A.O. Smith BTR-120, BTR-154, BTR-180, BTR-197, BTR-198 Installation Manual

...

Instruction Manual

CONTENT

COMMERCIAL GAS WATER HEATERS

MODELS BTR 120 - 400(A)

BTRC 120 - 400(A)

SERIES 118/119

500 Tennessee Waltz Parkway

Ashland City, TN 37015

LOW LEAD

INSTALLATION - OPERATION - SERVICE

- MAINTENANCE - LIMITED WARRANTY

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS:

Do not try to light any appliance.

•

Do not touch any electrical switch; do

•

not use any phone in your building. Immediately call your gas supplier

•

from a neighbor’s phone. Follow the gas supplier’s instructions.

If you cannot reach your gas supplier,

•

call the fire department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

Thank you for buying this energy efcient water heater. We appreciate your condence 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 0115 197288-004

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

Qualications .................................................................................... 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

Unconned Space ........................................................................... 16

Conned Space ............................................................................... 16

VENTING INSTALLATION .................................................................. 16

Venting ............................................................................................ 16

Vent Reducer .................................................................................. 16

Multiple Heater Manifold ................................................................. 17

Fresh Air Opening for Conned 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 H E AT ER INSTALL ATION ................................................. 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

Efkal RVGP-KSF Series Flue Damper Trouble Shooting Guide

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

WARR ANTY ........................................................................................ 59

........ 37

SAFE INSTALLATION, USE AND SERVICE

CONTENT

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 indicates an imminently

DANGER

WARNING

CAUTION

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

CAUTION

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.

symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage.

APPROVALS

LOW LEAD

Note: ASME construction is optional on the water heaters covered in this manual.

GENERAL SAFETY INFORMATION

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.

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.

For continued protection against

•

Fire Hazard

risk of fire: Do not install water heater on

carpeted floor.

Do not operate water heater if any part has been exposed to flooding or water damage.

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.

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

technician for installation and service.

Jumping out control circuits or components can

result in property damage, personal injury or death.

Service should only be performed by a qualified service

•

technician 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

Improper installation, use and service may result

in property damage.

•

Do not operate water heater if any part has been exposed to flooding or water damage.

•

Inspect anode rods regularly, replace if damaged.

•

Install in location with drainage.

•

Fill tank with water before operation.

•

Properly sized thermal expansion tanks are required on all closed water systems.

Refer to this manual for installation and service.

CAUTION

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.

GENERAL SAFETY INFORMATION

PRECAUTIONS

DO NOT USE THIS WATER HEATER IF ANY PART HAS

BEEN EXPOSED TO FLOODING OR WATER DAMAGE. Immediately call a qualified service technician to inspect the

water heater and to make a determination on what steps

should be taken next.

If the unit is exposed to the following, do not operate heater

until all corrective steps have been made by a qualified service technician.

1. External re.

2. Damage.

3. Firing without 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.

HYDROGEN GAS FLAMMABLE

Explosion Hazard

Flammable hydrogen gases may be present.

Keep all ignition sources away from faucet when turning on hot water.

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 ammable. 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 ow. 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 Qualied Agency (as dened by ANSI below) in the eld 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: “Qualied Agency” - “Any individual, rm, 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 qualied (as dened by ANSI above) and licensed or certied 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-red 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 rst 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 res.

Examine the lo c a t i o n to ensure the water he ater co m p l i e s 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.

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 signicantly reduce outlet water temperatures during heavy draws.

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 ow 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.

bur ns dur ing each running cyc le. Th e ma i n bu r n e r an d pi l o t ga s e s 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 rst sense pilot ignition.

IGNITION MODULE

FIGURE 3.

AUTOMATIC FLUE DAMPER

All units are equipped with an automatic ue damper that reduces heat loss during the OFF cycles. The automatic ue damper drive assembly is a eld 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 ue 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.

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

FLUE DAMPER

FIGURE 4.

UNCRATING

The heater is shipped with the ue 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.

