A.O. Smith 101 Series User manual
COMMERCIAL GAS WATER HEATERS
Instruction Manual
PRINTED IN THE U.S.A. 0310 197373-005
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
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.
MODELS BTH-300A/400A/500A
SERIES 100 & 101
INSTALLATION - OPERATION - SERVICE
- MAINTENANCE - LIMITED WARRANTY
ANSI / NSF 5
ASME CRN
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.
•
•
•
•
http://waterheatertimer.org/How-to-troubleshoot-gas-water-heater.html
2
Supply Gas Line Installation ............................................................ 37
Supply Gas Regulator Installation ................................................... 38
............................................................................... 39
......................................................................39
..............................................................................39
.................................................................. 40
............................................................... 40
TEMPERATURE REGULATION .......................................................... 41
............................................ 41
.......................................................................... 41
...................................................... 42
.............................................................. 42
.................................................................................42
..............................................................................................43
.......................................... 45
Temperatures Menu..................................................................................45
Heater Status Menu..................................................................................46
Display Settings........................................................................................47
Heater Information....................................................................................47
.............................................................................................48
.............................................................................................48
......................................................................................48
..........................................................................48
.....................................................................49
START UP ............................................................................................ 50
Initial Start Up .................................................................................. 50
.............................................................51
..........................................................51
................................................................ 52
................................................................ 52
LIGHTING THE WATER HEATER ....................................................... 53
Lighting & Operation Label .............................................................. 53
TROUBLESHOOTING ......................................................................... 54
........................................................................ 54
................................................................... 54
................................................ 55
Operational Problems...................................................................... 56
............................................................56
Momentary Ignition ...................................................................................56
Not Enough Or No Hot Water...................................................................56
............................................................... 57
........................................................................................57
........................................................................................57
........................................................57
....................................................................................57
.........................................................................58
................................................................................... 60
.................................................................... 60
DIAGRAMS .......................................................................................... 63
............................................... 63
BTH 300 Wiring Diagram................................................................. 64
......................................................... 65
.................................................. 66
Water Piping Diagrams.................................................................... 67
.......................................................................... 74
TABLE OF CONTENTS
.......................................... 3
...................................................... 4
........................................................................................ 4
.................................................................................... 6
..................................................................................... 6
....................................................... 6
........................................................... 6
......................................................... 7
................................................................................. 7
............................................................................................ 8
......................................................................................... 9
................................................... 10
Rough In Dimensions ...................................................................... 10
........................................................................ 10
...............................................................11
........................................................ 11
....................................................................................11
Insulation Blankets .......................................................................... 12
INSTALLATION REQUIREMENTS ...................................................... 13
Gas Pressure Requirements ........................................................... 13
Supply Gas Line .............................................................................. 13
Supply Gas Regulator ..................................................................... 13
.................................................................................. 13
Mixing Valves................................................................................... 14
.................................................................... 14
.................................................................... 14
Thermal Expansion.......................................................................... 14
Temperature-Pressure Relief Valve ................................................. 15
............................................................................ 16
Air Requirements............................................................................. 17
................................................... 20
VENTING INSTALLATION ................................................................... 21
General Venting Information............................................................ 21
..............................................................................21
.........................................................................21
..........................................................................21
........................................................... 21
Venting Requirements ..................................................................... 22
Maximum Equivalent Lengths ..................................................................22
Minimum Equivalent Lengths ...................................................................22
...................................................................22
......................................................... 23
.................................................................... 23
..................................................................... 23
....................................................... 24
...................................................... 26
.................................................. 27
...........................................30
........................................31
Venting Arrangements ..................................................................... 32
................................. 34
.................................. 35
WATER HEATER INSTALLATION........................................................ 36
......................................................... 36
3
SAFE INSTALLATION, USE AND SERVICE
DANGER
WARNING
CAUTION
CAUTION
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
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.
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.
ASME CRN ANSI / NSF 5
APPROVALS
4
PRECAUTIONS
1.
2. Damage.
3.
