.
23
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 8. 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: Fittings such as elbows, tees and line regulators will add to the pipe pressure drop.
Also refer to the latest version of the National Fuel Gas Code.
Schedule 40 Steel or Wrought Iron Pipe is the preferred material for the gas line of this water heater. It is imperative to follow the sizing recommendations in the latest version of the National Fuel
Gas Code if Corrugated stainless steel Tubing (CssT) is used as the gas line for this water heater.
The heater is not intended for operation at higher than 14.0" W.C.- natural gas, (1/2 pound per square inch gage) supply gas pressure. exposure to higher supply pressure may cause damage to the gas valve 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.
taBle 8. gas supply pipe lengths (in feet) maximum equivalent pipe length - natural gas only
Input rate
(BTU/HR)
120,000
154,000
180,000
199,000
250,000
275,000
310,000
366,000
1/2"
20
10
-
-
-
-
-
-
Schedule 40 Steel or Wrought Iron Pipe
3/4"
70
40
30
30
20
10
10
-
1"
200
150
100
90
60
50
40
30
1 1/4"
200
200
200
200
200
200
150
100
390,000 -
1.0
2.1
20 equivalent length in feet
100 fitting Type*
45°ell
90°ell
Tee
3.1
4.1
5.2
6.9
Natural Gas 0.60 Specific Gravity, 0.50" W.C. Pressure Drop
*Screwed Fittings
0.7
1.6
1.2
2.6
1.6
3.5
1 1/2"
200
200
200
200
200
200
200
200
200
1.9
4.0
8.0
It is important to guard against gas valve fouling from contaminants in gas ways. Such fouling 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 sediment trap must be incorporated in the piping (see Figure 21). The sediment trap must be readily accessible and not subject to freezing conditions.
Install in accordance with recommendations of serving gas suppliers.
Refer to the latest version of the National Fuel Gas Code.
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 compounds to the first two threads.
Use compounds resistant to the action of liquefied petroleum gases.
gas meter siZe – natural gases only be sure the gas meter has sufficient capacity to supply the full rated gas input of the water heater as well as the requirements of all other gas fired equipment supplied by the meter. If gas meter is too small, ask the gas company to install a larger meter having adequate capacity.
gas piping and sediment trap installation
gas line leak testing
Any time work is done on the gas supply system perform a leak test to avoid the possibility of fire or explosion.
1. For test pressures exceeding 1/2 psi (3.45 kPa) disconnect the water heater and its Main Gas Shutoff Valve from the gas supply piping system during testing, see Figure 21. The gas supply line must be capped when disconnected from the water heater.
2. For test pressures of 1/2 psi (3.45 kpa) or less, the water heater need not be disconnected, but must be isolated from the supply gas line by closing the Main Gas Shutoff Valve during testing.
3. Coat all supply gas line joints and connections upstream of the water heater with a non-corrosive soap and water solution to test for leaks. bubbles indicate a gas leak. Do not use matches, candles, flame or other sources of ignition for this purpose.
4. Repair any leaks before placing the water heater in operation.
purging
figure 21.
Fire and Explosion Hazard
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.
Gas line purging is required with new piping or systems in which air has entered.
Purging should be performed per the current edition of NFPA 54 the
National Fuel Gas Code.
24
operation
Fire or Explosion Hazard
Gas line purging is required with new piping or systems in which air has entered.
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.
Light the water heater in accordance with the Lighting and
Operation Instruction label on the water heater and in this manual on pages 27 and 28.
The water heaters covered by this manual are equipped with an electronic control system that automatically sequences the Igniter, the 24 VAC Gas Valve, the burner ignition, and flame sensing. before attempting start up, thoroughly study and know the exact
Sequence Of Operation. See written Sequence Of Operation on page 25 and Sequence Of Operation Flow Chart on page 26.
be certain that the water heater is full of water, that air is purged from the gas and water lines and that there are no leaks in the gas and water lines. ensure all inlet water valves are open.
Read instruction manual before installing, using or servicing
prior to start up
water heater.
Installation and start up of this water heater requires abilities and skills equivalent to that of a licensed tradesman in the field involved, see Qualifications on page 6.
Do not place the water heater in operation if any part has been under water. Immediately call a qualified service technician to inspect the water heater and to replace any part of the control system and any gas control which has been under water. filling the water heater
Follow these steps to fill the water heater prior to start up.
1. Close the heater drain valve.
2. Open a nearby hot water faucet to permit air in system to escape.
3. Fully open the cold water inlet valve allowing the piping and
water heater to fill with water.
4. Close hot water faucet opened in Step 2 as water starts to flow.
Read SeQUeNCe OF OPeRATION section of this manual prior to lighting and operating this water heater.
With above conditions satisfied, start the unit in accordance with the instructions on the operating label attached to the heater.
For your convenience a copy of the instructions are shown on pages 27 and 28.
seQuence of operation
The following information will describe the Sequence of Operation for this water heater.
1. Switch power on to unit.
2. Thermostat calls for heat.
3. Ignition Control performs diagnostic self check on system components.
4. The Ignition Control begins the trial for ignition.
5. The Ignition Control turns on the Spark Igniter and opens the Pilot
Gas Valve.
6. The Ignition Control monitors the Flame Sensor during the ignition trial period.
7. If the Ignition Control does not sense the pilot flame during the ignition trial period, the Ignition Control shuts the Pilot Gas
Valve and turns off the Spark Igniter. Depending on the water heater model, the Ignition Control will either retry the ignition trial at step 4 or lockout the ignition sequence. If the ignition sequence is locked out, the power to the unit must be cycled to restart the
Ignition Control.
8. If the pilot flame is proved during the ignition trial period, the
Ignition Control turns off the spark Ignitor and opens the main
Gas Valve.
