A.O. Smith BTR 500 User manual
COMMERCIAL GAS WATER HEATERS
Instruction Manual
PRINTED 0111 318230-001
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 BTR 500
SERIES 120/121
INSTALLATION - OPERATION - SERVICE
- MAINTENANCE - LIMITED WARRANTY
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
Do not try to light any appliance.
Do not touch any electrical switch; do
not use any phone in your building.
Immediately call your gas supplier
from a neighbor’s phone. Follow the
gas supplier’s instructions.
If you cannot reach your gas supplier,
call the fire department.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
•
•
•
•
ASME CRN
2
17
17
18
19
19
19
20
20
21
Gas Piping 22
Purging 22
22
23
23
23
23
24
25
25
25
Main Burner 25
25
26
26
26
26
26
27
27
27
28
28
28
28
30
30
30
30
30
30
30
32
33
34
49
50
51
TABLE OF CONTENTS
3
3
4
5
5
5
6
6
6
7
7
7
7
7
7
8
8
8
8
9
9
10
10
10
10
11
11
11
12
12
12
12
12
13
13
13
13
14
14
15
15
15
15
15
16
16
16
16
16
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
APPROVALS
4
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.
•
5
PRECAUTIONS
GROUNDING INSTRUCTIONS
HYDROGEN GAS FLAMMABLE
Explosion Hazard
Flammable hydrogen gases
may be present.
Keep all ignition sources away
from faucet when turning on
hot water.
GENERAL SAFETY INFORMATION
Verify the power to the water heater is turned off before performing any service procedures.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
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.
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
GENERAL SAFETY INFORMATION
6
ABBREVIATIONS USED
QUALIFICATIONS
QUALIFIED INSTALLER OR SERVICE AGENCY
INTRODUCTION
ANSI Z223.1 2006 Sec. 3.3.83:
7
THE ELIMINATOR (SELF-CLEANING SYSTEM)
Note: The Eliminator may have 1, 3 or 7 cross tubes.
FIGURE 1
HIGH LIMIT SWITCH
DIGITAL THERMOSTAT
FIGURE 2
ELECTRONIC IGNITION CONTROL
IGNITION CONTROL BOARD
FIGURE 3
EXHAUST INDUCER (BLOWER ASSY.)
EXHAUST INDUCER
FIGURE 4
UNCRATING
FEATURES AND COMPONENTS
8
ROUGH IN DIMENSIONS
RECOVERY CAPACITIES
GAS AND ELECTRICAL CHARACTERISTICS
FRONT VIEW
TOP VIEW
BACK VIEW
TABLE 2. RECOVERY CAPACITIES, based on 80% efciency
F
TOP
OUTLET
1 1/2” NPT
TOP
INLET
1 1/2” NPT
TABLE 3. GAS AND ELECTRICAL CHARACTERISTICS
TABLE 1. ROUGH-IN-DIMENSIONS
Input Rate
BD E
Gas
G
Dia
I
Top To p
BTR 500 85 812 857
BTR500 147 322 207 44 196 171 69 53 3 171 20 70 368 389
Input Rate
BTR 500 85 1616 1212 970 808 693 606 539 485 441 404 373 346
BTR 500 147 322 6118 4588 3671 3059 2622 2294 2039 1835 1668 1529 1412 1311
Gas Type
BTR-500 <5
BTR-500 Propane <5
INSTALLATION CONSIDERATIONS
FIGURE 5
9
FLAMMABLE ITEMS,
CLEARANCES
TABLE 4
MINIMUM CLEARANCES TO COMBUSTIBLES IN INCHES (mm)
MODEL
"A"
RIGHT
SIDE
"B"
LEFT
SIDE
"C"
BACK
"D"
CEILING
BTR 500
TABLE 5
MINIMUM CLEARANCES TO NONCOMBUSTIBLE CONSTRUCTION
MODEL
"A"
RIGHT
SIDE
"B"
LEFT
SIDE
"C"
BACK
"D"
CEILING
BTR 500 0 0 0
LOCATING THE WATER HEATER
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
CAUTION
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.
INSTALLATION CONSIDERATIONS
10
INSULATION BLANKET
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
• DO NOT
• DO NOT
• DO NOT
• DO
• DO
HARD WATER
CIRCULATION PUMPS
FIGURE 6
INSTALLATION ON COMBUSTIBLE FLOORING
FIGURE 7
11
Breathing Hazard - Carbon Monoxide Gas
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Under no circumstances should
the input exceed the rate shown
on the water heater’s rating label.
Overfiring could result in damage to
the water heater and sooting.
Gas and carbon monoxide detectors
are available.