INSTALLATION CONSIDERATIONS

ROUGH IN DIMENSIONS

MODELS BTR(C) 120 THROUGH 400

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

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

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

4.50”

12 cm

4.50”

12 cm

4.50”

12 cm

4.50”

12 cm

C D E

59.50”

50.87”

151 cm

129 cm

66.50”

57.87”

169 cm

147 cm

62.00”

53.62”

157 cm

136 cm

70.00”

61.62”

178 cm

157 cm

70.00”

61.62”

178 cm

157 cm

62.00”

53.62”

157 cm

136 cm

65.13”

55.87”

165 cm

142 cm

65.13”

55.87”

165 cm

142 cm

65.75”

57.25”

167 cm

145 cm

65.13”

55.87”

165 cm

142 cm

65.75”

57.25”

167 cm

145 cm

70.25”

62.50”

178 cm

159 cm

67.50”

58.25”

171 cm

148 cm

19.69”

50 cm

19.69”

50 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

19”

48 cm

19”

48 cm

21”

53 cm

21”

53 cm

21”

53 cm

21”

53 cm

23”

58 cm

23”

58 cm

NA NA1/2”

23”

58 cm

NA NA1/2”

23”

58 cm

23”

58 cm

GAS

INLET

1/2” 1/2”

1/2”

1/2” 3/4”

3/4” 3/4”

3/4”

VENT

DIA

51.88”

132 cm

59.00”

150 cm6”15 cm

54.62”

139 cm6”15 cm

62.62”

159 cm6”15 cm

61.50”

150 cm6”15 cm

54.62”

139 cm6”15 cm

56.38”

143 cm6”15 cm

56.38”

143 cm8”20 cm

58.75

149 cm8”20 cm

56.38”

143 cm8”20 cm

58.75

149 cm8”20 cm

63.00

160 cm8”20 cm

59.00”

150 cm8”20 cm

6”

15 cm

TOP FRONT BACK TOP FRONT BACK STD. ASME

27.75”

1.50”

71 cm

1.50”

27.75”

1.50”

71 cm

1.50”

27.75”

1.50”

71 cm

1.50”

27.75”

1.50”

71 cm

1.50”

27.75”

1.50”

71 cm

1.50”

27.75”

1.50”

71 cm

1.50”

30.25”

1.50”

77 cm

1.50”

30.25”

1.50”

77 cm

1.50”

27.75”

NA NA1.50”

70 cm

30.25”

1.50”

77 cm

1.50”

27.75”

NA NA1.50”

70 cm

27.75”

1.50”

70 cm

1.50”

30.25”

1.50”

77 cm

1.50”

CONNECTIONS

INLET OUTLET

1.50”

2.00”

1.50”

2.00”

1.50”

2.00”

1.50”

2.00”

1.50”

NA NA1.50”

1.50”

NA NA1.50”

1.50”

2.00”

1.50”

2.00”

1.50”

2.00”

1.50”

2.00”

1 .50”

2.00”

1.50”

2.00”

1.50”

2.00”

1.50”

2.00”

1.50”

2.00”

1.50”

2.00”

Approximate

ship. Weight

400 Lbs

182 Kg

470 Lbs

21 3 Kg

470 Lbs

21 3 Kg

603 Lbs

273 Kg

603 Lbs

273 Kg

470 Lbs

21 3 Kg

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

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

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

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

TABLE 1B. BTRC MODELS 120 THROUGH 400/A

B C D E F

4.25”

59.50”

50.87”

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

151 cm

66.50”

169 cm

63.75”

162 cm

74.75”

190 cm

63.75”

162 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

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

19.69” 50 cm

17.75” 45 cm

19.75” 50 cm

20.00” 51 cm

19.75”

50 cm

20.00” 51 cm

26.75”

68 cm

19”

48 cm

19”

48 cm

19”

48 cm

19”

48 cm

19”

48 cm

23”

58 cm

23”

58 cm

NA NA1/2”

23”

58 cm

NA NA1/2”

NA NA3/4”

23”

58 cm

GAS

INLET

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”

VENT

DIA

51.88”

132 cm

15 cm

59.00”

150 cm

15 cm

56.50”