9. The Ignition Control allows a 2 second pilot flame stabilization period to insure that the pilot flame is not extinguished by the main burner light-off process.
10. The Ignition Control monitors the Flame Sensor during the heating cycle. If the flame signal is lost, the Ignition Control shuts the Main Gas Valve and Pilot Gas Valve and re-starts the ignition process at step 4.
11. Once the unit is satisfied, the Ignition Control will shut off the
Main Gas Valve and the Pilot Gas Valve and the unit will be in standby mode until another call for heat is initiated by the thermostat.
See the flow chart on page 26 for more information.
25
seQuence of operation flow chart
Description of this flow chart can be found in the “SeQUeNCe OF OPeRATION” section found on page 25.
IDLE
(NOT POWERED)
“CALL FOR HEAT”
RECEIVED FROM
THERMOSTAT
POWER TO
MODULE AND
SELF CHECK
WAIT FOR
“CALL FOR HEAT”
TO BE REMOVED
ACTIVATE ALARM
CONTACT(S)
(OPTIONAL)
A
RETRY DELAY
(5 MINUTES)
TRIAL FOR
IGNITION
(TIMER STARTED)
SPARK ON
OPEN PILOT GAS
VALVE
RETRY
FLAME
PROVED?
NO CLOSE PILOT
GAS VALVE
SPARK OFF
YES
(BEFORE TRIAL FOR IGNITION TIMER EXPIRES)
SPARK OFF
OPEN MAIN GAS
VALVE
FLAME
STABILIZATION
(2 SECONDS)
RUN
RETRY OR
LOCKOUT
MODEL?
NO
“CALL
FOR HEAT”
ENDS?
NO
YES
CLOSE MAIN GAS
VALVE AND PILOT
GAS VALVE
FLAME
LOST?
YES
CLOSE MAIN GAS
VALVE AND PILOT
GAS VALVE
LOCKOUT
A flowchart 1.
26
lighting & operation laBel
for your safety read Before operating operating instructions for your safety read Before operating
figure 22. laBel for natural gas models
27
for your safety read Before operating operating instructions to turn off gas to appliance
figure 23. laBel for propane gas models
28
adjustments
ON INITIAL STARTUP SOMe ADJUSTMeNTS MAY be NeCeSSARY.
Check Manifold and inlet gas pressures (see GAS SUPPLY
SYSTeMS on page 13 and CHeCKING THe INPUT on page 29-30.)
Check Pilot burner (See Pilot burner section on page 34.)
TEsTING DAmPER oPERATIoN
With the Service Switch in the AUTOMATIC OPeRATION position, check the operation of the flue damper three (3) times with the water operating controls for proper operating sequence:
• The damper disc must be open (in the vertical position) before the ignition and combustion process begins.
• The damper disc must be in the open position when the main burner is firing.
• The gas control valve must close and the main burner must have ceased firing before the damper disc begins its return to the closed (horizontal) position.
If during testing of the operation of the damper you find that there is a problem with the operation of the water heater when the Service Switch is in the AUTOMATIC OPeRATION position:
Reset the Service Switch to the HOLD OPeN DAMPeR position and check operation again.
If the water heater does operate when placed in the HOLD OPeN
DAMPeR position:
• Refer to the eFFIKAL RVGP-FSF-SeRIeS TROUbLeSHOOTING
GUIDe on page 37.
If the water heater does not operate with the Service Switch in either position:
• Refer to the Troubleshooting Sections and Troubleshooting
Checklist.
checking Venting
The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation.
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1or the CAN/
CGA b149 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.
3. So far as is practical, close all building doors and windows and all doors between the space in which the water heater(s) connected to the venting system are located and other spaces of the building. Turn on all appliances not connected to the venting system. Turn on all exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Close fireplace dampers.
4. Follow the lighting instruction. Place the water heater being inspected in operation. Adjust thermostat so water heater shall operate continuously.
5. Test for draft hood spillage at the relief opening after 5 minutes of main burner operation.
6. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use.
7. If improper venting is observed during any of the above tests, the venting system must be corrected.
29
FAILURe TO CORReCT bACK DRAFTS MAY CAUSe AIR
CONTAMINATION AND UNSAFe CONDITIONS.
• If the back draft cannot be corrected by the normal method or if a suitable draft cannot be obtained, a blower type flue gas exhauster must be employed to ass ure proper venting and correct combustion.
checking the input
For installation locations with elevations above 2000 feet, refer to HIGH ALTITUDe INSTALLATIONS section of this manual for input reduction procedure.
1. Attach a pressure gauge or a manometer to the manifold pressure tap on the gas control valve and refer to Table
9, for correct manifold pressure.
2. Use this formula to “clock” the meter. be sure that other gas consuming appliances are not operating during this interval.
(3600/T) x H = btuh
T = Time in seconds to burn one cubic foot of gas.
H = btu’s per cubic foot of gas.
btuh = Actual heater input.
example: (Using bTR-250 heater)
T = 15.1 seconds
H = 1050 btu
btuh = ?
(3600/15.1) x 1050 = 250,000 (Compare with BTR-250 model and rating.) taBle 9.
approximate time reQuired to consume
1 cu. ft. of gas at full capacity input rate
(Btuh)
120,000
154,000
180,000
199,000
250,000
251,000
275,000
305,000
365,000
390,000 type of gas
NATURAl
PRoPANE
NATURAl
PRoPANE
NATURAl
PRoPANE
NATURAl
PRoPANE
NATURAl
PRoPANE
NATURAl
PRoPANE
NATURAl
PRoPANE
NATURAl
PRoPANE
NATURAl
PRoPANE
NATURAl
PRoPANE
Btuh per cu. ft.