GROUNDING INSTRUCTIONS
HYDROGEN GAS FLAMMABLE
THERE
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.
Verify the power to the water heater is turned off before performing any service procedures.
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.
CAUTION
Explosion Hazard
Flammable hydrogen gases
may be present.
Keep all ignition sources away
from faucet when turning on
hot water.
5
GENERAL SAFETY INFORMATION
Fire Hazard
Do not install water heater on
carpeted floor.
Do not operate water heater if
flood damaged.
For continued protection against
risk of fire:
Fire or Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Avoid all ignition sources if you smell gas.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating label.
Keep ignition sources away from faucets after extended
periods of non-use.
Maintain required clearances to combustibles.
Do not expose water heater controls to excessive gas
pressure.
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.
Breathing Hazard - Carbon Monoxide Gas
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
CAUTION
Fire and Explosion Hazard
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.
Use joint compound or Teflon tape
compatible with propane gas.
Fire and Explosion Hazard
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
Excessive gas pressure to gas valve can
cause serious injury or death.
Do not use water heater with any gas
other than the gas shown on the rating
label.
Turn off power to the water heater
before performing any service.
Electrical Shock Hazard
•
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.
•
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.
•
Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the appliance 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.
•
6
ABBREVIATIONS USED
QUALIFICATIONS
QUALIFIED INSTALLER OR SERVICE AGENCY
ANSI Z223.1 2006 Sec. 3.3.83:
ICOMM™ & BACNET COMPATIBLE
PREPARING FOR THE INSTALLATION
1.
safety.
INTRODUCTION
NOTE:
2.
3.
MA 02269.
4.
5.
Dimensions on page 10.
6.
95811.
7.
7
BASIC OPERATION
FEATURES AND COMPONENTS
BLOWER
BURNER
ASSEMBLY
MAIN
BURNER
(radial design)
HEAT
EXCHANGER
INTAKE AIR
(combustion air)
CONNECTION
4 INCH PVC
HELICAL
COIL
VENT (exhaust)
OUTLET
Figure 1
BLOWER/BURNER ASSEMBLY DETAIL
HOT SURFACE
IGNITER
COMBUSTION
BLOWER
FLAME
SENSOR
MAIN
BURNER
(radial design)
BLOWER
FLANGE
INTAKE AIR
(combustion air)
CONNECTION
4 INCH PVC
Figure 2
Hot Surface Igniter
the Main Burner.
NOTE:
breakage.
Flame Sensor
8
Operation on page 54.
11.
12.
13.
14.
15. Temperature-Pressure Relief Valve. See Temperature-
Pressure Relief Valve on page 15.
16.
17.
18.
on page 42.
TOP VIEW
3
2
4
5
6
79
11
13
12
2
14
15
17
1
18
16
10
8
FRONT
TOP VIEW COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
Supply Gas Line on page 13.
9.
10.
Figure 3
9
on page 42.
11. Temperature-Pressure Relief Valve. See Temperature-
Pressure Relief Valve on page 15.
12.
13.
14.
15.
16.
17.
18.
page 36.
SIDE VIEWS
1.
opening.
2.
3.
Supply on page 13.
4.
5.
6.
page 13.
7.
8.
9.
10.