144 cm

15 cm

67.50”

171 cm

15 cm

56.50”

144 cm

15 cm

56.38”

143 cm

15 cm

56.38”

143 cm8”20 cm

58.8 149 cm8” 20 cm

56.38”

143 cm8”20 cm

58.8 149 cm8” 20 cm

58.8

149cm8”20 cm

59.00” 20 cm

150 cm

6”

8”

27.75” 71 cm

30.25” 77 cm

27.75” 70 cm

30.25” 77 cm

27.75” 70 cm

30.25” 77 cm

TOP

1.50”

NA NA1.50”

1.50”

NA NA1 .50”

1.50”

CONNECTIONS

INLET OUTLET

FRONT BACK

1.50”

2.00”

1.50”

2.00”

1 .50”

1.50”

2.00”

1.50”

2.00”

1.50”

2.00”

1.50”

2.00”

TOP

FRONT BACK STD.

1.50”

1 .50”

1.50”

1 .50”

1.50”

2.00”

1.50”

2.00”

1.50”

2.00”

1.50”

2.00”

NA NA1.50”

1.50”

2.00”

1.50”

2.00”

NA NA1.50”

1.50”

NA NA1.50”

1.50”

1 .50”

2.00”

1 .50”

2.00”

1.50”

2.00”

1.50”

2.00”

1.50”

2.00”

Approximate

ship. Weight

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

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

INSTALLATION CONSIDERATIONS

TABLE 2. HEATER PERFORMANCE DATA BTR MODELS

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.

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

388

1469

498

1885

579

2192

643

2434

643

2434

614

2324

643

2434

808

3059

811

3071

889

3365

986

3732

1180

4466 1293

4894

28° C 33° C 39° C 44° C 50° C 56° C 61° C 67° C 72° C 78° C

291

233

1102

882

373

299

1412

1132

434

347

1314

1643

482

386

1461

1825

482

386

1461

1825

461

368

1745

1393

482

386

1461

1825

485

606

2294

1835

487

608

2303

1843

667

533

2524

2019

592

739

2799

2239

885

708

3349

2680

776

970

3671

2936

RECOVERY RATING CAPACITIES (GPH AND LPH)

129

116

194 734 249 943 289

1094

322

1219

322

1219

307

1162

322

1219

404

1529

406

1536

444

1682

493

1866

590

2233

646

2447

166 628 213 806 248 939 276

1045

276

1045

263 996 276

1045

346

1311

348

1316

381

1442

423

1599

506

1914

554

2097

145 549 187 708 217 821 241 912 241 912 230 871 241 912

303

1147

304

1152

333

1262

370

1399

442

1675

485

1835

488 166 628 193 731 214 810 214 810 205 776 214 810 269

1020

270

1024

296

1122

329

1244

393

1489

431

1631

439 149 564 174 659 193 731 193 731 184 697 193 731 242 918 243 921 267

1009

296

1120

354

1340

388

1468

106 401 136 515 158 598 175 662 175 662 167 632 175 662 220 834 221 838 242 918 269

1018

322

1218

353

1335

97 367 124 469 145 549 161 609 161 609 154 583 161 609 202 765 203 768 222 841 246 933 295 1116

323

1224

90 341 115 435 134 507 148 560 148 560 142 538 148 560 186 706 187 709 205 776 228 861 272

1031

298

1129

83 314 107 405 124 469 132 500 132 500 132 500 132 500 173 655 174 658 190 721

211 800 253 957 277

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

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

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.