1050
2500
1050
2500
1050
2500
1050
2500
1050
2500
1050
2500
1050
2500
1050
2500
1050
2500
1050
2500 time reQ’d to consume 1 cu. ft. of gas
31. 5 SeC.
75.0 SeC.
24.5 SeC.
58.4 SeC.
21.0 SeC.
50.0 SeC.
19.0 SeC.
45.2 SeC.
15.1 SeC.
36.0 SeC.
15.1 SeC.
35.9 SeC.
13.7 SeC.
32.7 SeC.
12.4 SeC.
29.5 SeC.
10.4 SeC.
24.7 SeC.
9.7 SeC.
23.1 SeC.
Should it be necessary to adjust the gas pressure to the burners to obtain the full input rate, the steps below should be followed:
3. Remove the regulator adjustment sealing cap and adjust the pressure by turning the adjusting screw with a screwdriver. See Figure 24.
Clockwise to increase gas pressure and input rate.
Counterclockwise to decrease gas pressure and input rate.
4. “Clock” the meter as in step 2 above.
5. Repeat steps 3 and 4 until the specified input rate is achieved.
6. Turn the gas control knob to PILOT. Remove the pressure gauge and replace the sealing cap and the Allen wrench set screw in the pressure tap opening.
figure 24.
UNDER No CIRCUmsTANCEs sHoUlD THE GAs INPUT EXCEED
THE INPUT sHoWN oN THE HEATER moDEl AND RATING
PLATe. OVeRFIRING COULD ReSULT IN DAMAGe OR SOOTING
OF THe HeATeR.
30
maintenance
Venting system
examine the venting system every six months for obstructions and/or deterioration of the vent piping.
Remove all soot or other obstructions from chimney which will retard free draft.
remote storage tank temperature control
The water temperature in the remote storage tank (if used) is controlled by the storage tank temperature control. The sensing element is mounted in the hot water storage tank, see Water
Piping Diagram section.
A change in water temperature in the storage tank lower than the tank temperature control setting will cause the sensor to activate the circulating pump. The pump then circulates the water through the heater where the thermostat senses the drop in water temperature and activates main burner operation of the water heater.
If the storage tank temperature control is out of calibration, replace with new control.
SHOULD OVeRHeATING OCCUR OR THe GAS SUPPLY FAIL
TO SHUT OFF, TURN OFF THe MANUAL GAS CONTROL VALVe
To THE WATER HEATER
.
temperature-pressure relief ValVe test
figure 25.
If the Temperature-Pressure Relief Valve on water heater weeps or discharges periodically, this may be due to thermal expansion.
NOTe: excessive water pressure is the most common cause of Temperature-Pressure Relief Valve leakage. excessive water system pressure is most often caused by "thermal expansion" in a "closed system." See Closed Water Systems and Thermal expansion on page 12. The Temperature-
Pressure Relief Valve is not intended for the constant relief of thermal expansion.
Temperature-Pressure Relief Valve leakage due to pressure build up in a closed system that does not have a thermal expansion tank installed is not covered under the limited warranty. Thermal expansion tanks must be installed on all closed water systems.
Do NoT PlUG THE TEmPERATURE-PREssURE RElIEf
VALVe OPeNING. THIS CAN CAUSe PROPeRTY DAMAGe,
SeRIOUS INJURY OR DeATH.
burn hazard.
Hot water discharge.
explosion hazard
Keep clear of Temperature-
Pressure Relief Valve discharge outlet.
Temperature-Pressure Relief
Valve must comply with ANSI Z21.22-
CsA
4.4 and ASMe code.
It is recommended that the Temperature-Pressure Relief Valve should be checked to ensure that it is in operating condition every
6 months.
When checking the Temperature-Pressure Relief Valve operation, make sure that (1) no one is in front of or around the outlet of the
Temperature-Pressure Relief Valve discharge line, and (2) that the water discharge will not cause any property damage, as the water may be extremely hot. Use care when operating valve as the valve may be hot.
To check the pressure relief valve , lift the lever at the end of the valve several times, see Figure 25. The valve should seat properly and operate freely.
If after manually operating the valve, it fails to completely reset and continues to release water, immediately close the cold water inlet to the water heater and drain the water heater, see Draining And
Flushing on page 32. Replace the Temperature-Pressure Relief
Valve with a properly rated/sized new one, see Temperature-
Pressure Relief Valve on pages 12-13 for instructions on replacement.
Properly sized temperaturepressure relief valve must be installed in opening provided.
Can result in overheating and excessive tank pressure.
Can cause serious injury or death.
anode rod inspection
CAUTION
Property Damage Hazard
•
•
Avoid water heater damage.
Inspection and replacement of anode rod required.
The anode rod is used to protect the tank from corrosion. Most hot water tanks are equipped with an anode rod. The submerged rod sacrifices itself to protect the tank. Instead of corroding tank,
31
water ions attack and eat away the anode rod. This does not affect water’s taste or color. The rod must be maintained to keep tank in operating condition.
Anode rod deterioration depends on water conductivity, not necessarily water condition. A corroded or pitted anode rod indicates high water conductivity and should be checked and/or replaced more often than an anode rod that appears to be intact.
Replacement of a depleted anode rod can extend the life of your water heater. Inspection should be conducted by a qualified technician, and at a minimum should be checked annually after the warranty period.
Artificially softened water is exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions.
The use of a water softener may decrease the life of the water heater tank.
The anode rod should be inspected after a maximum of three years and annually thereafter until the condition of the anode rod dictates its replacement. Anode replacement is not covered by warranty. NOTe: artificially softened water requires the anode rod to be inspected annually.
5. ensure the drain hose is secured before and during the entire flushing procedure. Flushing is performed with system water pressure applied to the water heater.
