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

...
4 (3)

Instruction Manual

COMMERCIAL GAS WATER HEATERS

500 Tennessee Waltz Parkway

Ashland City, TN 37015

LOW LEAD

CONTENT

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

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

WHAT TO DO IF YOU SMELL GAS:

Do not try to light any appliance.

Do not touch any electrical switch; do not use any phone in your building.

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

If you cannot reach your gas supplier, call the fire department.

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

Thankyouforbuyingthisenergyefficientwaterheater. We appreciate your confidence in our products.

MODELS BTR 120 - 400(A) BTRC 120 - 400(A)

SERIES 118/119

INSTALLATION - OPERATION - SERVICE - MAINTENANCE - LIMITED WARRANTY

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

Qualifications

6

Preparing for the Installation

6

FEATURES AND COMPONENTS

7

The Eliminator (Self Cleaning System)

7

High Limit Switch

7

Electronic Ignition Control

7

Automatic Flue Damper

7

Uncrating

7

INSTALLATION CONSIDERATIONS

8-12

Rough In Dimensions

8

Locating The Water Heater

10

Clearances

10

NSF Leg Kit

11

Insulation Blanket

11

Hard Water

11

Circulation Pumps

11-12

High Altitude Installations................................................................

12

INSTALLATION REQUIREMENTS

13

Gas Supply Systems.......................................................................

13

Supply Gas Regulator

13

Power Supply

13

Water Temperature Control and Mixing Valves

13

Dishwashing Machines

14

Closed Water Systems

14

Thermal Expansion

14

Temperature-Pressure Relief Valve

14-15

Contaminated Air

15

Air Requirements

15

Unconfined Space

16

Confined Space

16

VENTING INSTALLATION

16

Venting

16

Vent Reducer

16

Multiple Heater Manifold

17

Fresh Air Opening for Confined Spaces

17

Outdoor Air Through Two Openings

17

Outdoor Air Through One Opening

17

Outdoor Air Through Two Horizontal Ducts

17

Outdoor Air Through Two Vertical Ducts

18

Air From Other Indoor Spaces

18

Technical Data Venting

19-20

Mechanical Venting

21

WATER HEATER INSTALLATION

21-24

Water Line Connections

21

T&P Valve Discharge Pipe

21

Installation Diagrams - Top Inlet/Outlet Usage

22

Heater Wiring

23

Gas Piping

24

Gas Line Leak Testing

24

Purging

24

OPERATION

25

Prior to Start Up

25

SEQUENCE OF OPERATION

25

Sequence of Operation Flow Chart

26

Lighting & Operation Labels

27-28

Adjustments

29

Checking Venting

29

Checking the Input

29

MAINTENANCE

31

Venting System

31

Remote Storage Tank Temperature Control

31

Temperature-Pressure Relief Valve Test

31

Anode Rod Inspection

31-32

Draining and Flushing

32

Recommended Procedure for Periodic Removal or Lime Deposits

from the Tank Type Commercial Water Heaters

32

DeLiming Solvents

33

Tank Cleanout Procedure

33

Deliming Using Flo-Jug Method.................................................

33-34

Pilot Burner......................................................................................

34

Main Burner.....................................................................................

35

Gas Control Valve............................................................................

35

SERVICE

35

Electrical Servicing

35

TROUBLESHOOTING

36

Ignition Module................................................................................

36

Flue Damper....................................................................................

36

Effikal RVGP-KSF Series Flue Damper Trouble Shooting Guide........

37

Troubleshooting Checklist

38

FOR YOUR INFORMATION

39

Start up Conditions

39

Operational Conditions

39

WATER PIPING DIAGRAMS

40-54

MANIFOLD KITS

55

NOTES.............................................................................................

56-58

WARRANTY

59

2

SAFE INSTALLATION, USE AND SERVICE

The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.

Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use, or service this water heater.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates an imminently

DANGER hazardous situation which, if not avoided, will result in injury or death.

WARNING indicates a potentially hazardous

WARNING situation which, if not avoided, could result in injury or death.

CAUTION indicates a potentially hazardous

CAUTION situation which, if not avoided, could result in minor or moderate injury.

CAUTION used without the safety alert CAUTION symbol indicates a potentially hazardous

situation which, if not avoided, could result in property damage.

All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and how to avoid the risk of injury.

The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.

This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This water heater can cause low level exposure to some of the substances listed in the Act.

APPROVALS

LOW LEAD

CONTENT

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

3

GENERAL SAFETY INFORMATION

Fire or Explosion Hazard

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

Avoid all ignition sources if you smell gas.

Do not expose water heater controls to excessive gas pressure.

Use only the gas shown on the water heater rating label.

Maintain required clearances to combustibles.

Keep ignition sources away from faucets after extended periods of non-use.

Read instruction manual before installing, using or servicing water heater.

Fire Hazard

For continued protection against risk of fire:

Do not install water heater on carpeted floor.

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

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.

CAUTION

Property Damage Hazard

All water heaters eventually leak.

Do not install without adequate drainage.

Electrical Shock Hazard

Turn off power to the water heater before performing any service.

Label all wires prior to disconnecting when performing service. Wiring errors can cause improper and dangerous operation.

Verify proper operation after servicing.

Failure to follow these instructions can result in personal injury or death.

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.

4

GENERAL SAFETY INFORMATION

Read and understand this instruction manual and the safety messages herein before installing, operating or servicing this water heater.

Failure to follow these instructions and safety messages could result in death or serious injury.

This manual must remain with the water heater.

Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death.

Children, the elderly and the physically or mentally disabled are at highest risk for scald injury.

Feel water before bathing or showering.

Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at fixtures.

Explosion Hazard

Overheated water can cause water tank explosion.

Properly sized temperature and pressure relief valve must be installed in the opening provided.

CAUTION

Improper installation, use and service may result in property damage.

Do not operate water heater if 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.

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 fire.

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 flammable. To reduce the risk of injury under these conditions, it is recommended that a hot water faucet served by this water heater be opened for several minutes before using any electrical appliance connected to the hot water system. If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow. THERE SHOULD BE NO SMOKING OR OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.

5

INTRODUCTION

Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service.

ABBREVIATIONS USED

Abbreviations found in this Instruction Manual include :

ANSI - American National Standards Institute

ASME - American Society of Mechanical Engineers

AHRI - Air-Conditioning, Heating and Refrigeration Institute

NEC - National Electrical Code

NFPA - National Fire Protection Association

UL - Underwriters Laboratory

CSA - Canadian Standards Association

QUALIFICATIONS

QUALIFIED INSTALLER OR SERVICE AGENCY

Installation and service of this water heater requires ability equivalent to that of a Qualified Agency (as defined by ANSI below) in the field involved. Installation skills such as plumbing, air supply, venting, gas supply and electrical supply are required in addition to electrical testing skills when performing service.

ANSI Z223.1 2006 Sec. 3.3.83: “Qualified Agency” - “Any individual, firm, corporation or company that either in person or through a representative is engaged in and is responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair or servicing of appliances and equipment; that is experienced in such work; that is familiar with all precautions required; and that has complied with all the requirements of the authority having jurisdiction.”

If you are not qualified (as defined by ANSI above) and licensed or certified as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the procedures described in this manual. If you do not understand the instructions given in this manual do not attempt to perform any procedures outlined in this manual.

PREPARING FOR THE INSTALLATION

1.Read the “General Safety” section, page 4-5 of this manual first and then the entire manual carefully. If you don’t follow

the safety rules, the water heater will not operate properly. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.

This manual contains instructions for the installation, operation, and maintenance of the gas-fired water heater. It also contains warnings throughout the manual that you must read and be aware of. All warnings and all instructions are essential to the proper operation of the water heater and your safety. Since we cannot put everything on the first few pages, READTHE ENTIRE

MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE

THE WATER HEATER.

2.The installation must conform with these instructions and the local code authority having jurisdiction. In the absence of local codes, the installation must comply with the current editions of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or CAN/ CSA-B149.1 the Natural Gas and Propane Installation Code. All documents are available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131. NFPA documents are also available from the National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

3.If after reading this manual you have any questions or do not understand any portion of the instructions, call the local gas utility or the manufacturer whose name appears on the rating plate.

4.Carefully plan the place where you are going to put the water heater. Correct combustion, vent action, and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and fires.

Examine the location to ensure the water heater complies with the “Locating the New Water Heater” section in this manual.

5.For California installation this water heater must be braced, anchored, or strapped to avoid falling or moving during an earthquake. See instructions for correct installation procedures. Instructions may be obtained from California Office of the State Architect, 400 P Street, Sacramento, CA 95814.

6.Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248-CMR 2.00: State Plumbing Code and 248-CMR 5.00.

6

FEATURES AND COMPONENTS

THE ELIMINATOR (SELF-CLEANING SYSTEM)

TheseunitsincludeTheEliminator(Self-CleaningSystem)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 Eliminatorinlettubeineitherthetoporbackinletwaterconnection. TheEliminatormustbeorientedcorrectlyforproperfunction.There is a marked range on pipe nipple portion of the Eliminator, that must be aligned with top of inlet spud.Alabel 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.Apipe 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 poorperformanceofheaterandcansignificantlyreduceoutletwater 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 flow should the water temperature reach 203°F (95°C).

Intheeventofhighlimitswitchoperation,thewaterheatercannotbe 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 thanusualwatertemperatureisevidenceofhighlimitswitchoperation. The following is a possible reason for high limit switch operation:

Amalfunction 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.

burns during each running cycle. The main burner and pilot gases arecut offduringthe OFF cycle.Pilotgas ignition is proven by the pilot sensor. Main burner ignition will not occur if the pilot sensor does not first sense pilot ignition.

IGNITION MODULE

FIGURE 3.

AUTOMATIC FLUE DAMPER

All units are equipped with an automatic flue damper that reduces heat loss during the OFF cycles. The automatic flue damper drive assembly is a field replaceable part and may be obtained by contacting A. O. Smith Corporation at 500 Tennessee Waltz Parkway, Ashland City, TN 37015, 1-800-433-2545. In Canada, contact A.O. Smith Enterprises LTD., P.O. Box, 310 - 768 Erie Street, Stratford, Ontario, Canada N5A 6T3, 1-800-265-8520.