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

388

498

579

643

614

643

808

811

889

986

291

1102

373

1412

434

1643

482

1825

461

1745

482

1825

606

2294

608

2303

667

2524

739

2799

873

3304

970

3671

1469

1885

2192

2434

2324

2434

3059

3071

3365

3732 1164 4405

1293 4894

RECOVERY RATING CAPACITIES (GPH AND LPH)

28° C 33° C 39° C 44° C 50° C 56° C 61° C 67° C 72° C 78° C

194

166

233 882 299

1132

347

1314

386

1461

368

1393

386

1461

485

1835

487

1843

533

2019

592

2239

698

2643

776

2936

734 249 943 289

1094

322

1219

307

1162

322

1219

404

1529

406

1536

444

1682

493

1866

582

2202

646

2447

628 213 806 248 939 276

1045

263 996 276

1045

346

1311

348

1316

381

1442

423

1599

499

1888

554

2097

145 549 187 708 217 821 241 912 230 871 241 912 303

1147

304

1152

333

1262

370

1399

436

1652

485

1835

129 488 166 628 193 731 214 810 205 776 214 810 269

1020

270

1024

296

1122

329

1244

388

1468

431

1631

116 439 149 564 174 659 193 731 184 697 193 731 242 918 243 921 267

1009

296

1120

349

1321

388

1468

106 401 136 515 158 598 175 662 167 632 175 662 220 834 221 838 242 918 269

1018

317

1201

353

1335

97 367 124 469 145 549 161 609 154 583 161 609 202 765 203 768 222 841 246 933 291

1101

323

1224

90 341 115 435 134 507 148 560 142 538 148 560 186 706 187 709 205 776 228 861 269

1016

298

1129

83 314 107 405 124 469 132 500 132 500 132 500 173 655 174 658 190 721 211 800 249 944

277

1049

TABLE 4. GAS AND ELECTRICAL CHARACTERISTICS

Gas Supply Pressure

Model Type of Gas All Models Natural 4.5" W.C. (1.12 kPa) 14" W.C. (3.48 kPa) 3.5" W.C. (0.87 kPa) 120/60 <5 All Models Propane 11.0" W.C. (2.74kPa) 14" W.C. (3.48kPa) 10.0" W.C. (2.49 kPa) 120/60 <5

Gas Manifold Pressure Volts/Hz AmperesMinimum Maximum

CAUTION

INSTALLATION CONSIDERATIONS

LOCATING THE WATER HEATER

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.

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.

Flammable items, pressurized containers or any other potential re hazardous articles must never be placed on or adjacent to the heater. Open containers or ammable 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 oor 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 oors 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 ow.

CLEARANCES

These heaters are approved for installation on combustible ooring 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, bafes, thermostats, cleanout openings or drain valves.

Read instruction manual before

installing, using or servicing

water heater.

There is a risk in using fuel burning appliances such as gas water

heaters in rooms, garages or other areas where gasoline, other

ammable liquids or engine driven equipment or vehicles are stored, operated or repaired. Flammable vapors are heavy and travel along the oor and may be ignited by the heater’s igniter or main burner ames causing re or explosion. Some local codes permit operation of gas appliances in such areas if they are installed 18” or more above the oor. This may reduce the risk if location in such an area cannot be avoided.

Do not install this water heater directly on a carpeted oor. A re 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 oor 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.

TABLE 5. INSTALLATION CLEARANCES

(RIGHT SIDE)B(LEFTSIDE)

120 1” (2.54 cm) 1” (2.54 cm) 1” (2.54 cm) 12” (30.48 cm)

154 1” (2.54 cm) 1” (2.54 cm) 1” (2.54 cm) 12” (30.48 cm)

*180 1” (2.54 cm) 1” (2.54 cm) 1” (2.54 cm) 12” (30.48 cm)

*197 1” (2.54 cm) 1” (2. 54 cm) 1” (2.54 cm) 12” (30.48 cm)

198 1” (2.54 cm) 1” (2. 54 cm) 1” (2.54 cm) 12” (30.48 cm)

*199 1” (2. 54 cm) 1” (2. 54 cm) 1” (2. 54 cm) 12” (30.48 cm)

200 1” (2. 54 cm) 1” (2. 54 cm) 1” (2. 54 cm) 12” (30.48 cm)

250 2” (5.08 cm) 2” (5.08 cm) 2” (5.08 cm) 12” (30.48 cm)

251 2” (5.08 cm) 2” (5.08 cm) 2” (5.08 cm) 12” (30.48 cm)

275 2” (5.08 cm) 2” (5.08 cm) 2” (5.08 cm) 12” (30.48 cm)

305 2” (5.08 cm) 2” (5.08 cm) 2” (5.08 cm) 12” (30.48 cm)

**365 3” (7.75 cm) 3” (7.75 cm) 3” (7.75 cm) 12” (30.48 cm)

400 3” (7.75 cm) 3” (7.75 cm) 3” (7.75 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.