6. Open the water heater drain valve to flush the storage tank.
7. Flush the water heater storage tank to remove sediment and allow the water to flow until it runs clean.
8. Close the water heater drain valve when flushing is completed.
9. Remove the drain hose.
10. Fill the water heater - see Filling The Water Heater in this manual.
11. Turn on the electrical supply to place the water heater back in operation.
12. Allow the water heater to complete several heating cycles to ensure it is operating properly.
draining and flushing
Burn harzard.
Hot water discharge.
Keep hands clear of drain valve discharge.
It is recommended that the water heater storage tank be drained and flushed every 6 months to reduce sediment buildup. The water heater should be drained if being shut down during freezing temperatures. See Features And Components in this manual for the location of the water heater components described below.
to drain the water heater storage tank:
1. Turn off the electrical supply to the water heater.
2. Turn off the gas supply at the Main Gas Shutoff Valve if the water heater is going to be shut down for an extended period.
3. ensure the cold water inlet valve is open.
4. Open a nearby hot water faucet and let the water run until the water is no longer hot.
5. Close the cold water inlet valve to the water heater.
6. Connect a hose to the water heater drain valve and terminate it to an adequate drain.
7. Open the water heater drain valve and allow all the water to drain from the storage tank.
8. Close the water heater drain valve when all water in the storage tank has drained.
9. Close the hot water faucet opened in Step 4.
10. If the water heater is going to be shut down for an extended period, the drain valve should be left open.
to flush the water heater storage tank:
1. Turn off the electrical supply to the water heater.
2. ensure the cold water inlet valve is open.
3. Open a nearby hot water faucet and let the water run until the water is no longer hot. Then close the hot water faucet.
4. Connect a hose to the drain valve and terminate it to an adequate drain.
32
recommended procedure for periodic remoVal of lime deposits from tank type commercial water heaters
The amount of calcium carbonate (lime) released from water is in direct proportion to water temperature and usage, see chart.
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 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 all of the hardness (lime). For this reason it is recommended that a regular schedule for deliming be maintained.
The time between cleaning will vary from weeks to months depending upon water conditions and usage.
The depth of lime buildup should be measured periodically. Heaters equipped with cleanouts will have about 2" of lime buildup when the level of lime has reached the bottom of the cleanout opening. A schedule for deliming should then be set up,based on the amount of time it would take for a 1" buildup of lime. It is recommended that the water heater initially be inspected after 6 months.
example 1:
Initial inspection after 6 months shows 1/2" of lime accumulation.
Therefore, the heater should be delimed once a year.
example 2:
Initial inspection after 6 months shows 2" of lime accumulation.
Therefore, the heater should be delimed every 3 months.
figure 26.
deliming solVents
UN•LIMe is recommended for deliming. UN•LIMe is a patented food grade acid which is safe to handle and does not create the harmful fumes which are associated with other products.
UN•LIMe may be obtained from your dealer, distributor or water heater manufacturer. Order Part Number 9005416105,
1 gallon, packed 4 gallons per case or Part Number 9005417105,
5 gallon container.
NOTe: Un•Lime is not available for use in Canada.
Hydrochloric base acids are not recommended for use on glass lined tanks.
Observe handling instructions on label of product being used.
Explosion Hazard
Flammable hydrogen gases may be present.
Keep all ignition sources away from faucet when turning on hot water.
Do not smoke or have open flame or sparks in vicinity of heater.
Do not mix UN•LIMe with other chemicals. Do not allow contact with magnesium, aluminum or galvanized metals.
tank cleanout procedure
The following practices will ensure longer life and enable the unit to operate at its designed efficiency:
1. Once a month the heater should be flushed. Open the drain valve and allow two gallons of water to drain from the heater.
Inlet water valve should remain open to maintain pressure in tank.
2. A cleanout opening is provided for periodic cleaning of the tank. Gas must be shut off and heater drained before opening cleanout.
To clean heater through cleanout opening, proceed as follows:
3. Drain heater.
4. Remove outer cover plate from lower side of heater jacket.
5. Remove six (6) hex head screws securing tank cleanout plate and remove plate.
6. Remove lime, scale, or sediment using care not to damage the glass lining.
7. Inspect cleanout plate gasket, if new gasket is required, replace with part no. 9004099215.
8. Install cleanout plate. be sure to draw plate up tight by tightening screws securely.
9. Replace outer jacket cover plate.
In some water areas the sediment might not be removed by this method and may result in the water heater making rumbling or boiling noises. To dissolve and remove these more stubborn mineral deposits, UN•LIMe Professional Delimer should be used.
deliming using flo-jug method
UN•LIMe in the 5 gallon size is recommended for deliming of all models. Contact your local dealer, distributor or, water heater manufacturer:
Telephone: (800) 433-2545
Fax: (800) 433-2515
Website: www.hotwater.com/parts
Prepare the Water Heater
To delime the water heater using the Flo-Jug method, first prepare the heater for deliming.
Chemical Hazard
• Product contains phosphoric acid.
• Keep out of reach of children.
• Use rubber or neoprene gloves.
Contains phosphoric acid. In case of external contact, flush with cool water. If irritation persists, get medical attention. If swallowed, give 1 or 2 glasses of water or milk and call physician.
Get immediate medical attention for eyes. Keep out of reach of children.
note: the use of ruBBer or neoprene gloVes is recommended, especially if you haVe any open sores or cuts to aVoid unnecessary irritation or discomfort.
1. Turn off fuel and/or power supply to heater. Also, turn off power to any electrical device or equipment, which is attached, or part of the system.
2. Open hot water side of faucet closest to heater and allow water to run until it is cool enough to handle safely.
3. Close cold water inlet valve to heater.
4. Connect hose to drain valve at bottom of heater and start draining heater into suitable floor drain area.
5. Remove pressure relief valve while heater is draining. NOTe:
Do not replace pressure relief valve until deliming is completed.