Each automatic flue damper drive assembly is equipped with a “Service Switch”, as shown in Figure 4

The “Service Switch” has 2 positions:AUTOMATIC OPERATION and HOLD OPEN DAMPER. For normal operation the switch should be in the AUTOMATIC OPERATION position.

If there is a problem with the damper the “Service Switch” can be placed in the HOLD OPEN DAMPER position. When the switch is placed in the HOLD OPEN DAMPER position the damper disc will rotate to the open position and the heater may be used until vent assembly is repaired or replaced. DO NOT turn the damper discmanually;damagewilloccurtothedriveassemblyifoperated 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 solidstateignitioncontrolignitesthepilotburnergasbycreatinga spark at the pilot assembly. See Figure 3. Pilot gas is ignited and

FLUE DAMPER

FIGURE 4.

UNCRATING

The heater is shipped with the flue damper already installed. The wiring conduit runs from the thermostat to the damper drive cover. Before turning unit on, check to make sure the wiring conduit is securely plugged into damper drive.

7

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

INPUT

 

 

APPROX

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GAS

 

 

 

VENT

 

 

 

 

 

 

 

CONNECTIONS

 

Approximate

MODEL

 

RATE

 

 

TANK

 

 

A

 

 

B

 

C

 

 

D

 

E

 

F

 

INLET

H

 

DIA

 

J

 

 

 

 

INLET

 

 

 

OUTLET

 

ship. Weight

 

 

BTU/Hr.

 

 

CAP.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

G

 

 

 

 

 

I

 

 

 

 

TOP

FRONT

BACK

TOP

FRONT

 

BACK

STD.

 

ASME

BTR120

 

120,000 BTU/Hr.

 

71 Gal

 

 

69.75”

 

4.25”

 

59.50”

 

 

50.87”

 

19.69”

19”

 

1/2”

 

51.88”

6”

 

27.75”

 

1.50”

1.50”

1.50”

1.50”

1.50”

 

1.50”

400 Lbs

 

NA

 

 

35 Kw/Hr

 

 

268 L

 

 

177 cm

11 cm

 

151 cm

 

 

129 cm

50 cm

48 cm

 

1/2”

 

132 cm

15 cm

71 cm

 

1.50”

1.50”

1.50”

1.50”

1.50”

 

1.50”

182 Kg

 

NA

BTR154

 

154,000 BTU/Hr

 

81 Gal

 

 

73.00”

 

4.25”

 

66.50”

 

 

57.87”

 

19.69”

19”

 

1/2”

 

59.00”

6”

 

27.75”

 

1.50”

1.50”

1.50”

1.50”

1.50”

 

1.50”

470 Lbs

 

NA

 

45 Kw/Hr

 

 

307 L

 

 

185 cm

11 cm

 

169 cm

 

147 cm

50 cm

48 cm

 

1/2”

 

150 cm

15 cm

71 cm

 

1.50”

1.50”

1.50”

1.50”

1.50”

 

1.50”

21 3 Kg

 

NA

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR180

 

180,000 BTU/Hr

 

81Gal

 

 

67.50”

 

4.50”

 

62.00”

 

 

53.62”

 

20.50”

21”

 

1/2”

 

54.62”

6”

 

27.75”

 

1.50”

1.50”

1.50”

1.50”

1.50”

 

1.50”

470 Lbs

 

NA

 

53 Kw/Hr

 

 

307 L

 

 

171 cm

12 cm

 

157 cm

 

136 cm

52 cm

53 cm

 

1/2”

 

139 cm

15 cm

71 cm

 

1.50”

1.50”

1.50”

1.50”

1.50”

 

1.50”

21 3 Kg

 

NA

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR197

 

199,000 BTU/Hr

 

100 Gal

 

75.00”

 

4.50”

 

70.00”

 

 

61.62”

 

20.50”

21”

 

1/2”

 

62.62”

6”

 

27.75”

 

1.50”

1.50”

1.50”

1.50”

1.50”

 

1.50”

603 Lbs

 

NA

 

58 kW/Hr

 

 

379 L

 

 

192 cm

12 cm

 

178 cm

 

157 cm

52 cm

53 cm

 

1/2”

 

159 cm

15 cm

71 cm

 

1.50”

1.50”

1.50”

1.50”

1.50”

 

1.50”

273 Kg

 

NA

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR198

 

199,000 BTU/Hr.

 

100 Gal

 

75.00”

 

4.50”

 

70.00”

 

 

61.62”

 

20.50”

21”

 

1/2”

 

61.50”

6”

 

27.75”

 

1.50”

1.50”

2.00”

1.50”

1.50”

 

2.00”

603 Lbs

 

NA

 

 

58 Kw/Hr

 

 

379 L

 

 

192 cm

12 cm

 

178 cm

 

157 cm

52 cm

53 cm

 

1/2”

 

150 cm

15 cm

71 cm

 

1.50”

1.50”

2.00”

1.50”

1.50”

 

2.00”

273 Kg

 

NA

BTR199

 

199,000 BTU/Hr

 

81 Gal

 

 

67.50”

 

4.50”

 

62.00”

 

 

53.62”

 

20.50”

21”

 

1/2”

 

54.62”

6”

 

27.75”

 

1.50”

1.50”

1.50”

1.50”

1.50”

 

1.50”

470 Lbs

 

NA

 

58 kW/Hr

 

 

307 L

 

 

171 cm

12 cm

 

157 cm

 

136 cm

52 cm

53 cm

 

1/2”

 

139 cm

15 cm

71 cm

 

1.50”

1.50”

1.50”

1.50”

1.50”

 

1.50”

21 3 Kg

 

NA

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR 200

 

199,000 BTU/Hr

 

100 Gal

 

72.00”

 

4.50”

 

65.13”

 

 

55.87”

 

19.75”

23”

 

1/2”

 

56.38”

6”

 

30.25”

 

1.50”

2.00”

2.00”

1.50”

2.00”

 

2.00”

630 Lbs

 

725 Lbs

 

58 kW/Hr

 

 

379 L

 

 

183 cm

12 cm

 

165 cm

 

142 cm

50 cm

58 cm

 

1/2”

 

143 cm

15 cm

77 cm

 

1.50”

2.00”

2.00”

1.50”

2.00”

 

2.00”

286 Kg

 

329 Kg

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR 250

 

250,000 BTU/Hr

 

100 Gal

 

72.00”

 

4.50”

 

65.13”

 

 

55.87”

 

19.75”

23”

 

1/2”

 

56.38”

8”

 

30.25”

 

1.50”

2.00”

2.00”

1.50”

2.00”

 

2.00”

630 Lbs

 

725 Lbs

 

72 kW/Hr

 

 

379 L

 

 

183 cm

12 cm

 

165 cm

 

142 cm

50 cm

58 cm

 

1/2”

 

143 cm

20 cm

77 cm

 

1.50”

2.00”

2.00”

1.50”

2.00”

 

2.00”

286 Kg

 

329 Kg

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR 251

 

251,000 BTU/Hr

 

65 Gal

 

 

75.00”

 

4.50”

 

65.75”

 

 

57.25”

 

20.00”

NA

 

1/2”

 

58.75

 

8”

 

27.75”

 

NA

1.50”

1.50”

NA

1.50”

 

1.50”

750Lbs

 

862 Lbs

 

73 kW/Hr

 

 

246 L

 

 

191 cm

12 cm

 

167 cm

 

145 cm

51 cm

NA

 

1/2”

 

149 cm

20 cm

70 cm

 

NA

1.50”

1.50”

NA

1.50”

 

1.50”

341 Kg

 

391 Kg

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR 275

 

275,000 BTU/Hr

 

100 Gal

 

72.00”

 

4.50”

 

65.13”

 

 

55.87”

 

19.75”

23”

 

1/2”

 

56.38”

8”

 

30.25”

 

1.50”

2.00”

2.00”

1.50”

2.00”

 

2.00”

630 Lbs

 

725 Lbs

 

80 kW/Hr

 

 

379 L

 

 

183 cm

12 cm

 

165 cm

 

142 cm

50 cm

58 cm

 

1/2”

 

143 cm

20 cm

77 cm

 

1.50”

2.00”

2.00”

1.50”

2.00”

 

2.00”

286 Kg

 

329 Kg

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR 305

 

305,000 BTU/Hr

 

65 Gal

 

 

75.00”

 

4.50”

 

65.75”

 

 

57.25”

 

20.00”

NA

 

1/2”

 

58.75

 

8”

 

27.75”

 

NA

1.50”

1.50”

NA

1.50”

 

1.50”

750 Lbs

 

862 Lbs

 

89 kW/Hr

 

 

246 L

 

 

191 cm

12 cm

 

167 cm

 

145 cm

51 cm

NA

 

1/2”

 

149 cm

20 cm

70 cm

 

NA

1.50”

1.50”

NA

1.50”

 

1.50”

341 Kg

 

391 Kg

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR 365

 

365,000 BTU/Hr

 

85 Gal

 

 

79.50”

 

4.50”

 

70.25”

 

 

62.50”

 

22.50”

23”

 

3/4”

 

63.00

 

8”

 

27.75”

 

1.50”

1.50”

1.50”

1.50”

1.50”

 

1.50”

725 Lbs

 

833 Lbs

 

107kW/Hr

 

 

322 L

 

 

202 cm

12 cm

 

178 cm

 

159 cm

57 cm

58 cm

 

3/4”

 

160 cm

20 cm

70 cm

 

1.50”

1.50”

1.50”

1.50”

1.50”

 

1.50”

329 Kg

 

379 Kg

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR 400

 

390,000 BTU/Hr

 

100 Gal

 

75.50”

 

4.50”

 

67.50”

 

 

58.25”

 

26.75”

23”

 

3/4”

 

59.00”

8”

 

30.25”

 

1.50”

2.00”

2.00”

1.50”

2.00”

 

2.00”

760 Lbs

 

874 Lbs

 

114kW/Hr

 

 

379 L

 

 

192 cm

12 cm

 

171 cm

 

 

148 cm

68 cm

58 cm

 

3/4”

 

150 cm

20 cm

77 cm

 

1.50”

2.00”

2.00”

1.50”

2.00”

 

2.00”

345 Kg

 

396 Kg

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TABLE 1B. BTRC MODELS 120 THROUGH 400/A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

INPUT

APPROX.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GAS

 

 

 

 

VENT

 

 

 

 

 

 

 

 

CONNECTIONS

 

Approximate

MODEL

 

RATE

 

TANK

 

 

 

A

 

 

B

 

 

C

 

 

 

D

 

 

E

 

F

INLET

 

 

H

 

 

DIA

 

 

J

 

 

 

 

INLET

 

 

 

OUTLET

 

ship. Weight

 

 

BTU/Hr.