(BACK)

(CEILING)

FIGURE 6.

NSF LEG KIT

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.

FIGURE 7.

INSULATION BLANKET

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 identication of components mentioned below. Failure to follow these instructions can restrict the air ow required for proper combustion, potentially resulting in re, 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 ow to the burners.

• DO NOT allow insulation to come within 9 inches (23 cm)

of oor, (within 2 inches (5 cm) of bottom cover) to prevent blockage of combustion air ow 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 ow.

HARD WATER

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.

CIRCULATION PUMPS

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

must be periodically oiled. Refer to the pump manufacturer’s

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 WATER HEATER AS THIS MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION.

instructions for lubrication requirements.

CIRCULATING PUMP WIRING DIAGRAM

STORAGE TANK OR BUILDING RECIRCULATION

FIELD SUPPLIED TEMPERATURE CONTROL INSTALLED IN THE STORAGE TANK

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

OR CIRCULATING LOOP RETURN LINE

CIRC

PUMP

MOTOR

Breathing Hazard - Carbon Monoxide Gas

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.

Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.

FIGURE 8.

CIRCULATING PUMP WIRING DIAGRAM

DISHWASHER LOOP WITH TOGGLE SWITCH

DISHWASHER TOGGLE SWITCH

NOTE: USE SEPARATE 120 VAC POWER SUPPLY FOR PUMP CIRCUIT. DO NOT SHARE POWER WITH WATER HEATER AS THIS MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION.

L1 HOT

120 VAC POWER

L2 NEUTRAL

FIELD SUPPLIED TEMPERATURE CONTROL INSTALLED IN THE CIRCULATING LOOP RETURN LINE

FIGURE 9.

HIGH ALTITUDE INSTALLATIONS

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.

CIRC

PUMP

MOTOR

Installations above 2000 feet (610 meters) require replacement of burner orifices in accordance with current edition of the National Fuel Gas Code (ANSI Z223.1). For Canadian installations consult Canadian Installations Code CAN/CSA B149.1. 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 sho u l d cont a ct your gas su pp l i er for any sp e c i f i c ch a ng e s 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 w i t h th e r e d u c e d ox yg e n su p p l y. Fa i l u r e to ma k e th i s re d u c t i o n would result in an over firing of the heater causing sooting, poor combustion and/or unsatisfactory heater performance.

Ratings specied 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 60 0 0 fe e t (1829 m) the correct input rating should be 59,280 Btuh (17.4 Kwh).

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 eld 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 specied 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 owing (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 red appliances connected to the common main ring at full capacity. If the supply pressure drops more than 1.5” W.C. as gas begins to ow 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 owing (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 specications.

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 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.

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 inrm 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 ts 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

satises 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 Qualied Installer or Service Agency. Follow mixing valve manufacturer’s instructions for installation of the valves.

TABLE 6.

Water Temperature °F

110 116 (pain threshold) 116 35 minutes 45 minutes 122 1 minute 5 minutes 131 5 seconds 25 seconds 140 2 seconds 5 seconds 149 1 second 2 seconds 154 instantaneous 1 second

(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978)

Time for 1st Degree Burn

(Less Severe Burns)

(normal shower temp.)

Time for Permanent Burns

2nd & 3rd Degree

(Most Severe Burns)

HOT WATER

OUTLET

TEMPERED WATER

OUTLET

12” TO 15” (30-38 cm)

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 technician 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

VALV E

TO TANK

INLET

CHECK

VALV E

MIXING

VALV E

FIGURE 10.

DISHWASHING MACHINES

All dishwashing machines meeting the National Sanitation Foundation requirements are designed to operate with water ow 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 ow 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 ow rate should be just enough to provide 180°F (82°C) water at the point of take-off to the dishwashing machine.