Pressure relief valve opening will also act as a vent in case of possible contact between the delimer and the anode rod(s), which may produce flammable hydrogen-air mixtures.
6. If pressure relief valve appears to be limed-up, place it in a clean glass or plastic container adequate in size so that you can pour enough UN•LIMe® into container to cover the valve and allow space for foaming. When foaming stops, run fresh cool water into the container and rinse the pressure relief valve for a few minutes.
7. If heater does not drain completely after a reasonable length of time, turn off the main water supply valve to stop water from entering the tank due to a by-pass problem or defective cold water inlet valve. Also, check for clogged drain valve opening.
Heater must be completely drained before introducing UN•LIMe.
8. Remove the cleanout cover and place a clean plastic bucket next to the cleanout opening.
Partially open the cold water inlet valve to allow time to accomplish the following and then close the valve.
33
While the water is being run through the tank, insert a stiff wire, copper tube flattened at one end or an opened wire coat hanger through the cleanout opening and scrape out any loose deposits of scale or sediment. This is an economical way to avoid unnecessary usage of the deliming solution.
Repeat the opening and closing of the cold water inlet valve as necessary but be sure the heater is completely drained when ready to introduce the UN•LIMe.
Upon completion, reinstall the cleanout cover and use a new cleanout cover gasket (part number 9004099215).
Remove the drain valve.
9. Install the long plastic male adapter insert fitting into the drain valve opening of heater after applying Teflon tape or paste to threads. Tighten firmly by hand and use wrench or adjustable pliers to check for secure connection. Do not over tighten to avoid damage to threads and fittings.
Prepare the Up-N-Down Transfer Kit
The next step is the preparation on the Up-N-Down Transfer Kit, if you have not already done so:
1. With the 5 gallon Up-N-Down container in the vertical position, unscrew the plastic vent cap in the handle and pierce the plastic membrane over the vent boss under the cap to allow the container to vent.
note:
If your container does not have the vent cap and vent boss, drill a 3/16” hole in the handle. When you have finished deliming you will be able to plug this drilled vent with the stainless steel screw that is supplied with the kit.
2. Remove the container’s cap and cut the plastic membrane located in the 3/4” IPT opening in the cap. Take care to not damage the threads.
3. Find the 3/4” male adapter, apply teflon tape to the threaded end and screw it into the 3/4” IPT opening in the cap.
4. Put cap with male adapter back on the container and slide
3/4” hose over end of male adapter and fasten in place using hose clamp provided.
figure 27.
pilot Burner
At least once a year, check the pilot burner, Figure 29, and the main burner, Figure 30, for proper operation. See Figure 28 for the location of the Pilot burner and the Main burners. For access to pilot, unfasten two screws to burner cover and remove. Locate the burner with pilot and remove screw holding burner to manifold.
Unfasten pilot tubing from valve and slide out burner and pilot.
Servicing of the pilot burner includes keeping pilot free of lint, cleaning the burner head, the primary air opening and the orifice of the pilot burner.
figure 28.
Delime using flo-Jug method
5. Slide the hose clamp over end of hose and slide hose over the male adapter in the water heater drain opening and secure in place using hose clamp.
6. Lift container to the “Pour” Position, see Figure 27, being careful to keep the vent in the handle above the liquid level and pour the UN•LIMe into the heater.
7. Lower container, you may have to place the container on its empty carton to prevent the UN•LIMe from flowing back into the container.
8. Let UN•LIMe remain in the heater for 5 minutes and then lower the container to the “Drain” Position, see Figure 27.
9. Deliming activity is indicated by foaming on the surface of the
UN•LIMe. If there is deliming activity, repeat steps 6 thru 8.
Normally, lime removal will be completed within one hour.
Severe build-up of lime may take longer than an hour to complete descaling.
Note: To check UN•LIMe for continued use, place some scale or white chalk in a glass with a small amount of UN•LIMe. If the material is vigorously dissolved by the UN•LIMe, it can be reused; if not, the UN•LIMe should be replaced.
34 figure 29.
Pilot burner flame is affected by:.
1. Low gas pressure.
• Adjust pilot flame by means of the pilot gas adjustment located on the gas control valve. See Figure 31.
• The pilot flame should envelop sensing device with 5/8” (1.6cm) flame, Figure30. Remove pilot adjustment cover screw, Figure
31. Turn inner adjustment screw clockwise to decrease, or counterclockwise to increase pilot flame. be sure to replace cover screw on gas control valve after adjustment to prevent possible gas leakage.
2. Clogged pilot burner orifice.
• Clean or replace orifice. A clogged orifice will restrict gas flow.
Pilot sensing device must sense a flame before sparking will stop.
Loose wires or a draft may cause intermittent or abnormal sparking. To eliminate this condition, first correct loose wiring condition, and then, if necessary, increase pilot flame.
main Burner
The main burner, figure 30, should display the following characteristics:
• Cause rapid ignition and carry over of flame across entire burner.
• Give reasonably quiet operation during ignition, burning and extinction.
• Cause no excessive lifting of flame from burner ports.
If the preceding burner characteristics are not evident, check for accumulation of lint or other foreign material that restricts or other foreign material that restricts or blocks air openings to burner or heater.
To clean main burners:
1. Remove main burners from unit.
2. Check that burner venturi and ports are free of foreign matter.
3. Clean burners with bristle brush and/or vacuum cleaner
DO NOT distort burner ports or pilot location.
4. Reinstall burners in unit. Make sure front and rear of burners are installed correctly in burner support brackets.
Also check for good flow of combustion and ventilating air to the unit.
gas control ValVe
Figure 31 shows the two types of combination gas control valves used on these heaters.