 

 

CAP.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

G

 

 

 

 

 

I

 

 

 

 

TOP

FRONT

 

BACK

 

TOP

FRONT

 

BACK

STD.

 

ASME

BTRC120

120,000 BTU/Hr.

 

71 Gal

 

 

69.75”

 

4.25”

 

59.50”

 

 

50.87”

 

19.69”

 

19”

 

1/2”

 

51.88”

 

 

6”

 

27.75”

1.50”

 

1.50”

 

1.50”

 

1.50”

1.50”

 

1.50”

400 LBS

 

NA

 

 

35 Kw/Hr

 

 

268 L

 

177 cm

 

11 cm

 

151 cm

 

129 cm

 

50 cm

48 cm

 

1/2”

 

132 cm

 

15 cm

 

71 cm

1.50”

 

1.50”

 

1.50”

 

1.50”

1.50”

 

1.50”

182 Kg

 

NA

BTRC154

 

154,000 BTU/Hr

 

81 Gal

 

 

73.00”

 

4.25”

 

66.50”

 

 

57.87”

 

19.69”

 

19”

 

1/2”

 

59.00”

 

 

6”

 

27.75”

1.50”

 

1.50”

 

1.50”

 

1.50”

1.50”

 

1.50”

470 LBS

 

NA

 

 

45 Kw/Hr

 

 

307 L

 

185 cm

 

11 cm

 

169 cm

 

147 cm

 

50 cm

48 cm

 

1/2”

 

150 cm

 

15 cm

 

71 cm

1.50”

 

1.50”

 

1.50”

 

1.50”

1.50”

 

1.50”

213Kq

 

NA

BTRC180

 

180,000 BTU/Hr

 

76 Gal

 

 

70.50”

 

4.25”

 

63.75”

 

 

55.13”

 

17.75”

 

19”

 

1/2”

 

56.50”

 

 

6”

 

27.75”

1.50”

 

1.50”

 

1.50”

 

1.50”

1.50”

 

1.50”

470 LBS

 

NA

 

 

53 Kw/Hr

 

 

288 L

 

179 cm

 

11 cm

 

162 cm

 

140 cm

 

45 cm

48 cm

 

1/2”

 

144 cm

 

15 cm

 

71 cm

1.50”

 

1.50”

 

1.50”

 

1.50”

1.50”

 

1.50”

213Kq

 

NA

BTRC197

 

199,000 BTU/Hr

 

94 Gal

 

 

81.50”

 

4.25”

 

74.75”

 

 

66.13”

 

17.75”

 

19”

 

1/2”

 

67.50”

 

 

6”

 

27.75”

1.50”

 

1.50”

 

1.50”

 

1.50”

1.50”

 

1.50”

603 LBS

 

NA

 

 

58 kW/Hr

 

 

356 L

 

207 cm

 

11 cm

 

190 cm

 

168 cm

 

45 cm

48 cm

 

1/2”

 

171 cm

 

15 cm

 

71 cm

1.50”

 

1.50”

 

1.50”

 

1.50”

1.50”

 

1.50”

273 Kg

 

NA

BTRC199

 

199,000 BTU/Hr

 

76 Gal

 

 

70.50”

 

4.25”

 

63.75”

 

 

55.13”

 

17.75”

 

19”

 

1/2”

 

56.50”

 

 

6”

 

27.75”

1.50”

 

1.50”

 

1.50”

 

1.50”

1.50”

 

1.50”

470 LBS

 

NA

 

 

58 kW/Hr

 

 

288 L

 

179 cm

 

11 cm

 

162 cm

 

140 cm

 

45 cm

48 cm

 

1/2”

 

144 cm

 

15 cm

 

71 cm

1.50”

 

1.50”

 

1.50”

 

1.50”

1.50”

 

1.50”

213Kq

 

NA

BTRC200

 

199,000 BTU/Hr

 

100 Gal

 

 

72.00”

 

4.50”

 

65.13”

 

 

55.87”

 

19.75”

 

23”

 

1/2”

 

56.38”

 

 

6”

 

30.25”

1.50”

 

2.00”

 

2.00”

 

1.50”

2.00”

 

2.00”

630 Ibs

 

725 Ibs

 

 

58 kW/Hr

 

379 L

 

183 cm

12 cm

 

165 cm

 

142 cm

 

50 cm

58 cm

 

1/2”

 

143 cm

 

15 cm

 

77 cm

1.50”

 

2.00”

 

2.00”

 

1.50”

2.00”

 

2.00”

286 Kg

 

329 Kg

BTRC250

 

250,000 BTU/Hr

 

100 Gal

 

 

72.00”

 

4.50”

 

65.13”

 

 

55.87”

 

19.75”

 

23”

 

1/2”

 

56.38”

 

 

8”

 

30.25”

1.50”

 

2.00”

 

2.00”

 

1.50”

2.00”

 

2.00”

630 Ibs

 

725 Ibs

 

 

72 kW/Hr

 

379 L

 

183 cm

12 cm

 

165 cm

 

142 cm

 

50 cm

58 cm

 

1/2”

 

143 cm

 

20 cm

 

77 cm

1.50”

 

2.00”

 

2.00”

 

1.50”

2.00”

 

2.00”

286 Kg

 

329 Kg

BTRC251

 

251,000 BTU/Hr

 

65 Gal

 

 

75.00”

 

4.50”

 

65.75”

 

 

57.25”

 

20.00”

 

NA

 

1/2”

58.8 149

 

 

8”

 

27.75”

 

NA

 

1.50”

 

1.50”

 

NA

1.50”

 

1.50”

750 Ibs

 

862 Ibs

 

 

73 kW/Hr

 

 

246 L

 

191 cm

12 cm

 

167 cm

 

145 cm

 

51 cm

 

NA

 

1/2”

 

 

cm

 

20 cm

 

70 cm

 

NA

 

1.50”

 

1.50”

 

NA

1.50”

 

1.50”

341 Kg

 

391 Kg

BTRC275

 

275,000 BTU/Hr

 

100 Gal

 

 

72.00”

 

4.50”

 

65.13”

 

 

55.87”

 

19.75”

 

23”

 

1/2”

 

56.38”

 

 

8”

 

30.25”

1.50”

 

2.00”

 

2.00”

 

1.50”

2.00”

 

2.00”

630 Ibs

 

725 Ibs

 

 

80 kW/Hr

 

379 L

 

183 cm

12 cm

 

165 cm

 

142 cm

 

50 cm

58 cm

 

1/2”

 

143 cm

 

20 cm

 

77 cm

1.50”

 

2.00”

 

2.00”

 

1.50”

2.00”

 

2.00”

286 Kg

 

329 Kg

BTRC305

 

305,000 BTU/Hr

 

65 Gal

 

 

75.00”

 

4.50”

 

65.75”

 

 

57.25”

 

20.00”

 

NA

 

1/2”

58.8 149

 

 

8”

 

27.75”

 

NA

 

1.50”

 

1.50”

 

NA

1.50”

 

1.50”

750 Ibs

 

862 Ibs

 

 

89 kW/Hr

 

 

246 L

 

191 cm

12 cm

 

167 cm

 

145 cm

 

51 cm

 

NA

 

1/2”

 

 

cm

 

20 cm

 

70 cm

 

NA

 

1.50”

 

1.50”

 

NA

1.50”

 

1.50”

341 Kg

 

391 Kg

BTRC365

 

365,000 BTU/Hr

 

65 Gal

 

 

75.00”

 

4.50”

 

65.75”

 

 

57.25”

 

20.00”

 

NA

 

3/4”

 

 

58.8

 

 

8”

 

27.75”

 

NA

 

1.50”

 

1.50”

 

NA

1.50”

 

1.50”

750 Ibs

 

862 Ibs

 

 

107kW/Hr

 

 

246 L

 

191 cm

12 cm

 

167 cm

 

145 cm

 

51 cm

 

NA

 

3/4”

 

149cm

 

20 cm

 

70 cm

 

NA

 

1.50”

 

1.50”

 

NA

1.50”

 

1.50”

341 Kg

 

391 Kg

BTRC400

 

390,000 BTU/Hr

 

100 Gal

 

 

75.50”

 

4.50”

 

67.50”

 

 

58.25”

 

26.75”

 

23”

 

3/4”

 

59.00”

 

 

8”

 

30.25”

1.50”

 

2.00”

 

2.00”

 

1.50”

2.00”

 

2.00”

760 Ibs

 

874 Ibs

 

 

114kW/Hr

 

379 L

 

192 cm

12 cm

 

171 cm

 

148 cm

 

68 cm

58 cm

 

3/4”

 

150 cm

 

20 cm

 

77 cm

1.50”

 

2.00”

 

2.00”

 

1.50”

2.00”

 

2.00”

345 Kg

 

396 Kg

8

INSTALLATION CONSIDERATIONS

TABLE 2. HEATER PERFORMANCE DATA BTR MODELS

 

 

 

 

INPUT

APPROX.

EFF.

 

 

 

 

 

 

 

RECOVERY RATING CAPACITIES (GPHAND LPH)

 

 

MODEL

 

 

 

RATE

GAL.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

30°F

40°F

50°F

 

60°F

 

70°F

80°F

90°F

 

100°F

110°F

 

120°F

 

130°F

 

140°F

 

 

 

 

BTUH

CAP.