10
816
27
6
5
11
12
17
18
13
14
15
RIGHT SIDE
11
12
14
15
13
3
2
1
4
5
6
7
8
9
10
LEFT SIDE
Figure 4 Figure 5
10
STORAGE CAPACITIES
TABLE 2
MODEL U. S. GALLONS LITERS
BTH 300 130 492
BTH 400 130 492
BTH 500 130 492
Figure 6
ROUGH IN DIMENSIONS
GAS LINE CONNECTION SIZE
TABLE 1
MODEL SERIES NATURAL GAS PROPANE GAS
BTH 300 100/101
BTH 400 100/101
† BTH 500 100/101
TABLE 3
U. S. GALLONS/HR & LITERS/HR AT TEMPERATURE RISE INDICATED
Type of
Gas
Input
Btu/hr kW
BTH 300 Natural 88 GPH 1746 1164 873 699 582 499 436 388 349 318 291 269 250
Propane LPH 6610 4406 3304 2644 2203 1888 1652 1469 1322 1201 1102 1017 945
BTH 400 Natural 117 GPH 2328 1552 1164 931 776 665 582 517 466 423 388 359 332
Propane LPH 8813 5875 4406 3525 2938 2518 2203 1958 1763 1602 1469 1356 1259
BTH 500 Natural 146 GPH 2878 1919 1439 1151 959 822 720 640 576 523 480 443 411
Propane LPH 10894 7263 5447 4358 3631 3113 2724 2421 2179 1981 1816 1676 1556
INSTALLATION CONSIDERATIONS
35°
20°
70°
18°
45°
45°
CLEANOUT
T & P VALVE
GAS
*1 1/2” NPT
WATER
OUTLET
FRONT
TOP
DRAIN VALVE
INTAKE AIR
4 INCH PVC
VENT
4 INCH
PVC
FRONTBACK
CLEANOUT
T & P
3/4” NPT
DRAIN
1 1/2” NPT
WATER INLET
4” PVC
VENT CONNECTION
(exhaust elbow)
4” PVC
INTAKE AIR
CONNECTION
1 1/4” SUPPLY GAS
CONNECTION
33.12” (84.1 cm)
OUTSIDE
DIAMETER
4.86”
(12.34 cm)
50.77”
(129 cm)
75.50”
(191.8 cm)
69”
(175.3 cm)
69”
(175.3 cm)
12”
(30.5 cm)
* Center line of water outlet on top of the water heater is 7 inches from the front edge of the water heater.
WATER
OUTLET
HEIGHT
63 INCHES
(160 cm)
CONDENSATE
DRAIN CONNECTION
1/2 INCH PVC
RECOVERY CAPACITIES
11
LOCATING THE WATER HEATER
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
CAUTION
1.
2.
3.
4.
5.
6.
usage.
7.
8.
Requirements on page 17.
9.
10.
11.
Fire or Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Avoid all ignition sources if you smell gas.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating label.
Keep ignition sources away from faucets after extended
periods of non-use.
Maintain required clearances to combustibles.
Do not expose water heater controls to excessive gas
pressure.
heater.
CLEARANCE TO COMBUSTIBLE MATERIALS
NOTE:
TOP VIEW
0
0
0
ALCOVE
FRONT VIEW
CLEARANCES TO COMBUSTIBLE
AND NON COMBUSTIBLE
CONSTRUCTION MATERIALS
WATER
HEATER
FRONT
TOP COVER
FRONT
Figure 7
SERVICE CLEARANCE
INTAKE AIR AND VENT PIPE CLEARANCES
12
EXTENDED VENT TERMINATIONS
OPTIONAL CONCENTRIC TERMINATIONS
on page 27.
HARD WATER
CIRCULATION PUMPS
heater. See the Water Piping Diagrams beginning on page 67 for
INSULATION BLANKETS
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.
Breathing Hazard - Carbon Monoxide Gas
DO NOT
DO NOT
heater.
DO NOT
DO NOT
DO
existing labels.
DO
13
POWER SUPPLY
POWER FLUCTUATIONS AND ELECTRICAL NOISE
information.
NOTE:
DEDICATED POWER WIRING AND BREAKERS
POLARITY SENSITIVE
TABLE 4
MODEL
NATURAL GAS PROPANE GAS NATURAL GAS PROPANE GAS NATURAL GAS PROPANE GAS
BTH 300
BTH 400
BTH 500
also.
SUPPLY GAS LINE
DOES
NOT
DO NOT
on page 37.
MINIMUM SUPPLY GAS LINE SIZE
TABLE 5
MODEL *NATURAL GAS PROPANE GAS
BTH 300
BTH 400
† BTH 500
on page 37.
SUPPLY GAS REGULATOR
NOTE:
See Supply Gas Regulator Installation on page 38.