If gas control valve becomes defective, repairs should not be attempted. A new valve should be installed in place of defective one.
lp ValVe typical pilot and main Burner flames figure 30.
natural ValVe figure 31.
serVice
The installer may be able to observe and correct certain problems which may arise when the unit is put into operation. HOWeVeR, it is recommended that only a qualified service technician or qualified agencys, using appropriate test equipment, be allowed to service the heater.
As preliminary step, check wiring against diagram, check for grounded, broken or loose wires. Check all wire ends to be sure that they are making good contact.
electrical serVicing
LAbeL ALL WIReS PRIOR TO DISCONNeCTION WHeN SeRVICING
CONTROLS. WIRING eRRORS CAN CAUSe IMPROPeR AND
DANGeROUS OPeRATION.
VeRIFY PROPeR OPeRATION AFTeR SeRVICING.
35
trouBleshooting
ignition module
before calling your service agent, the following checklist should be examined to eliminate obvious problems from those requiring replacement or servicing.
• Check that “main manual gas shut-off valve” is fully open and that gas service has not been interrupted.
• Check that after following the water OPeRATING
INSTRUCTIONS, the “Top Knob” of the gas control valve is in “ON” position.
• Check electrical supply to the water heater for possible blown (or tripped) fusing or power interruption.
• Is the water temperature in tank below the thermostat dial setting on the thermostat (calling for heat)?
• It is possible that the high limit (e.C.O.) has functioned to shut off the water heater
. See FeATUReS - Water Temperature
Control for reset procedure. Contact your serviceman if limit continues to function to shut off water heater.
Green LED
Flash Code a
OFF
Flash Fast
Heartbeat
Indicates
No “Call for Heat”
Power up - internal check
Norma l startup – ignition sequence started (including prepurge)
Device in run mode. “x” = flame current to the nearest μ A.
Next System Action
Not applicable
Not applicable
Not applicable
Recommended Service Action
None
None
None
4 Seconds
ON then “x” flashes
2
3
5 minute Retry Delay - Pilot flame not detected during trial for ignition
Recycle - Flame failed during run
Not applicable
Initiate new trial for ignition after retry delay completed.
Initiate new trial for ignition. Flash code will remain through the ignition trial until flame is proved.
None
If system fails to light on next trial for ignition check gas supply, pilot burner, spark and flame sense wiring, flame rod contaminated or out of position, burner ground connection.
If system fails to light on next trial for ignition, check gas supply, pilot burner, flame sense wiring, contamination of flame rod, burner ground connection.
Check for pilot flame. Replace gas valve if pilot flame present. If no pilot flame, cycle “Call for Heat.” If error repeats, replace con trol.
4
6
Flame sensed out of sequence
Control Internal Error
If situation self corrects within 10 seconds, control returns to normal sequence. If flam e out of sequence remains longer than 10 seconds, control will resume normal operation 1 hour after error is corrected.
Control remains in wait mode.
When the fault corrects, control resumes normal operation.
Control remains in wait mode.
When the fault corrects, control resumes normal operation.
Cycle “Call for Heat”. If error repeats, replace control.
7
8
Flame rod shorted to ground
Low secondary voltage supply Control remains in wait mo de.
When the fault corrects, control resumes normal operation.
Check flame sense lead wire for damage or shorting. Check that flame rod is in proper position.
Check flame rod ceramic for cracks, damage or tracking.
Check transformer and AC line for proper input voltage to the control.
Check with full system load on the transformer. a Flash Code Descriptions:
- Flash Fast: rapid blinking.
- Heartbeat: Constant ½ second bright, ½ second dim cycles.
- 4 second solid on pulse followed by “x” 1 second flashes indicates flame current to the nearest μ A. This is only available in run mode.
- A single flash code number signifies that the LED flashes X times at 2H z, remains off for two seconds, and then repeats the sequence.
flue damper
Do not turn damper open manually or motor damage will result, use the service switch. All readings are taken from harness
36 receptacle. Do not push meter leads into harness receptacle.
This opens the pins and will create connection problems. See the following eFFIKAL RVGP-KSF-SeRIeS FLUe DAMPeR
TROUbLe SHOOTING GUIDe.
effikal rVgp-ksf-series flue damper trouBle shooting guide
Do not turn damper open manually or motor damage will result, use the service switch.
All readings are taken from harness receptacle. Do not push meter leads into harness receptacle.
This opens the pins and will create connection problems.
pin end View note: damper disc shown in open position.
Effikal Pinouts
& wire colors
1. brown
2. Orange
3. Yellow
4. black function
24 VAC HOT
Signal In
Signal Out
24 VAC Common
Adapter wire colors in* black
Yellow
Red
White
24 V.a.c. normal seQuence of operation
A. FLUe DAMPeR OPeN OR OPeNING
(Unit is calling for heat and damper disc should be in vertical position)
VOLTAGe ACROSS:
4 & 1 All Times that High Limit is closed
warning
Do not negate the action
4 & 2 Calling for Heat open or opening of any existing safety or operational controls.
4 & 3 During Combustion Damper open+ b. FLUe DAMPeR CLOSeD (Unit is not calling for heat and damper disc should be in horizontal position)
NOTe: POSITION 4 IS COMMON AND POSITION 3 IS HOT 24VAC
VOLTAGe ACROSS:
4 & 1
NO VOLTAGe ACROSS:
All Times that High Limit is closed
4 & 3 or 4 & 2 1.Thermostat not calling for heat. aBnormal operation
A. NOTHING WORKING
NO VOLTAGe ACROSS:
4 & 1 1. High Limit has tripped and is OPeN. Determine reason for tripping of high limit
2. bad Transformer
3. Loose or broken connections
4. blown fuse or circuit breaker
5. Disconnect switch off
6. Harness not plugged into water heater receptacle b. DAMPeR HAS OPeNeD,
No ComBUsTIoN
VOLTAGe ACROSS:
4 & 1; 4 & 2; 4 & 3: 1. Check for power at ignition module terminals. If 24VAC power is present damper
is working properly.