 

%

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

17°C

22° C

28°C

 

33°C

 

39° C

44°C

50°C

 

56°C

61°C

 

67°C

 

 

72°C

 

78°C

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR

 

 

120,000 BTUH

71Gal

 

80

388

291

233

 

 

194

 

166

 

145

 

129

 

 

116

 

106

 

 

97

 

 

90

 

 

83

120

 

 

 

35Kw/Hr

268L

 

1469

1102

882

 

 

734

 

628

 

549

 

488

 

 

439

 

401

 

 

367

 

 

341

 

 

314

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR

 

 

154,000 BTUH

81Gal

 

80

498

373

299

 

 

249

 

213

 

187

 

166

 

 

149

 

136

 

 

124

 

 

115

 

 

107

154

 

 

 

45Kw/Hr

306L

 

1885

1412

1132

 

 

943

 

806

 

708

 

628

 

 

564

 

515

 

 

469

 

 

435

 

 

405

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR

 

 

180,000 BTUH

81Gal

 

80

579

434

347

 

 

289

 

248

 

217

 

193

 

 

174

 

158

 

 

145

 

 

134

 

 

124

180

 

 

 

53Kw/Hr

306L

 

2192

1643

1314

 

 

1094

 

939

 

821

 

731

 

 

659

 

598

 

 

549

 

 

507

 

 

469

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR

 

 

199,000 BTUH

100Gal

 

80

643

482

386

 

 

322

 

276

 

241

 

214

 

 

193

 

175

 

 

161

 

 

148

 

 

132

197

 

 

 

58Kw/Hr

379L

 

2434

1825

1461

 

 

1219

 

1045

 

912

 

810

 

 

731

 

662

 

 

609

 

 

560

 

 

500

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR

 

 

199,000 BTUH

100Gal

 

80

643

482

386

 

 

322

 

276

 

241

 

214

 

 

193

 

175

 

 

161

 

 

148

 

 

132

198

 

 

 

58Kw/Hr

379L

 

2434

1825

1461

 

 

1219

 

1045

 

912

 

810

 

 

731

 

662

 

 

609

 

 

560

 

 

500

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR

 

 

199,000 BTUH

81Gal

 

80

614

461

368

 

 

307

 

263

 

230

 

205

 

 

184

 

167

 

 

154

 

 

142

 

 

132

199

 

 

 

58Kw/Hr

306L

 

2324

1745

1393

 

 

1162

 

996

 

871

 

776

 

 

697

 

632

 

 

583

 

 

538

 

 

500

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR

 

 

199,000 BTUH

100Gal

 

80

643

482

386

 

 

322

 

276

 

241

 

214

 

 

193

 

175

 

 

161

 

 

148

 

 

132

200

 

 

 

58Kw/Hr

379L

 

2434

1825

1461

 

 

1219

 

1045

 

912

 

810

 

 

731

 

662

 

 

609

 

 

560

 

 

500

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR

 

 

250,000 BTUH

100Gal

 

80

808

606

485

 

 

404

 

346

 

303

 

269

 

 

242

 

220

 

 

202

 

 

186

 

 

173

250

 

 

 

73Kw/Hr

379L

 

3059

2294

1835

 

 

1529

 

1311

 

1147

 

1020

 

918

 

834

 

 

765

 

 

706

 

 

655

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR

 

 

251,000BTUH

65Gal

 

80

811

608

487

 

 

406

 

348

 

304

 

270

 

 

243

 

221

 

 

203

 

 

187

 

 

174

251

 

 

 

73Kw/Hr

246L

 

3071

2303

1843

 

 

1536

 

1316

 

1152

 

1024

 

921

 

838

 

 

768

 

 

709

 

 

658

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR

 

 

275,000 BTUH

100Gal

 

80

889

667

533

 

 

444

 

381

 

333

 

296

 

 

267

 

242

 

 

222

 

 

205

 

 

190

275

 

 

 

80Kw/Hr

379L

 

3365

2524

2019

 

 

1682

 

1442

 

1262

 

1122

 

 

1009

918

 

 

841

 

 

776

 

 

721

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR

 

 

305,000 BTUH

65Gal

 

80

986

739

592

 

 

493

 

423

 

370

 

329

 

 

296

 

269

 

 

246

 

 

228

 

 

211

305

 

 

 

89Kw/Hr

246L

 

3732

2799

2239

 

 

1866

 

1599

 

1399

 

1244

 

1120

 

1018

 

 

933

 

 

861

 

 

800

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR

 

 

365,000

85Gal

 

80

1180

885

708

 

 

590

 

506

 

442

 

393

 

 

354

 

322

 

 

295

 

 

272

 

 

253

365

 

 

 

107Kw/Hr

322L

 

4466

3349

2680

 

 

2233

 

1914

 

1675

 

1489

 

1340

1218

 

 

1116

 

 

1031

 

 

957

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTR

 

 

390,000 BTUH 1

100Gal

 

80

1293

970

 

776

 

 

646

 

554

 

485

 

431

 

 

388

 

353

 

 

323

 

 

298

 

 

277

400

 

 

 

14Kw/Hr

379L

 

4894

3671

2936

 

 

2447

 

2097

 

1835

 

1631

 

 

1468

1335

 

 

1224

 

 

1129

 

 

1049

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TABLE 3. HEATER PERFORMANCE DATA BTRC MODELS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MODEL

 

INPUT RATE

APPROX.

EFF.

 

 

 

 

 

 

RECOVERY RATING CAPACITIES (GPHAND LPH)

 

 

 

 

 

 

 

 

 

 

 

BTUH

GAL.

 

%

30°F

40°F

50°F

 

60°F

 

70°F

 

80°F

 

90°F

 

100° F

 

110°F

 

 

120°F

 

130° F

 

 

140°F

 

 

 

 

 

CAP.

 

 

17°C

22° C

28°C

 

33°C

 

39° C

 

44°C

 

50°C

 

 

56°C

 

61°C

 

 

67°C

 

 

72°C

 

 

78°C

BTRC

 

120,000 BTUH

71Gal

 

80

388

291

 

233

 

 

194

166

 

145

 

129

 

116

 

106

 

 

97

 

90

 

83

120

 

 

 

35Kw/Hr

268L

 

1469

1102

 

882

 

 

734

628

 

549

 

488

 

439

 

401

 

 

367

 

341

 

314

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTRC

 

154,000 BTUH

81Gal

 

80

498

373

 

299

 

 

249

213

 

187

 

166

 

149

 

136

 

 

124

 

115

 

107

154

 

 

 

45Kw/Hr

306L

 

1885

1412

1132

 

 

943

806

 

708

 

628

 

564

 

515

 

 

469

 

435

 

405

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTRC

 

180,000 BTUH

76Gal

 

80

579

434

 

347

 

 

289

248

 

217

 

193

 

174

 

158

 

 

145

 

134

 

124

180

 

 

 

53Kw/Hr

288L

 

2192

1643

1314

 

 

1094

939

 

821

 

731

 

659

 

598

 

 

549

 

507

 

469

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTRC

 

199,000 BTUH

94Gal

 

80

643

482

 

386

 

 

322

276

 

241

 

214

 

193

 

175

 

 

161

 

148

 

132

197

 

 

 

58Kw/Hr

356L

 

2434

1825

1461

 

 

1219

1045

 

912

 

810

 

731

 

662

 

 

609

 

560

 

500

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTRC

 

199,000 BTUH

76Gal

 

80

614

461

 

368

 

 

307

263

 

230

 

205

 

184

 

167

 

 

154

 

142

 

132

199

 

 

 

58Kw/Hr

288L

 

2324

1745

1393

 

 

1162

996

 

871

 

776

 

697

 

632

 

 

583

 

538

 

500

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTRC

 

199,000 BTUH

100Gal

 

80

643

482

 

386

 

 

322

276

 

241

 

214

 

193

 

175

 

 

161

 

148

 

132

200

 

 

 

58Kw/Hr

379L

 

2434

1825

1461

 

 

1219

1045

 

912

 

810

 

731

 

662

 

 

609

 

560

 

500

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTRC

 

250,000 BTUH

100Gal

 

80

808

606

 

485

 

 

404

346

 

303

 

269

 

242

 

220

 

 

202

 

186

 

173

250

 

 

 

73Kw/Hr

379L

 

3059

2294

1835

 

 

1529

1311

 

1147

 

1020

 

918

 

834

 

 

765

 

706

 

655

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTRC

 

251,000BTUH

65Gal

 

80

811

608

 

487

 

 

406

348

 

304

 

270

 

243

 

221

 

 

203

 

187

 

174

251

 

 

 

73Kw/Hr

246L

 

3071

2303

1843

 

 

1536

1316

 

1152

 

1024

 

921

 

838

 

 

768

 

709

 

658

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTRC

 

275,000 BTUH

100Gal

 

80

889

667

 

533

 

 

444

381

 

333

 

296

 

267

 

242

 

 

222

 

205

 

190

275

 

 

 

80Kw/Hr

379L

 

3365

2524

2019

 

 

1682

1442

 

1262

 

1122

 

1009

 

918

 

 

841

 

776

 

721

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTRC

 

305,000 BTUH

65Gal

 

80

986

739

 

592

 

 

493

423

 

370

 

329

 

296

 

269

 

 

246

 

228

 

211

305

 

 

 

89Kw/Hr

246L

 

3732

2799

2239

 

 

1866

1599

 

1399

 

1244

 

1120

 

1018

 

 

933

 

861

 

800

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTRC

 

360,000 BTUH

65Gal

 

80

1164

873

 

698

 

 

582

499

 

436

 

388

 

349

 

317

 

 

291

 

269

 

249

365

 

 

 

105Kw/Hr

246L

 

4405

3304

2643

 

 

2202

1888

 

1652

 

1468

 

1321

 

1201

 

 

1101

 

1016

 

944

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTRC

 

390,000 BTUH

100Gal

 

80

1293

970

 

776

 

 

646

554

 

485

 

431

 

388

 

353

 

 

323

 

298

 

277

400

 

 

 

114Kw/Hr

379L

 

4894

3671

2936

 

 

2447

2097

 

1835

 

1631

 

1468

 

1335

 

 

1224

 

1129

 

1049

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TABLE 4. GAS AND ELECTRICAL CHARACTERISTICS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Gas Supply Pressure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Model

 

Type of Gas

 

 

Minimum

 

 

Maximum

Gas Manifold Pressure

 

 

Volts/Hz

 

 

Amperes

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

9

INSTALLATION CONSIDERATIONS

LOCATING THE WATER HEATER

CAUTION

Property Damage Hazard

All water heaters eventually leak.