INSTALLATION REQUIREMENTS
GAS PRESSURE REQUIREMENTS
14
HOT WATER
OUTLET
TO TANK
INLET
CHECK
VALVE
MIXING
VALVE
COLD
WATER
INLET
TEMPERED WATER
OUTLET
12” TO 15”
(30-38 cm)
CHECK
VALVE
Figure 8
beginning on page 67.
NOTE:
CLOSED WATER SYSTEMS
THERMAL EXPANSION
Diagrams beginning on page 67.
MIXING VALVES
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
Water Temperature
Nearly instantaneous
Nearly instantaneous
More than 5 minutes
DISHWASHING MACHINES
limits.
15
Water Damage Hazard
Temperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
•
CAUTION
T&P Valve Discharge Pipe Requirements:
Shall not be smaller in size than the outlet pipe size of the
pipe.
Burn hazard.
Hot water discharge.
Keep clear of Temperature-
Pressure Relief Valve
discharge outlet.
The Temperature-Pressure Relief Valve must be manually
NOTE: The purpose of a Temperature-Pressure Relief Valve is
TEMPERATURE-PRESSURE RELIEF VALVE
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22-
CSA 4.4 and ASME code.
Properly sized temperature-
pressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
NOTE:
Valve for remote storage tanks.
16
CONDENSATE DRAIN
NOTE:
CONDENSATE DRAIN
LINE - FIELD INSTALLED
CONDENSATE DRAIN
LINE CONNECTION
EXHAUST (VENT)
ELBOW
BUILDING
DRAIN
FACTORY INSTALLED
CONDENSATE TRAP
CLEANOUT
PLUG IS
REMOVED
TO CLEAR
DRAIN
Figure 9
CONDENSATE DRAIN WATER TRAP
Ensure a functioning water trap is
installed in the condensate drain.
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.
Breathing Hazard - Carbon Monoxide Gas
Installation on page 36.
CONDENSATE PH LEVEL
NOTE:
COMBUSTIBLE MATERIAL STORAGE
Fire or Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Avoid all ignition sources if you smell gas.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating label.
Keep ignition sources away from faucets after extended
periods of non-use.
Maintain required clearances to combustibles.
Do not expose water heater controls to excessive gas
pressure.
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.
intake air pipe. See Venting Installation on page 21.
17
UNUSUALLY TIGHT CONSTRUCTION
CONFINED SPACE
IS LESS THAN
AND the total Btu/hr input rating of all
DIRECT VENT APPLIANCES
EXHAUST FANS
LOUVERS AND GRILLES
AIR REQUIREMENTS
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.
UNCONFINED SPACE
IS NOT LESS THAN
18
1.
2.
OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS
Figure 12
FRESH AIR OPENINGS FOR CONFINED SPACES
only. DO NOT refer to these illustrations for the purpose of vent
OUTDOOR AIR THROUGH TWO OPENINGS
Figure 10
OUTDOOR AIR THROUGH ONE OPENING
Figure 11
19
AIR FROM OTHER INDOOR SPACES
Figure 14
OUTDOOR AIR THROUGH TWO VERTICAL DUCTS
DO NOT refer to these illustrations for the purpose of vent
Figure 13
20
COMMONWEALTH OF MASSACHUSETTS
INSTALLATION OF CARBON MONOXIDE DETECTORS
APPROVED CARBON MONOXIDE DETECTORS
SIGNAGE
“GAS VENT DIRECTLY BELOW. KEEP
CLEAR OF ALL OBSTRUCTIONS.”
INSTALLATION REQUIREMENTS - COMMONWEALTH OF MASSACHUSETTS
INSPECTION
EXEMPTIONS
1.
2.
MANUFACTURER REQUIREMENTS - GAS
EQUIPMENT VENTING SYSTEM PROVIDED
1.
2.
system.
MANUFACTURER REQUIREMENTS - GAS
EQUIPMENT VENTING SYSTEM NOT PROVIDED
1.
2.
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