Adjust ow by throttling a full port ball valve installed in the circulating line on the outlet side of the pump. Never throttle ow 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 ow 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.

Explosion Hazard

Temperature-Pressure Relief Valve must comply with ANSI Z21.22CSA 4.4 and ASME code.

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.

This water heater is provided with a properly rated/sized and certied combination Temperature-Pressure Relief Valve (T&P valve) by the manufacturer. The valve is certied 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 TemperaturePressure Relief Valve rated/sized and certied 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 TemperaturePressure 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 tting 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 oor 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.

No valve or other obstruction is to be placed between the

CAUTION

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 ow may cause property damage.

Water Damage Hazard

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.

Temperature-Pressure Relief Valve discharge

•

pipe must terminate at adequate drain.

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 oor

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.

Burn hazard.

Hot water discharge.

Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.

Corrosion of the ue 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

Breathing Hazard - Carbon Monoxide Gas

Keep clear of TemperaturePressure Relief Valve discharge outlet.

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 TemperaturePressure 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.

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.

For safe operation an adequate supply of fresh uncontaminated air for combustion and ventilation must be provided.

An insufcient 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 ame, causing sooting of the combustion chamber, burners and ue tubes and creates a risk of asphyxiation.

Do not install the water heater in a conned space unless an adequate supply of air for combustion and ventilation is brought in to that space using the methods described in the Conned Space section that follows.

Never obstruct the ow 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 re or explosion and cause property damage, serious bodily injury or death.

UNCONFINED SPACE

An Unconned 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 unconned space.

Makeup air requirements for the operation of exhaust fans,

kitchen ventilation systems, clothes dryers and replaces shall also be considered in determining the adequacy of a space to provide combustion, ventilation and dilution air.

UNUSUALLY TIGHT CONSTRUCTION

In unconned spaces in buildings, inltration may be adequate to provide air for combustion, ventilation and dilution of ue 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 Conned Space section that follows.

CONFINED SPACE

A Conned 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 conned spaces. The required size for the openings is dependent on the method used to provide fresh air to the conned space and the total Btu/hr input rating of all appliances installed in the space.

DIRECT VENT APPLIANCES

Appliances installed in a Direct Vent conguration 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 conned 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, sufcient 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 re 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 specied. 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 xed 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 red 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.

Each adapter ts on top of the installed ue 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.

VENT REDUCER

Model BTR 120 is shipped with a 6" to 5" ue outlet adapter. Models BTR 250, 251 and 275 are shipped with a 8" to 6" ue outlet adapter.

FIGURE 12.

MULTIPLE HEATER MANIFOLD

Figure 13 and tables on pages 19 and 20 should be used for

horizontally manifolding two or more heaters.

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 conned spaces. The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into conned 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.

OUTDOOR AIR THROUGH ONE OPENING

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 mm2 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 14.

The conned 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

of all appliances installed in the enclosure. Each opening shall not be less than 100 square inches (645 cm

per kW) of the aggregate input rating

FIGURE 16.

The conned 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

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 conned 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.

AIR FROM OTHER INDOOR SPACES

FIGURE 18.

FIGURE 17.

The conned 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

per kW) of the aggregate input

rating of all appliances installed in the enclosure.

Each opening shall communicate directly with an additional room(s) of sufcient volume so that the combined volume of all spaces meets the criteria for an Unconned Space.

Each opening shall have a minimum free area of 1 square inch

per 1,000 Btu/hr (2200 mm2 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

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 (gure 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 10 15 20 30 50 100

Number of

Heaters

2 3

4 480 12 12 12 10 10 10 8 8

MODEL BTR(C)-154 Input: 154,000 Btuh Total Vent Height (Feet) Draft Hood: 6” 6 8 10 15 20 30 50 100

Numbers of

Heaters

2 3

4 616 14 14 12 12 12 10 1 10

Input Btuh Rise Vent Connector Diameter (inches)

120,000 1 Ft. 7 7 7 6 6 6 6 6 120,000 2 Ft. 6 6 6 6 6 6 6 5 120,000 3 Ft. 6 6 6 6 6 5 5 5