Do not install without adequate drainage.

When installing the heater, consideration must be given to proper location. Location selected should be as close to the stack or chimney as practicable, with adequate air supply and as centralized with the piping system as possible.

Fire or Explosion Hazard

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

Avoid all ignition sources if you smell gas.

Do not expose water heater controls to excessive gas pressure.

Use only the gas shown on the water heater rating label.

Maintain required clearances to combustibles.

Keep ignition sources away from faucets after extended periods of non-use.

Read instruction manual before installing, using or servicing water heater.

There is a risk in using fuel burning appliances such as gas water heaters in rooms, garages or other areas where gasoline, other flammable liquids or engine driven equipment or vehicles are stored, operated or repaired. Flammable vapors are heavy and travel along the floor and may be ignited by the heater’s igniter or main burner flames causing fire or explosion. Some local codes permit operation of gas appliances in such areas if they are installed 18” or more above the floor. This may reduce the risk if location in such an area cannot be avoided.

Do not install this water heater directly on a carpeted floor. A fire hazard may result. Instead the water heater must be placed on a metal or wood panel extending beyond the full width and depth by at least 3 inches in any direction. If the heater is installed in a carpeted alcove, the entire floor shall be covered by the panel. Also, see the DRAINING requirements in MAINTENANCE Section.

The heater shall be located or protected so it is not subject to physical damage by a moving vehicle.

Flammable items, pressurized containers or any other potential fire hazardous articles must never be placed on or adjacent to the heater. Open containers or flammable material should not be stored or used in the same room with the heater.

The heater must not be located in an area where it will be subject to freezing.

Locate it near a floor drain. The heater should be located in an area where leakage from heater or connections will not result in damage to adjacent area or to lower floors of the structure.

When such locations cannot be avoided, a suitable metal drain pan should be installed under heater. Such pans should be fabricated with sides at least 2” deep, with length and width at least 2” greater than diameter of heater and must be piped to an adequate drain. Pan must not restrict combustion air flow.

CLEARANCES

These heaters are approved for installation on combustible flooring in an alcove when the minimum clearance from combustion or non-combustible construction are followed as indicated in Figure 6 and Table 5.

In all installations the minimum combustible clearances from draft hood surface or vent piping shall be 6” (152mm). Vent piping passing through a combustible wall or ceiling must be a continuous run (no joints) and retain 6” (152mm) clearance unless an approved reducing thimble is used.

A service clearance of 24” (610mm) should be maintained from serviceableparts,suchasreliefvalves,baffles,thermostats,cleanout openings or drain valves.

TABLE 5. INSTALLATION CLEARANCES

 

A

B

C

D

 

(RIGHT SIDE)

(LEFTSIDE)

(BACK)

(CEILING)

 

 

 

 

 

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.

10

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 identification of components mentionedbelow.Failure tofollow theseinstructions canrestricttheairflowrequiredforpropercombustion,potentially resulting in fire, asphyxiation, serious personal injury or death.

DO NOT apply insulation to the top of the water heater, as this will interfere with safe operation of the draft hood.

DO NOT cover the gas control valve, thermostat or the Temperature-Pressure Relief Valve.

DO NOT allow insulation to come within 2” (5 cm) of the burners, to prevent blockage of combustion air flow to the burners.

DO NOT allow insulation to come within 9 inches (23 cm) of floor, (within 2 inches (5 cm) of bottom cover) to prevent blockage of combustion air flow to the burners..

DO NOT cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.

DO obtain new warning and instruction labels from the manufacturer for placement on the blanket directly over the existing labels.

DO inspect the insulation blanket frequently to make certain it does not sag, thereby obstructing combustion air flow.

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

11

must be periodically oiled. Refer to the pump manufacturer’s instructions for lubrication requirements.

CIRCULATING PUMP WIRING DIAGRAM

STORAGE TANK OR BUILDING RECIRCULATION

FIELD SUPPLIED TEMPERATURE CONTROL INSTALLED IN THE STORAGE TANK

OR CIRCULATING LOOP RETURN LINE

NOTE: USE SEPARATE 120 VAC POWER

SUPPLY FOR PUMP CIRCUIT. DO NOT

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

L1 HOT

120 VAC

CIRC

POWER

PUMP

 

MOTOR

L2 NEUTRAL

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

CIRC

PUMP

MOTOR

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.

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.

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 should contact your gas supplier for any specific changes which may be required in your area.

As the elevation above sea level is increased, there is less oxygen per cubic foot of air. Therefore, the heater input rate should be reduced at high altitudes for satisfactory operation with the reduced oxygen supply. Failure to make this reduction would result in an over firing of the heater causing sooting, poor combustion and/or unsatisfactory heater performance.

Ratings specified by manufacturers for most appliances apply for elevations up to 2000 feet (610m). For elevations above 2000 feet (610), ratings must be reduced at the rate of 4% for each 1000 feet (305m) above sea level. For example, if a heater is rated at 78,000 Btuh (22.9 Kwh) at sea level, to rate the heater at 4000 feet (1219m), you subtract 4 (once for each thousand feet) x.04 (4% input reduction) x 78,000 (original rating) from the original rating.

Therefore, to calculate the input rating at 4,000 feet (1219m): 4 x .04 x 78,000 = 12,480 Btuh (3.7 Kwh), 78,000 (22.9 Kwh) - 12,480 (3.7 Kwh) = 65,520 Btuh (19.2 Kwh). At 6000 feet (1829m) the correct input rating should be 59,280 Btuh (17.4 Kwh).

12

INSTALLATION REQUIREMENTS

GAS SUPPLY SYSTEMS

Low pressure building gas supply systems are defined as those systems that cannot under any circumstances exceed 14” W.C. (1/2 PSI Gauge). These systems do not require pressure regulation. Measurements should be taken to insure that gas pressures are stable and fall within the requirements stated on the water heater rating plate. Readings should be taken with all gas burning equipment off (static pressure) and with all gas burning equipment running at maximum rate (dynamic pressure). The gas supply pressure must be stable within 1.5” W.C. from static to dynamic pressure to provide good performance. Pressure drops that exceed 1.5” W.C. may cause rough starting, noisy combustion or nuisance outages. Increases or spikes in static pressure during off cycles may cause failure to ignite or in severe cases damage to appliance gas valves. If your low pressure system does NOT meet these requirements, the installer is responsible for the corrections.

High Pressure building supply systems use pressures that exceed 14” W.C. (1/2 PSI Gauge). These systems must use field supplied regulators to lower the gas pressure to less than 14” W.C. (1/2 PSI Gauge). Water heaters require gas regulators that are properly sized for the water heater input and deliver the rating plate specified pressures. Gas supply systems where pressure exceeds 5 PSI often require multiple regulators to achieve desired pressures. Systems in excess of 5 PSI building pressure should be designed by gas delivery professionals for best performance. Water heaters connected to gas supply systems that exceed 14” W.C. (1/2 PSI Gauge) at any time must be equipped with a gas supply regulator.

All models require a minimum gas supply pressure of 4.5" W.C. for natural gas and 11.0" W.C. for propane gas. The minimum supply pressure is measured while gas is flowing (dynamic pressure). The supply pressure should never fall below 4.5" W.C. for natural gas and 11.0" W.C. for propane gas. The supply pressure should be measured with all gas fired appliances connected to the common main firing at full capacity. If the supply pressure drops more than 1.5” W.C. as gas begins to flow to the water heater then the supply gas system including the gas line and/or the gas regulator may be restricted or undersized. See Supply Gas Regulator section and Gas Piping section of this manual. The gas valve on all models has a maximum gas supply pressure limit of 14” W.C. The maximum supply pressure is measured while gas is not flowing (static pressure).

SUPPLY GAS REGULATOR

The maximum allowable gas supply pressure for this water heater is 14 inches W.C. (3.48 kPa). Install a positive lock-up gas pressure regulator in the gas supply line if inlet gas pressure can exceed 14 inches W.C. (3.48 kPa) at any time. Regulators must be sized/used according to manufacturer’s specifications.

If a positive lock-up regulator is required follow these instructions:

1.Positivelock-upgaspressureregulatorsmustberatedatorabove 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.

Waterheatedtoatemperaturewhichwillsatisfyclotheswashing,dish washing, and other sanitizing needs can scald and cause permanent injury upon contact. Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the water heater’s temperature setting by up to 20°F (11°C).

Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm and the physically/mentally disabled. Table 6 shows approximate time-to-burn relationship for normal adult skin. If anyone using hot water provided by the water heater being installed fits into one of these groups or if there is a local code or state law requiring a certain water temperature at the point of use, then special precautions must be taken.

In addition to using the lowest possible temperature setting that satisfies the demand of the application a Mixing Valve should be installed at the water heater (see Figure 10) or at the hot water taps to further reduce system water temperature.

Mixing valves are available at plumbing supply stores. Consult a QualifiedInstallerorServiceAgency.Followmixingvalvemanufacturer’s instructions for installation of the valves.

TABLE 6.

 

Time for 1st Degree Burn

Time for Permanent Burns

Water Temperature °F

(Less Severe Burns)

2nd & 3rd Degree

 

 

(Most Severe Burns)

110

(normal shower temp.)

 

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)

13

HOT WATER

OUTLET

12” TO 15” (30-38 cm)

TEMPERED WATER

OUTLET

COLD

 

CHECK

WATER

 

VALVE

INLET

 

MIXING

 

CHECK

 

VALVE

 

VALVE

 

 

 

TO TANK

 

INLET

FIGURE 10.