PROPANE INSTALLATIONS
NATURAL GAS INSTALLATIONS
CIRCULATING PUMP WIRING DIAGRAM
STORAGE TANK OR BUILDING RECIRCULATION
FIELD SUPPLIED TEMPERATURE CONTROL
INSTALLED IN THE STORAGE TANK
OR CIRCULATING LOOP RETURN LINE
CIRC
PUMP
MOTOR
L1 HOT
L2 NEUTRAL
120 VAC
POWER
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH APPLIANCE AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
CIRCULATING PUMP WIRING DIAGRAM
DISHWASHER LOOP WITH TOGGLE SWITCH
FIELD SUPPLIED TEMPERATURE
CONTROL INSTALLED IN THE
CIRCULATING LOOP RETURN LINE
DISHWASHER
TOGGLE
SWITCH
CIRC
PUMP
MOTOR
L1 HOT
L2 NEUTRAL
120 VAC
POWER
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH APPLIANCE AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
FIGURE 8.
CIRCULATING PUMP WIRING DIAGRAM
STORAGE TANK OR BUILDING RECIRCULATION
FIELD SUPPLIED TEMPERATURE CONTROL
INSTALLED IN THE STORAGE TANK
OR CIRCULATING LOOP RETURN LINE
CIRC
PUMP
MOTOR
L1 HOT
L2 NEUTRAL
120 VAC
POWER
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH APPLIANCE AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
CIRCULATING PUMP WIRING DIAGRAM
DISHWASHER LOOP WITH TOGGLE SWITCH
FIELD SUPPLIED TEMPERATURE
CONTROL INSTALLED IN THE
CIRCULATING LOOP RETURN LINE
DISHWASHER
TOGGLE
SWITCH
CIRC
PUMP
MOTOR
L1 HOT
L2 NEUTRAL
120 VAC
POWER
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH APPLIANCE AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
FIGURE 9.
HIGH ALTITUDE INSTALLATIONS
Fire and Explosion Hazard
Gas and carbon monoxide detectors are
available.
Overfiring could result in fire or
explosion.
Under no circumstances should the
input exceed the rate shown on the
water heater’s rating label.
12
WATER TEMPERATURE CONTROL AND 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.
GAS PRESSURE REQUIREMENTS
SUPPLY GAS REGULATOR
POWER SUPPLY
INSTALLATION REQUIREMENTS
13
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 10
DISHWASHING MACHINES
CLOSED WATER SYSTEMS
THERMAL EXPANSION
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.
14
Water Damage Hazard
Temperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
•
CAUTION
T&P Valve Discharge Pipe Requirements:
Burn hazard.
Hot water discharge.
Keep clear of Temperature-
Pressure Relief Valve
discharge outlet.
NOTE:
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.
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.
15
LOUVERS AND GRILLES
VENT ADAPTER
FIGURE 11
UNCONFINED SPACE
UNUSUALLY TIGHT CONSTRUCTION
CONFINED SPACE
EXHAUST FANS
VENTING INSTALLATION
VENTING
FIGURE 12
16
MULTIPLE HEATER MANIFOLD
FIGURE 13
FRESH AIR OPENINGS FOR CONFINED SPACES
OUTDOOR AIR THROUGH TWO OPENINGS
FIGURE 14
OUTDOOR AIR THROUGH ONE OPENING
FIGURE 15
2
OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS
FIGURE 16
2
17
AIR FROM OTHER INDOOR SPACES
FIGURE 18
2
2
OUTDOOR AIR THROUGH TWO VERTICAL DUCTS
DO NOT
FIGURE 17
2
18
TYPE B GAS VENT
Multiple Gas Fired Tank-Type Heaters
TABLE 7. TECHNICAL DATA VENTING
Model 500
Input: 500,000 btu/hr
6 8 10 15 20 30 50 100
Rise
- 10 10 10 9 8 8 7
10 10 10 9 9 8 8 7
10 10 9 9 9 8 7 7
Multiple Fan Assisted Water Heaters
6 8 10 15 20 30 50 100
2 14 14 12 12 10 10 9 8
3 16 16 14 14 14 12 12 10
4 18 18 16 16 14 14 12 12
Combination of Multiple Fan Assisted and Natural Draft Water Heaters
6 8 10 15 20 30 50 100
2 16 14 14 14 12 12 10 9
3 18 18 16 16 14 14 12 10
4 20 20 18 18 16 16 14 12
19
WATER HEATER INSTALLATION
Water Damage Hazard
Temperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
•
CAUTION
T&P Valve Discharge Pipe Requirements:
WATER LINE CONNECTIONS
WATER (POTABLE) HEATING AND SPACE HEATING
THERMOMETERS (NOT SUPPLIED)
WATER PIPING DIAGRAMS
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 temperature-
pressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
20
INSTALLATION DIAGRAMS - TOP INLET/OUTLET USAGE
TUBE INLET INSTALLATION
FIGURE 19
CODE RESTRICTIONS
TEMPERATURE SETTING SHOULD NOT EXCEED
SAFE USE TEMPERATURE AT FIXTURES. SEE WATER
TEMPERATURE CONTROL AND MIXING VALVE WARNING
ON PAGE 12. IF HIGHER PREHEAT TEMPERATURES ARE
NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT,
ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED
TO FIXTURES.
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