2. Defective component in water heater after the flue damper.
3. If 24 VAC is not present at the ignition module, look for loose or broken
connections between damper and ignition module.
4. If the connections from damper to ignition module seem proper, replace damper
assembly. If a damper assembly is not available, place the service switch in the
hold open position. This should keep the damper in the open position and allow
the customer to have automatic heat, until a replacement damper can be installed.
C. DAMPeR ROTATeS
CoNTINUoUsly Change the entire damper assembly
D. DAMPeR STICKS 1. Make sure no screws obstruct the damper blade.
2. Make sure damper pipe assembly is not egg shaped.
3. Make sure damper rod is not rubbing on pipe assembly.
See figure on front page of this insert sheet important: damper must Be open Before comBustion takes place. if all steps have been tried and damper problems persists call a.o. smith technical center at 1-800-527-1953.
37
trouBleshooting checklist
complaint
Water not hot enough.
Insufficient hot water
Water temperature too hot.
Heater makes sounds: sizzling.
cause
Thermostat set too low.
Upper and/or lower temperature probe out of calibration.
Thermostat set too low.
Upper and/or lower temperature probe out of calibration.
Main manual gas shutoff valve partially closed.
Heater too small for demand.
user set thermostat dial to a higher temperature.
remedy
Qualified serVice agency
Call qualified service agency.
Check continuity and resistance
(ohms) of upper and lower thermostat probes. Replace probes if out of specification.
set thermostat dial to a higher temperature.
Call qualified service agency.
Check continuity and resistance
(ohms) of upper and lower thermostat probes. Replace probes if out of specification..
open main manual gas shutoff valve to fullest extent.
Space usage to give heater time to restore water temperature.
Heater recovery is slower.
Draft hood not installed or one or more baffles.
Thermostat set too high.
Call qualified service agency.
Call qualified service agency.
Set thermostat to a lower setting.
Check gas input. If incorrect, adjust gas pressure or replace main burner orifice.
Install draft hood or baffles as furnished with unit.
Condensation on outside of tank - normal.
Rumbling.
Ticking or metallic sounds.
Pounding / water hammer.
Combustion noises.
Water leaks.
Gas odors.
Sediment accumulation on bottom of tank.
Drain a quantity of water through drain valve. If rumbling persists, call a qualified service agency.
Delime heater.
expansion and contractionnormal.
Air chambers in piping have become waterlogged. Thermal expansion tank damaged, improperly charged, or improperly sized.
Drain piping system and refill.
Heater must be off while this is being done. Check thermal expansion tank charge pressure when the water system pressure is zero.
Adjust shutters.
Too much primary air.
Overtired heater. Incorrect burners or orifice for types of gas used.
Drain valve not closed tightly.
Call qualified service agency.
If leakage source cannot be corrected or identified, call qualified service agency.
Heater is overtired.
Follow the manufacturer's instructions for proper charging of the thermal expansion tank.
Check and correct as necessary.
If drain valve cannot be closed tightly, replace.
shut off gas supply to heater and close cold water inlet valve to heater.
shut off gas supply to heater and call qualified service agency.
Repair or in case of suspected tank leakage, be certain to confirm before replacing heater.
Check for sooted flue passage.
Check for obstructed vent line.
Check backdraft or lack of draft.
Draft hood may be improperly installed or not sized properly.
Possible gas leaks.
shut off gas supply to heater and call gas company at once.
38
for your information
start up conditions
smoke/odor
It is not uncommon to experience a small amount of smoke and odor during the initial start-up. This is due to burning off of oil from metal parts, and will disappear in a short while.
strange sounds
Possible noises due to expansion and contraction of some metal parts during periods of heat-up and cool-down do not necessarily represent harmful or dangerous conditions.
Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal. See “Condensation" section in this manual.
operational conditions
c. A sulfate reducing bacteria which has accumulated within the water heater (this harmless bacteria is nontoxic to humans).
d. An excess of active hydrogen in the tank. This is caused by the corrosion protective action of the anode rod.
Smelly water may be eliminated or reduced in some water heater models by replacing the anode rod(s) with one of less active material, and then chlorinating water heater tank and all water lines.
Contact the local water heater supplier or service agency for further information concerning an Anode Rod Replacement Kit and this chlorination treatment.
If smelly water persists after anode rod replacement and chlorination treatment, we can only suggest that chlorination or aeration of the water supply be considered to eliminate the water problem.
Do not remove the anode rod leaving the tank unprotected. by doing so, all warranty on the water heater tank is voided.
condensation
Whenever the water heater is filled with cold water, some condensate will form while the burner is on. A water heater may appear to be leaking when in fact the water is condensation.
This usually happens when: a. A new water heater is filled with cold water for the first time.
b. burning gas produces water vapor in water heaters, particularly high efficiency models where flue temperatures are lower.
c. Large amounts of hot water are used in a short time and the refill water in the tank is very cold.
Moisture from the products of combustion condense on the cooler tank surfaces and form drops of water which may fall onto the burner or other hot surfaces to produce a “sizzling” or “frying” noise.
“air” in hot water faucets
HYDROGeN GAS: Hydrogen gas can be produced in a hot water system that has not been used for a long period of time
(generally two weeks or more). Hydrogen gas is extremely flammable and explosive. To prevent the possibility of injury under these conditions, we recommend the hot water faucet, located farthest away, be opened for several minutes before any electrical appliances which are connected to the hot water system are used (such as a dishwasher or washing machine). If hydrogen gas is present, there will probably be an unusual sound similar to air escaping through the pipe as the hot water faucet is opened.