DISHWASHING MACHINES

All dishwashing machines meeting the National Sanitation Foundation requirements are designed to operate with water flow pressures between 15 and 25 pounds per square inch (103 kPa and 173 kPa). Flow pressures above 25 pounds per square inch (173 kPa), or below 15 pounds per square inch (103 kPa), will result in improperly sanitized dishes. Where pressures are high, a water pressure reducing or flow regulating control valve should be used in the 180°F (82°C) line to the dishwashing machine and should be adjusted to deliver water pressure between these limits.

The National Sanitation Foundation also recommends circulation of 180°F (82°C) water. The circulation flow rate should be just enough to provide 180°F (82°C) water at the point of take-off to the dishwashing machine.

Adjust flow by throttling a full port ball valve installed in the circulating line on the outlet side of the pump. Never throttle flow on the suction side of a pump. See Water Piping Diagrams in this manual.

NOTE: These water heaters meet the NSF Standard 5 for sanitary installations when used with the leg kit part number

9003425205.

CLOSED WATER SYSTEMS

Water supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure reducing valves, check valves, and back flow preventers. Devices such as these cause the water system to be a closed system.

THERMAL EXPANSION

As water is heated, it expands (thermal expansion). In a closed system the volume of water will grow when it is heated. As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent Temperature-Pressure Relief Valve operation: water discharged from the valve due to excessive pressure build up. This condition is not covered under the limited warranty. The Temperature-Pressure Relief Valve is not intended for the constant relief of thermal expansion.

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

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.

Thiswaterheaterisprovidedwithaproperlyrated/sizedandcertified combination Temperature-Pressure Relief Valve (T&P valve) by the manufacturer. The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for

Pressure Relief Valves for Hot Water Supply Systems,ANSI Z21.22

• CSA 4.4, and the code requirements of ASME.

If replaced, the new T&P valve must meet the requirements of local codes, but not less than a combination TemperaturePressure Relief Valve rated/sized and certified as indicated in the above paragraph. The new valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (150 psi = 1,035 kPa) and a discharge capacity not less than the water heater Btu/hr or kW input rate as shown on the water heater’s model rating label.

NOTE: In addition to the factory installed Temperature-Pressure Relief Valve on the water heater, each remote storage tank that maybeinstalledandpipedtoawaterheatingappliancemustalso 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 fitting of the water heater designed for the pressure relief valve . Install discharge piping so that any discharge will exit the pipe within 6 inches (15.2 cm) above an adequate floor drain, or external to the building. In cold climates it is recommended that it be terminated at an adequate drain inside the building. Be certain that no contact is made with any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstances. Excessive length, over 30 feet (9.14 m), or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve.

14

No valve or other obstruction is to be placed between the Temperature-Pressure Relief Valve and the tank. Do not connect discharge piping directly to the drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in adequate quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water flow may cause property damage.

CAUTION

Water Damage Hazard

Temperature-Pressure Relief Valve discharge pipe must terminate at adequate drain.

T&P Valve Discharge Pipe Requirements:

Shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions.

Shall not be plugged or blocked.

Shall not be exposed to freezing temperatures.

Shall be of material listed for hot water distribution.

Shall be installed so as to allow complete drainage of both the Temperature-Pressure Relief Valve and the discharge pipe.

Must terminate a maximum of six inches above a floor drain or external to the building. In cold climates, it is recommended that the discharge pipe be terminated at an adequate drain inside the building.

Shall not have any valve or other obstruction between the pressure relief valve and the drain.

Burn hazard.

Hot water discharge.

Keep clear of TemperaturePressure Relief Valve discharge outlet.

TheTemperature-PressureReliefValvemustbemanuallyoperated 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.

CONTAMINATED AIR

Breathing Hazard - Carbon Monoxide Gas

Install water heater in accordance with the Instruction Manual and NFPA 54 or CAN/CSA-B149.1.

To avoid injury, combustion and ventilation air must be taken from outdoors.

Do not place chemical vapor emitting products near water heater.

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

Corrosion of the flue ways and vent system may occur if air for combustion contains certain chemical vapors. Such corrosion may result in failure and risk of asphyxiation.

Combustion air that is contaminated can greatly diminish the life span of the water heater and water heater components such as hot surface igniters and burners. Propellants of aerosol sprays, beauty shop supplies, water softener chemicals and chemicals usedindrycleaningprocessesthatarepresentinthecombustion, 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

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 insufficient supply of air can cause recirculation of combustion products resulting in contamination that may be hazardous to life. Such a condition often will result in a yellow, luminous burner flame, causing sooting of the combustion chamber, burners and flue tubes and creates a risk of asphyxiation.

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

Never obstruct the flow of ventilation air. If you have any doubts or questions at all, call your gas supplier. Failure to provide the proper amount of combustion air can result in a fire or explosion and cause property damage, serious bodily injury or death.

15

UNCONFINED SPACE

An Unconfined Space is one whose volume IS NOT LESS THAN 50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input rating of all appliances installed in the space. Rooms communicating directly with the space, in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconfined space.

Makeup air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers and fireplaces shall also be considered in determining the adequacy of a space to provide combustion, ventilation and dilution air.

UNUSUALLY TIGHT CONSTRUCTION

In unconfined spaces in buildings, infiltration may be adequate to provide air for combustion, ventilation and dilution of flue gases. However, in buildings of unusually tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.) additional air must be provided using the methods described in the Confined Space section that follows.

CONFINED SPACE

A Confined Space is one whose volume is less than 50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input rating of all appliances installed in the space.

Openings must be installed to provide fresh air for combustion, ventilation and dilution in confined spaces. The required size for the openings is dependent on the method used to provide fresh air to the confined space and the total Btu/hr input rating of all appliances installed in the space.

DIRECT VENT APPLIANCES

Appliances installed in a Direct Vent configuration that derive all air for combustion from the outdoor atmosphere through sealed intake air piping are not factored in the total appliance input Btu/ hr calculations used to determine the size of openings providing fresh air into confined spaces.

EXHAUST FANS

Where exhaust fans are installed, additional air shall be provided to replace the exhausted air. When an exhaust fan is installed in the same space with a water heater, sufficient openings to provide fresh air must be provided that accommodate the requirements for all appliances in the room and the exhaust fan. Undersized openings will cause air to be drawn into the room throughthewaterheater’sventsystemcausing poor combustion. Sooting, serious damage to the water heater and the risk of fire or explosion may result. It can also create a risk of asphyxiation.

LOUVERS AND GRILLES

The free areas of the fresh air openings in the instructions that follow do not take in to account the presence of louvers, grilles or screens in the openings.

The required size of openings for combustion, ventilation and dilution air shall be based on the “net free area” of each opening. Where the free area through a design of louver or grille or screen is known, it shall be used in calculating the size of opening required to provide the free area specified. Where the louver and grille design and free area are not known, it shall be assumed that wood louvers will have 25% free area and metal louvers and grilles will have 75% free area. Non motorized louvers and grilles shall be fixed in the open position.

VENTING INSTALLATION

VENTING

THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST BE FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULATIONOFFLUEGASES. SUCHCONDITIONSCAUSE SOOTING OR RISKS OF FIREANDASPHYXIATION.

Heater must be protected from freezing downdrafts.

Removeallsootorotherobstructionsfromthechimneythatwillretard a free draft.

TypeBventingisrecommendedwiththeseheaters.Fortypicalventing application see TECHNICAL DATAVENTING on pages 19 and 20.

This water heater must be vented in compliance with all local codes, thecurrentrevisionoftheNationalFuelGasCode(ANSI-Z223.1)and with the Category I Venting Tables.

If any part of the vent system are exposed to ambient temperatures below 40°F it must be insulated to prevent condensation.

Do not connect the heater to a common vent or chimney with solid fuel burning equipment. This practice is prohibited by many local building codes as is the practice of venting gas fired equipment to the duct work of ventilation systems.

Whereaseparateventconnectionisnotavailableandtheventpipe from the heater must be connected to a common vent with an oil burning furnace, the vent pipe should enter the smaller common vent or chimney at a point above the large vent pipe.

VENT REDUCER

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

Each adapter fits on top of the installed flue damper. Use only vent reducers supplied with the unit. The venting must comply with the current editions of the NATIONAL FUEL GAS CODE, ANSI Z223.1/

NFPA 54 or NATURAL GAS AND PROPANE INSTALLATION CODE

CAN/CSA-B149.1

FIGURE 11.

FIGURE 12.

16

MULTIPLE HEATER MANIFOLD

Figure 13 and tables on pages 19 and 20 should be used for horizontally manifolding two or more heaters.

FIGURE 13.

FRESH AIR OPENINGS FOR CONFINED SPACES

The following instructions shall be used to calculate the size, number and placement of openings providing fresh air for combustion, ventilation and dilution in confined spaces. The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only. DO NOT refer to these illustrations for the purpose of vent installation. See Venting Installation on page 16 for complete venting installation instructions.

OUTDOOR AIR THROUGH TWO OPENINGS

FIGURE 14.

The confined space shall be provided with two permanent openings, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The openings shall communicate directly with the outdoors. See Figure 14.

Each opening shall have a minimum free area of 1 square inch per 4,000 Btu/hr (550 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 cm2).

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

FIGURE 16.

The confined space shall be provided with two permanent horizontal ducts, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The horizontal ducts shall communicate directly with the outdoors. See Figure 16.

Each duct opening shall have a minimum free area of 1 square inch per 2,000 Btu/hr (1100 mm2 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.

17

OUTDOOR AIR THROUGH TWO VERTICAL DUCTS

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

DO NOT refer to these illustrations for the purpose of vent installation. See Venting Installation on page 14 for complete venting installation instructions.

FIGURE 17.

The confined space shall be provided with two permanent vertical ducts, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The vertical ducts shall communicate directly with the outdoors. See Figure 17.

Each duct opening shall have a minimum free area of 1 square inch per 4,000 Btu/hr (550 mm2 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.

AIR FROM OTHER INDOOR SPACES

FIGURE 18.

The confined space shall be provided with two permanent openings, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. See Figure 18.

Each opening shall communicate directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an Unconfined Space.

Each opening shall have a minimum free area of 1 square inch per 1,000 Btu/hr (2200 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 cm2).

18

TABLE 7. TECHNICAL DATA VENTING

TYPE B GAS VENT

Multiple Gas Fired Tank-Type Heaters

When venting multiple tank type heaters using Type B vent pipe, follow the installation diagram (figure 13) and tables below which give sizing and data based upon NFPA 54/ANSI

Z223. 1992.

MODEL BTR(C)-120

 

 

 

 

 

 

 

 

 

 

 

 

 

Input: 120,000 Btuh

 

Total Vent Height (Feet)

 

 

 

 

 

 

 

Draft Hood: 5”

 

 

 

6

 

8

 

10

15

20

30

50

100

 

 

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

Number of

 

Combined Input in

 

Manifold and Common Vent Diameter (In inches)

 

 

Heaters

 

Thousands of Btuh

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

 

240

 

 

10

 

8

 

8

7

7

7

6

7

3

 

360

 

 

10

 

10

 

10

10

8

8

7

7

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

 

 

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

Numbers of

 

Combined Input in

 

Manifold and Common Vent Diameter (in inches)

 

 

Heaters

 

Thousands of Btuh

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

 

308

 

 

10

 

10

 

10

8

8

7

7

7

3

 

462

 

 

12

 

12

 

12

10

10

10

8

8

4

 

616

 

 

14

 

14

 

12

12

12

10

1

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

 

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

Number of

 

Combined Input in

 

 

 

 

Manifold & Common Vent Diameter

 

 

Heaters

 

Thousands of Btuh

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

 

360

 

 

10

 

10

 

10

10

8

8

7

7

 

398

 

 

12

 

10

 

10

10

10

8

8

7

 

 

 

 

 

 

3

 

540

 

 

14

 

12

 

12

12

10

10

10

8

 

597

 

 

14

 

14

 

12

12

12

10

10

10

 

 

 

 

 

 

4

 

720

 

 

14

 

14

 

14

12

12

12

10

10

 

796

 

 

16

 

14

 

14

14

12

12

12

10

 

 

 

 

 

 

19

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

20

MECHANICAL VENTING

SINGLE UNIT INSTALLATION

When mechanical venting of these heaters is desired, the following kits are available.

Models 120 through the 200/A

A. O. Smith part number 9005381205

Models 250/A through the 400/A

A. O. Smith part number 9003434205

Where an approved power venter is to be installed to operate in conjunction with the water heater thermostat, the following codes must be adhered to. Field wiring should conform to the current edition of the National Electrical Code NFPA 70. For Canadian installations the electrical connections and grounding shall be done in accordance with the current edition of the Canadian Electrical Code CSAC22.1 and/or local codes.

VENT INSTALLATION

Seal all joints between the power venter and the vent termination. This is to prevent leakage of exhaust products into the room(s) due to positive pressure of blower.

The “Sequence of Operation” description will be the same with mechanical venting except;

When the water heater thermostat calls for heat:

Thermostat contacts “Close” and the power venter blower (120 VAC) is energized. Sufficient draft must be established for the “Draft Prover Switch (N.O.)” to “Close”. When the draft prover switch “Closes” the relay coil of the flue damper is energized.

MULTIPLE UNIT INSTALLATION

For multiple unit installations, contact A. O. Smith, Technical Support Center at 1-800-527-1953.

WATER HEATER INSTALLATION

WATER LINE CONNECTIONS

The water piping installation must conform to these instructions and to all local code authority having jurisdiction. Good practice requires that all heavy piping be supported.

Read and observe all requirements in the following sections before installation of the water piping begins:

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

1.Water Temperature Control and Mixing Valves on page 13. pump. Adjust flow by throttling a full port ball valve installed in the

2.Dishwashing Machines on page 14.

3.Temperature-Pressure Relief Valve on page 14-15.

circulating line on the outlet side of the pump. Never throttle flow on the suction side of a pump. See the Water Piping Diagrams beginning on page 40.

4.Closed Systems and Thermal Expansion on page 14. NOTE: In addition to the factory installed Temperature-Pressure

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 field installed as shown in the installation diagrams.

Thermometers are installed in the system as a means of detecting the temperature of the outlet water supply.

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.

21

This water heater is provided with a properly rated/sized and certified combination temperature - pressure (T&P) relief valve by themanufacturer.SeeTemperature-PressureReliefValveonpages 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 floor drain. Do not connect discharge piping directly to the drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in adequate quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water flow may cause property damage.

T&P VALVE DISCHARGE PIPE REQUIREMENTS:

Shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions.

Shall not be plugged or blocked.

Shall not be exposed to freezing temperatures.

Shall be of material listed for hot water distribution.

Shall be installed so as to allow complete drainage of both Temperature-Pressure Relief Valve and the discharge pipe.

Must terminate a maximum of six inches above a floor drain or external to the building. In cold climates, it is recommended that the discharge pipe be terminated at an adequate drain inside the building.

Shall not have any valve or other obstruction between the relief valve and the drain.

INSTALLATION DIAGRAMS - TOP INLET/OUTLET USAGE

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

TUBE INLET INSTALLATION

FIGURE 19.

22

HEATER WIRING

All electrical work must be installed in accordance with the current edition of the National Electrical Code ANSI/NFPA No. 70 or Canadian Electrical

Code CSAC22.1 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 2500C type F must be used for the flame sensor and igniter leads.

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

24VA

 

1

3

 

 

 

 

C

 

4

2

 

TO

 

DAMPER DRIVE

 

NEUTRAL24

CONTROLIGNITION

24VA

 

 

 

BLK

 

 

C

 

 

 

 

Y

 

 

 

RLOWER PROBE

UPPER

PROBE/ECO

R

LEGEND:

W--WHITE

BLK--BLACK BL--BLUE

R--RED W Y--YELLOW

BL

DAMPER

DRIVE

 

 

11E79

LINE

 

ON/OFF

 

 

 

 

 

 

 

 

 

 

 

IN

 

 

 

 

 

 

 

SWITCH

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

X

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

2

 

 

BLK

BLK

 

 

 

 

 

 

 

 

120 vac

 

1

 

 

 

 

 

 

 

 

W

 

 

 

 

 

 

 

 

W

 

 

 

 

 

 

 

NEUTRAL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PV

 

MV/PV

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PV

MV

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MV

 

 

 

 

 

 

 

 

TH TR

 

 

 

W

 

 

 

PROPANE

 

 

 

 

 

 

 

GAS

 

 

 

 

 

 

 

VALVE

 

 

 

D

 

 

 

BL

 

 

 

 

 

 

 

BLK

 

C

SPARKER

 

 

MV MV/PV PV BURNER-GND GNV24 V24

 

 

 

 

 

 

Y

 

P

 

 

 

 

 

 

 

 

 

 

 

 

 

 

M

 

 

 

 

 

 

 

 

NATURAL

 

 

 

 

 

 

 

 

GAS

 

 

HONEYWELL IGNITION

 

 

 

 

VALVE

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.

23

GAS PIPING

Contact your local gas service company to ensure that adequate gas service is available and to review applicable installation codes for your area.

Size the main gas line in accordance with Table 8. The figures shown are for straight lengths of pipe at 0.5 in. W.C. pressure drop, which is considered normal for low pressure systems. Note: Fittings such as elbows, tees and line regulators will add to the pipe pressure drop. Also refer to the latest version of the National Fuel Gas Code.

Schedule 40 Steel or Wrought Iron Pipe is the preferred material for the gas line of this water heater. It is imperative to follow the sizing recommendations in the latest version of the National Fuel

Gas Code if Corrugated Stainless Steel Tubing (CSST) is used as the gas line for this water heater.

The heater is not intended for operation at higher than 14.0" W.C.- natural gas, (1/2 pound per square inch gage) supply gas pressure. Exposure to higher supply pressure may cause damage to the gas valve which could result in fire or explosion. If overpressure has occurred such as through improper testing of gas lines or emergency malfunction of the supply system, the gas valve must be checked for safe operation. Make sure that the outside vents on the supply regulators and the safety vent valves are protected against blockage. These are parts of the gas supply system, not the heater. Vent blockage may occur during ice storms.

TABLE 8. GAS SUPPLY PIPE LENGTHS (IN FEET) Maximum Equivalent Pipe Length - Natural Gas Only

Input rate

 

Schedule 40 Steel or Wrought Iron Pipe

 

(BTU/HR)

1/2"

3/4"

1"

1 1/4"

1 1/2"

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

Natural Gas 0.60 Specific Gravity, 0.50" W.C. Pressure Drop

 

*Screwed Fittings

 

 

 

 

 

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

If copper supply lines are used they must be internally tinned and certified for gas service. Before attaching the gas line, be sure that all gas pipe is clean on the inside.

To trap any dirt or foreign material in the gas supply line, a sediment trap must be incorporated in the piping (see Figure 21).The sediment trapmustbereadilyaccessibleandnotsubjecttofreezingconditions. 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 threadsofpipejoints.Donotapplycompoundstothefirsttwothreads. Use compounds resistant to the action of liquefied petroleum gases.

GAS METER SIZE – NATURAL GASES ONLY

Be sure the gas meter has sufficient capacity to supply the full rated gas input of the water heater as well as the requirements of all other gasfiredequipmentsuppliedbythemeter.Ifgasmeteristoosmall,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 fire or explosion.

1.For test pressures exceeding 1/2 psi (3.45 kPa) disconnect the water heater and its Main Gas Shutoff Valve from the gas supply piping system during testing, see Figure 21. The gas supply line must be capped when disconnected from the water heater.

2.For test pressures of 1/2 psi (3.45 kpa) or less, the water heater need not be disconnected, but must be isolated from the supply gas line by closing the Main Gas Shutoff Valve during testing.

3.Coat all supply gas line joints and connections upstream of the water heater with a non-corrosive soap and water solution to test for leaks. Bubbles indicate a gas leak. Do not use matches, candles, flame or other sources of ignition for this purpose.

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

PURGING

Gas line purging is required with new piping or systems in which air has entered.