Combined Input in Thousands of Btuh

240 10 8 8 7 7 7 6 7 360 10 10 10 10 8 8 7 7

Input Btuh Rise Vent Connector Diameter (in inches)

154,000 1 Ft. 8 8 7 7 7 7 7 7 154,000 2 Ft. 7 7 7 7 7 6 6 6 154,000 3 Ft. 7 7 7 6 6 6 6 6

Combined Input in Thousands of Btuh

308 10 10 10 8 8 7 7 7 462 12 12 12 10 10 10 8 8

Manifold and Common Vent Diameter (In inches)

Manifold and Common Vent Diameter (in inches)

MODEL BTR(C)-180, 197, 198, 199, 200 Input: 180,000, 199,000 Btuh Total Vent Height (Feet) Draft Hood: 6” 6 8 10 15 20 30 50 100

Number of

Heaters

Input Btuh Rise Vent Connector Diameter (in inches)

180,000 1 Ft. 8 8 8 8 8 7 7 7 199,000 - - 8 8 8 8 8 7 180,000 2 Ft. 8 8 7 7 7 7 7 7 199,000 8 8 8 8 7 7 7 7 180,000 3 Ft. 7 7 7 7 7 7 6 6 199,000 8 8 7 7 7 7 7 6

Combined Input in Thousands of Btuh

360 10 10 10 10 8 8 7 7 398 12 10 10 10 10 8 8 7 540 14 12 12 12 10 10 10 8 597 14 14 12 12 12 10 10 10 720 14 14 14 12 12 12 10 10 796 16 14 14 14 12 12 12 10

Manifold & Common Vent Diameter

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.

WATER HEATER INSTALLATION

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 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

THERMOMETERS (NOT SUPPLIED)

Thermometers should be obtained and eld 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.

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 ow by throttling a full port ball valve installed in the circulating line on the outlet side of the pump. Never throttle ow 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 Z21.22CSA 4.4 and ASME code.

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.

This water heater is provided with a properly rated/sized and certied 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

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 oor 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 ow 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.

• 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 oor

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.

INSTALLATION DIAGRAMS - TOP INLET/OUTLET USAGE

Use of the top inlet water connection requires an inlet dip tube (refer to gure 19). The tube is supplied in the heater. Follow caution labels if applying heat to this tting. Do not allow pipe dope to contact the plastic tube during installation.

TUBE INLET INSTALLATION

FIGURE 19.

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

used for the ame sensor and igniter leads.

The controls of this water heater are polarity sensitive. Be certain to properly wire the hot and neutral connections.

24 VAC TO IGNITION CONTROL

DAMPER DRIVE

C type F must be

BLK

DAMPER

DRIVE

24 NEUTRAL

24 VAC

11E79

LINE IN

ON/OFF SWITCH

BLK

120 vac

NEUTRAL

PROPANE GAS VALV E

MV/PV

LOWER PROBE

UPPER PROBE/ECO

2 1

24 V

GND-BURNER

HONEYWELL IGNITION

C P

NATURAL GAS VALV E

LEGEND: W--WHITE BLK--BLACK BL--BLUE R--RED Y--YELLOW

SPARKER

BLK

MV/PV

24 V GND

FACTORY WIRED

BY INSTALLER

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED MUST BE REPLACED, USE ONLY TYPE 105O C THERMOPLASTIC OR EQUIVALENT. FLAME SENSOR IGNITION CABLE MUST BE 250O C TYPE F.

197287-000 REV 02

FIGURE 20.

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 gures 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 re 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 20 70 200 200 200 154,000 10 40 150 200 200 180,000 - 30 100 200 200 199,000 - 30 90 200 200 250,000 - 20 60 200 200 275,000 - 10 50 200 200 310,000 - 10 40 150 200 366,000 - - 30 100 200 390,000 - - 20 100 200

Fitting Type* Equivalent length in feet

45°Ell 0.7 1.0 1.2 1.6 1.9 90°Ell 1.6 2.1 2.6 3.5 4.0

Tee 3.1 4.1 5.2 6.9 8.0

*Screwed Fittings

Natural Gas 0.60 Specic Gravity, 0.50" W.C. Pressure Drop

It is important to guard against gas valve fouling from contaminants in gas ways. Such fouling may cause improper operation, re or explosion.