There must be no smoking or open flame near the faucet at the time it is open.
hot water odor
In each water heater there is installed at least one anode rod for corrosion protection of the tank. Certain water conditions will cause a reaction between this rod and the water. The most common complaint associated with the anode rod is one of a
“rotten egg smell” in the hot water. The smell is a result of four factors which must all be present for the odor to develop: a. A concentration of sulfate in the supply water.
b. Little or no dissolved oxygen in the water.
high water temperature shut off system
This water heater is equipped with a manual reset type high limit
(energy Cutout) switch. The high limit switch interrupts the main burner gas flow should water temperature reach 203°F (95°C).
In the event of high limit switch operation, the water heater cannot be restarted unless the water temperature is reduced to approximately 120F (49C). The high limit reset button on the front of the thermostat then needs to be depressed. See Figure 2 for the location of the reset button.
39
water piping diagrams
40
41
PIPE T&P TO OPEN DRAIN
42
COLD WATER SUPPLY
WATER RETURN
EXPANSION TANK
43
44
45
46
47
48
49
50
AOS
STORAGE TANK
51
52
53
AOS
STORAGE TANK
54
two unit manifold kit
(9003426205)
manifold kits
three unit manifold kit
(9003427205)
dimensions “a” inches (cm) model low profile Vertical hood “a”
250
251
275
305
365
400
120
154
180
197
198
199
200
Btr models
69.75” (177cm)
73.00” (185cm)
67.50” (171cm)
75.00 (192cm)
75.00” (192cm)
67.50” (171cm)
72.00” (183cm)
72.00” (183cm)
75.00” (191cm)
72.00” (183cm)
75.00” (191cm)
79.50” (202cm)
75.50” (192cm)
Btrc models
69.75” (177cm)
73.00” (185cm)
70.50” (179cm)
81.50” (207cm)
N/A
70.50” (179cm)
72.00” (183cm)
72.00” (183cm)
75.00” (191cm)
72.00” (183cm)
75.00” (191cm)
75.00” (191cm)
75.50” (192cm)
four unit manifold kit
(9003428205)
55
notes
56
notes
57
notes
58
model Btr(c) limited warranty
A. O. Smith Corporation, the warrantor, extends the following LIMITeD WARRANTY to the owner of this water heater.
1. the tank
If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable water therein, during the first THRee years after initial installation, the warrantor will supply a complete new A. O. Smith water heater of equivalent size and current model. Some government agencies are requiring energy efficient standards for water heaters. In the event regulations prohibit sale of a model of equivalent size and construction, A. O. 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. all other 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./CGA and approved by the American Society of Mechanical engineers, must have been installed.
a. This warranty shall apply only when the heater is:
(1)
(2)
(3)
(4)
(5)
(6) used at temperatures not exceeding the maximum calibrated setting of its thermostat; used at water pressure not exceeding the working pressure shown on the heater; filled with potable water, free to circulate at all times and with the tank free of damaging water sediment or scale deposits; used in a non-corrosive and non-contaminated atmosphere; used with factory approved anode rod(s) installed; in its original installation location;
(7)
(8)
(9)
(10) in the United states, its territories or possessions, and Canada; sized in accordance with proper sizing techniques for commercial and/or residential water heaters; bearing a rating plate which has not been altered, defaced or removed, except as required by the warrantor; used in an open system or in a closed system with properly sized and installed thermal expansion tank;
(11)
(12)
(13)
(14) operated with properly installed sediment trap; fired with the fuel for which it was factory built; fired at the factory rated input; operated with the inner and outer combustion chamber doors in place.
b. Any accident to the water heater, any misuse, abuse (including freezing) or alteration of it, any operation of it in a modified form, any use of insulation blankets, or any attempt to repair tank leaks will void this warranty.
c. This warranty is void if a device acting as a backflow prevention device (check valves etc.) is installed in 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 relief 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. All cost necessary or incidental for any material and/or permits required for installation of the replacement heater or part.
5. limitations on implied warranties
Implied warranties, including the warranty of merchantability imposed on the sale of this heater under state or provincial law are limited to one (1) year duration for the heater or any of its parts. Some states and provinces do not allow limitation 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 heater, or with any other dealer handling the warrantor’s products. If this is not practicable, the owner should contact:
U.S. Customers
A. O. Smith
500 Tennessee Waltz Parkway
Canadian Customers
A. O. Smith enterprises Ltd.
P. O. box, 310 - 768 erie Street
Ashland City, TN 37015
Telephone: 1-800-527-1953 stratford, ontario N5A 6T3
Telephone: 1-800-265-8520
a. 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 mERCHANTABIlITy
OF THe HeATeR OR THe INSTALLATION, OPeRATION, RePAIR OR RePLACeMeNT OF THe HeATeR. THe WARRANTOR SHALL NOT be Re-
SPONSIbLe 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 TO ANY
PeRSONS OR PROPeRTY, WHeTHeR DIReCT OR INDIReCT, AND WHeTHeR ARISING IN CONTRACT OR IN TORT.
a. Some states or provinces do not allow the exclusion or limitation of the incidental or consequential damage, so the above limitations or exclusions may not apply to you.
b. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or province to province.
Fill in the following for your own reference. Keep it. Registration is not a condition of warranty. The model and serial number are found on the heater’s rating plate.
Model No. _________________________________ Serial No. ________________________________ Date Installed ______________________
Dealer’s Name _________________________________________________________________________________________________________
Dealer’s Address __________________________________________________________________ Phone No. ___________________________
City and State/Province ______________________________________________________________zip/PostalCode _______________________ keep this warranty posted adjacent to the heater for future reference
59
500 Tennessee Waltz Parkway, Ashland City, TN 37015
Technical Support: 800-527-1953 • Parts: 800-433-2545 www.hotwater.com
Copyright © 2012 A. O. Smith, All rights reserved.
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