Purging should be performed per the current edition of NFPA 54 the National Fuel Gas Code.

24

OPERATION

Fire or Explosion Hazard

Gas line purging is required with new piping or systems in which air has entered.

To avoid risk of fire or explosion purge discharge must not enter into confined areas or spaces where ignition can occur.

The area must be well ventilated and all sources of ignition must be deactivated or removed.

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 field involved, see Qualifications on page 6.

Do not place the water heater in operation if any part has been under water. Immediately call a qualified service technician to inspect the water heater and to replace any part of the control system and any gas control which has been under water.

Light the water heater in accordance with the Lighting and Operation Instruction label on the water heater and in this manual on pages 27 and 28.

The water heaters covered by this manual are equipped with an electronic control system that automatically sequences the Igniter, the 24 VAC Gas Valve, the Burner ignition, and flame sensing.

Before attempting start up, thoroughly study and know the exact Sequence Of Operation. See written Sequence Of Operation on page 25 and Sequence Of Operation Flow Chart on page 26.

Be certain that the water heater is full of water, that air is purged from the gas and water lines and that there are no leaks in the gas and water lines. Ensure all inlet water valves are open.

FILLING THE WATER HEATER

Follow these steps to fill the water heater prior to start up.

1.Close the heater drain valve.

2.Open a nearby hot water faucet to permit air in system to escape.

3.Fully open the cold water inlet valve allowing the piping and water heater to fill with water.

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

Read SEQUENCE OF OPERATION section of this manual prior to lighting and operating this water heater.

With above conditions satisfied, start the unit in accordance with the instructions on the operating label attached to the heater. For your convenience a copy of the instructions are shown on pages 27 and 28.

SEQUENCE OF OPERATION

The following information will describe the Sequence of Operation for this water heater.

1.Switch power on to unit.

2.Thermostat calls for heat.

3.Ignition Control performs diagnostic self check on system components.

4.The Ignition Control begins the trial for ignition.

5.TheIgnitionControlturnsontheSparkIgniterandopensthePilot Gas Valve.

6.TheIgnitionControlmonitorstheFlameSensorduringtheignition trial period.

7.If the Ignition Control does not sense the pilot flame during the ignition trial period, the Ignition Control shuts the Pilot Gas

Valve and turns off the Spark Igniter. Depending on the water heater model, the Ignition Control will either retry the ignition trial at step 4 or lockout the ignition sequence. If the ignition sequence

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

8.If the pilot flame is proved during the ignition trial period, the

Ignition Control turns off the Spark Ignitor and opens the Main

Gas Valve.

9.The Ignition Control allows a 2 second pilot flame stabilization period to insure that the pilot flame is not extinguished by the main burner light-off process.

10.The Ignition Control monitors the Flame Sensor during the heating cycle. If the flame signal is lost, the Ignition Control shuts the Main Gas Valve and Pilot Gas Valve and re-starts the ignition process at step 4.

11.Once the unit is satisfied, the Ignition Control will shut off the Main Gas Valve and the Pilot Gas Valve and the unit will be in

standby mode until another call for heat is initiated by the thermostat.

See the flow chart on page 26 for more information.

25

SEQUENCE OF OPERATION FLOW CHART

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

IDLE

(NOT POWERED)

“CALL FOR HEAT”

 

 

 

 

 

 

 

 

 

 

 

WAIT FOR

RECEIVED FROM

 

 

 

 

 

 

 

 

 

 

 

“CALL FOR HEAT”

THERMOSTAT

 

 

 

 

 

 

 

 

 

 

 

TO BE REMOVED

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POWER TO

 

 

 

 

 

 

 

 

 

 

 

ACTIVATE

ALARM

MODULE AND

 

 

 

 

 

 

 

 

 

 

 

CONTACT(S)

SELF CHECK

 

 

 

 

 

 

 

 

 

 

 

(OPTIONAL)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A

 

 

 

 

 

RETRY DELAY

 

 

 

 

 

 

 

 

 

 

 

 

(5 MINUTES)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TRIAL FOR

 

 

 

 

 

OPEN PILOT GAS

 

 

 

 

 

 

IGNITION

 

 

SPARK ON

 

 

 

 

 

 

 

 

 

 

 

 

VALVE

 

 

 

 

 

 

(TIMER STARTED)

 

 

 

 

 

 

RETRY

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FLAME

 

NO

 

 

CLOSE PILOT

 

 

SPARK OFF

RETRY OR

LOCKOUT

PROVED?

 

 

 

 

 

LOCKOUT

 

 

 

 

 

 

 

 

GAS VALVE

 

 

 

 

 

 

 

 

 

 

 

 

 

MODEL?

 

(BEFORE TRIAL FOR IGNITION TIMER EXPIRES)

YES

SPARK OFF

OPEN MAIN GAS

VALVE

FLAME

STABILIZATION (2 SECONDS)

 

 

 

 

 

 

 

NO

 

 

 

 

 

 

 

 

 

 

 

“CALL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FLAME

 

CLOSE MAIN GAS

 

 

RUN

 

FOR HEAT”

 

NO

 

 

YES

VALVE AND PILOT

 

A

 

 

 

 

LOST?

 

 

 

 

 

ENDS?

 

 

 

 

 

 

GAS VALVE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YES

CLOSE MAIN GAS

VALVE AND PILOT

GAS VALVE

FLOW CHART 1.

26

LIGHTING & OPERATION LABEL

FOR YOUR SAFETY READ BEFORE OPERATING

OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE OPERATING

FIGURE 22. LABEL FOR NATURAL GAS MODELS

27

FOR YOUR SAFETY READ BEFORE OPERATING

OPERATING INSTRUCTIONS

TO TURN OFF GAS TO APPLIANCE

FIGURE 23. LABEL FOR PROPANE GAS MODELS

28

ADJUSTMENTS

ON INITIALSTARTUPSOMEADJUSTMENTS MAYBE NECESSARY.

Check Manifold and inlet gas pressures (see GAS SUPPLY SYSTEMSonpage13andCHECKINGTHEINPUTonpage29-30.)

Check Pilot Burner (See Pilot Burner section on page 34.)

TESTING DAMPER OPERATION

With the Service Switch in the AUTOMATIC OPERATION position, check the operation of the flue damper three (3) times with the water operating controls for proper operating sequence:

The damper disc must be open (in the vertical position) before the ignition and combustion process begins.

The damper disc must be in the open position when the main burner is firing.

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

If during testing of the operation of the damper you find that there is a problem with the operation of the water heater when the Service Switch is in the AUTOMATIC OPERATION position: Reset the Service Switch to the HOLD OPEN DAMPER position and check operation again.

If the water heater does operate when placed in the HOLD OPEN DAMPER position:

Refer to the EFFIKALRVGP-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

Thefollowingstepsshallbefollowedwitheachapplianceconnected totheventingsystemplacedinoperation,whileanyotherappliances connected to the venting system are not in operation.

1.Seal any unused openings in the venting system.

2.Inspecttheventingsystemforpropersizeandhorizontalpitch,as requiredintheNationalFuelGasCode,ANSIZ223.1ortheCAN/ CGAB149InstallationCodesandtheseinstructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

3.So far as is practical, close all building doors and windows and all doors between the space in which the water heater(s) connected to the venting system are located and other spaces of the building. Turn on all appliances not connected to the venting system.Turn on all exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Close fireplace dampers.

4.Follow the lighting instruction. Place the water heater being inspected in operation.Adjust thermostat so water heater shall operate continuously.

5.Test for draft hood spillage at the relief opening after 5 minutes of main burner operation.

6.After it has been determined that each appliance connected to theventingsystemproperlyventswhentestedasoutlinedabove, returndoors,windows,exhaustfans,fireplacedampersandany 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.

FAILURE TO CORRECT BACK DRAFTS MAY CAUSE AIR CONTAMINATION AND UNSAFE CONDITIONS.

If the back draft cannot be corrected by the normal method or if a suitable draft cannot be obtained, a blower type flue gas exhauster must be employed to 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.)

TABLE 9.

APPROXIMATE TIME REQUIRED TO CONSUME 1 CU. FT. OF GAS AT FULL CAPACITY

INPUT

TYPE

BTUH

TIME REQ’D TO

RATE

OF

PER

CONSUME 1 CU.

(BTUH)

GAS

CU. FT.

FT. OF GAS

120,000

NATURAL

1050

31. 5 SEC.

PROPANE

2500

75.0 SEC.

 

154,000

NATURAL

1050

24.5 SEC.

PROPANE

2500

58.4 SEC.

 

180,000

NATURAL

1050

21.0 SEC.

PROPANE

2500

50.0 SEC.

 

199,000

NATURAL

1050

19.0 SEC.

PROPANE

2500

45.2 SEC.

 

250,000

NATURAL

1050

15.1 SEC.

PROPANE

2500

36.0 SEC.

 

251,000

NATURAL

1050

15.1 SEC.

PROPANE

2500

35.9 SEC.

 

275,000

NATURAL

1050

13.7 SEC.

PROPANE

2500

32.7 SEC.

 

 

 

 

 

305,000

NATURAL

1050

12.4 SEC.

PROPANE

2500

29.5 SEC.

 

 

 

 

 

365,000

NATURAL

1050

10.4 SEC.

PROPANE

2500

24.7 SEC.

 

 

 

 

 

390,000

NATURAL

1050

9.7 SEC.

PROPANE

2500

23.1 SEC.

 

 

 

 

 

29

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. Counterclockwisetodecreasegaspressureandinputrate.

4.“Clock” the meter as in step 2 above.

5.Repeat steps 3 and 4 until the specified input rate is achieved.

6.Turn the gas control knob to PILOT. Remove the pressure gauge and replace the sealing cap and the Allen wrench set screw in the pressure tap opening.

FIGURE 24.

UNDER NO CIRCUMSTANCES SHOULD THE GAS INPUT EXCEED THE INPUT SHOWN ON THE HEATER MODEL AND RATING

PLATE. OVERFIRING COULD RESULT IN DAMAGE OR SOOTING OF THE HEATER.

30

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