If copper supply lines are used they must be internally tinned and certied 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 rst two threads. Use compounds resistant to the action of liqueed petroleum gases.

Schedule 40 Steel or Wrought Iron Pipe

1/2" 3/4" 1" 1 1/4" 1 1/2"

GAS METER SIZE – NATURAL GASES ONLY

Be sure the gas meter has sufcient capacity to supply the full rated

gas input of the water heater as well as the requirements of all other

gas red 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

FIGURE 21.

GAS LINE LEAK TESTING

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.

Any time work is done on the gas supply system perform a leak test

to avoid the possibility of re 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, ame or other sources of ignition for this purpose.

4. Repair any leaks before placing the water heater in operation.

PURGING

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.

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 cer tain 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

water heater.

PRIOR TO START UP

Installation and start up of this water heater requires abilities and

skills equivalent to that of a licensed tradesman in the eld involved, see Qualications on page 6.

Do not place the water heater in operation if any part has been under water. Immediately call a qualied 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.

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 ame 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

FILLING THE WATER HEATER

Follow these steps to ll 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 ll with water.

4. Close hot water faucet opened in Step 2 as water starts to ow.

Read SEQUENCE OF OPER ATION 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.

is locked out, the power to the unit must be cycled to restart the Ignition Control.

8. If the pilot ame 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 ame stabilization period to insure that the pilot ame is not extinguished by the main burner light-off process.

10. The Ignition Control monitors the Flame Sensor during the heating cycle. If the ame 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 satised, 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 ow chart on page 26 for more information.

Description of this ow chart can be found in the “SEQUENCE OF OPERATION” section found on page 25.

IDLE

(NOT POWERED)

SEQUENCE OF OPERATION FLOW CHART

“CALL FOR HEAT” RECEIVED FROM

THERMOSTAT

POWER TO

MODULE AND

SELF CHECK

TRIAL FOR

IGNITION

(TIMER STARTED)

FLAME

PROVED?

(BEFORE TRIAL FOR IGNITION TIMER EXPIRES)

YES

SPARK ON

CLOSE PILOT

GAS VALV E

OPEN PILOT GAS

VALV E

SPARK OFF

RETRY DELAY

(5 MINUTES)

RETRY

RETRY OR

LOCKOUT

MODEL?

WAIT FOR “CALL FOR HEAT” TO BE REMOVED

ACTIVATE ALARM

CONTACT(S)

(OPTIONAL)

LOCKOUT

SPARK OFF

OPEN MAIN GAS

VALV E

FLAME

STABILIZATION

(2 SECONDS)

RUN

“CALL

FOR HEAT”

ENDS?

YES

CLOSE MAIN GAS VALVE AND PILOT

GAS VALV E

FLAME LOST?

YES

FLOW CHART 1.

CLOSE MAIN GAS VALV E AND PILOT

GAS VALV E

LIGHTING & OPERATION LABEL

FOR YOUR SAFETY READ BEFORE OPERATING

OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE OPERATING

FIGURE 22. LABEL FOR NATURAL GAS MODELS

FOR YOUR SAFETY READ BEFORE OPERATING

OPERATING INSTRUCTIONS

TO TURN OFF GAS TO APPLIANCE

FIGURE 23. LABEL FOR PROPANE GAS MODELS

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 ue 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 ring.

• The gas control valve must close and the main burner must have ceased ring before the damper disc begins its return to the closed (horizontal) position.

If during testing of the operation of the damper you nd 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

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 ue gas exhauster must be employed to assure 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.)

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 deciencies 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 replace 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, replace 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.

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

GAS

NATURAL PROPANE

BTUH

PER

CU. FT.

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 specied 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.

+ 90 hidden pages

A.O. Smith BTR-120, BTR-154, BTR-180, BTR-197, BTR-198 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual