A.O. Smith BTR 151 THRU 201/A manual

1 MODELS BTR 151 THRU 201/A COMMERCIAL GAS, GLASS-LINED, TANK-TYPE WATER HEATER • INSTALLATION • OPERATION • MAINTENANCE • LIMITED WARRANTY PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE. Printed in U.S.A. 1004 P ART NO. 196308-001 A DIVISION OF A. O. SMITH CORPORA TION McBEE, SOUTH CAROLINA, USA w[...]

2 FOREWORD These designs comply with ANSI Z21.10.3 as a Booster type water heater . Detailed installation diagrams are found in this manual. These diagrams will serve to provide the installer with a reference for the materials and methods of piping necessary . It is highly essential that all water , gas piping and wiring be installed as shown on th[...]

3 GENERAL SAFETY INFORMA TION PRECAUTIONS DO NOT USE THIS APPLIANCE IF ANY P ART HAS BEEN UNDER W A TER. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water . IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO NOT OPERA TE HEA TER UNTIL ALL CO[...]

4 OPERA TION OF THESE F ANS CAN PRODUCE A NEGA TIVE DRAFT IN THE AREA OF THE W A TER HEA TER PREVENTING THE PRODUCTS OF COMBUSTION FROM EXHAUSTING THROUGH THE CHIMNEY OR VENT PIPE. The venting of the water heater should be inspected by a qualified service technician at the time of installation and periodically thereafter to ensure a down-draft cond[...]

5 possibility of changing the orientation by accidentally overtightening the inlet supply . Improper orientation of the Eliminator may cause temperature buildup issues or spells of colder than usual water temperatures. HIGH LIMIT SWITCH The digital thermostat (see Figure 3) contains the high limit (energy cutoff) sensor . The high limit switch inte[...]

6 INST ALLA TION INSTRUCTIONS REQUIRED ABILITY INST ALLA TION OR SERVICE OF THIS W A TER HEA TER REQUIRES ABILITY EQUIV ALENT TO THA T OF A LICENSED TRADESMAN IN THE FIELD INVOL VED. PLUMBING , AIR SUPPL Y , VENTING , GAS SUPPL Y AND ELECTRICAL WORK A RE REQUIRED. WARNING F AILURE TO FOLLOW THESE INSTRUCTIONS CAN RESUL T IN SERIOUS PERSONAL INJUR Y[...]

7 CARBONING OR SOOTING OF THE COMBUSTION CHAMBER, BURNERS AND FLUE TUBES AND CREA TES A RISK OF ASPHYXIA TION. Where an exhaust fan is supplied in the same room with a heater , sufficient openings for air must be provided in the walls. UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRA WN INTO THE ROOM THROUGH THE CHIMNEY , CAUSING POOR COMBUSTION. SOOTI[...]

8 FIGURE 7 • Where a separate vent connection is not available and the vent pipe from the heater must be connected to a common vent with an oil burning furnace, the vent pipe should enter the smaller common vent or chimney at a point above the large vent pipe. MUL TIPLE HEA TER MANIFOLD When horizontally manifolding two or more heaters vent as sh[...]

9 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 T able 2. 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. No[...]

10 Do not subject the combination gas valve to inlet gas pressures of more than 14.0" W .C. - natural gas. A service regulator is necessary if higher gas pressures are encountered. Manifold gas pressure in inches of water column is 3.5. The gas pressure specified refers to flow pressure taken at pressure tap of automatic gas valve while heater[...]

11 INST ALLA TION DIAGRAMS GENERAL The type, size and location of the relief valves must be in accordance with local codes. The locations of the relief valves shown in the installation diagrams are typical. The heater has a factory installed high temperature limit switch and temperature and pressure relief valve. Cold water lines to heater should b[...]

12 VERTICAL ST ORAGE T ANK AND FORCED CIRCULA TION DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE A T FIXTURES. SEE W A TER TEMPERATURE CONTROL WARNING ON P AGE 20. IF HIGHER PREHEA T TEMPERA TURES ARE NECESSAR Y TO OBT AIN ADEQUATE BOOSTER OUTPUT , ADD AN ANTI-SCALD V AL VE FOR HOT W A TER SUPPLIED TO FIXTURES. HORIZONT AL ST O[...]

13 DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERA TURE A T FIXTURES. SEE W A TER TEMPERA TURE CONTROL W ARNING ON P AGE 20. IF HIGHER PREHEA T TEMPERA TURES ARE NECESSARY T O OBTAIN ADEQUA TE BOOSTER OUTPUT , ADD AN ANTI-SCALD V AL VE FOR HOT W A TER SUPPLIED TO FIXTURES. TWO TEMPERA TURE - ONE HEA TER HIGH TEMPERA TURE ST ORAGE WIT[...]

14 INST ALLA TION DIAGRAMS-SIDE INLET/OUTLET USAGE DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERA TURE A T FIXTURES. SEE W A TER TEMPERA TURE CONTROL W ARNING ON PAGE 20. IF HIGHER PREHEA T TEMPERA TURES ARE NECESSARY TO OBT AIN ADEQUA TE BOOSTER OUTPUT , ADD AN ANTI-SCALD V AL VE FOR HOT W A TER SUPPLIED TO FIXTURES. A listed tempe[...]

15 ONE OR TWO TEMPERATURE - ONE HEATERS,HIGH TEMPERATURE STORAGE WITH OR WITHOUT RECIRCULATION HEATER WITH OR WITHOUT MIXING VALVE HEATER WITH MIXING VALVE AND RECIRCULATED SANITIZING LOOP NOTE 1: TOGGLE SWITCH CONTROLS 180°F (82°C) W A TER CIRCULATION. INST ALL ON OR CLOSE TO DISHWASHING MACHINE. TOGGLE SWITCH MUST BE CLOSED (ON) DURING THE RINS[...]

16 TWO TEMPERATURE - TWO PRE-HEATERS WITH MIXING VALVE OR BOOSTER HEATER WITH OR WITHOUT BUILING RECIRCULATION TWO PRE-HEATERS WITH MIXING VALVE TWO PRE-HEATERS WITH BOOSTER HEATER DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERA TURE A T FIXTURES. SEE WA TER TEMPERA TURE CONTROL W ARNING ON P AGE 20. IF HIGHER PREHEA T TEMPERA TURES [...]

17 MEDIUM TEMPERATURE - ONE HEATER WITH AUXILIARY STORAGE TANK FORCED CIRCULATION WITH OR WITHOUT BUILDING RECIRCULATION VERTICAL STORAGE TANK HORIZONTAL STORAGE TANK DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERA TURE A T FIXTURES. SEE W A TER TEMPERA TURE CONTROL W ARNING ON P AGE 20. IF HIGHER PREHEA T TEMPERA TURES ARE NECESSAR [...]

18 OPERA TION IMPORT ANT A qualified person must perform the initial firing of the heater . At this time the user should not hesitate to ask the individual any questions which they may have in regard to the operation and maintenance of the unit. An Operational Checklist is included at the rear of this manual. By using this checklist the user may be[...]

19 A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner . Do not try to light the burner by hand. B . BEFORE OPERA TING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor . “WHA T TO DO IF[...]

20 set for 120° to 180°F water temperature, but 120°F is the recommended starting point. It is suggested the dial be placed on the lowest setting which produces an acceptable hot water supply . This will always give the most energy efficient operation. The temperature control has a 4°F (2°C) fixed differential. PREVENTIVE MAINTENANCE CHECK THE[...]

21 NOTE: 1. Remove main burners from unit. 2. Check that burner venturi and ports are free of foreign debris. 3. Clean burners with bristle brush and/or vacuum cleaner - DO NOT distort burner ports or pilot location. 4. Reinstall burners in unit. Make sure front and rear of burners are installed correctly in burner support brackets. Also check for [...]

22 RELIEF V AL VE At least once a year , the temperature and pressure relief valve should be checked to ensure that it is in operating condition. Lift the lever at the top of the valve several times until the valve seats properly and operates freely . If the appliance installation includes other relief valves, such as in “remote” storage tanks [...]

23 FIGURE 14 DELIMING SOL VENTS A. O. Smith recommends the use of UN•LIME for deliming. UN•LIME is a patented food grade acid which is safe to handle and does not create the harmful fumes which are associated with other products. UN•LIME may be obtained from your dealer , distributor or the A. O. Smith Product Service Division. Order Part Num[...]

24 the appliance. The indicator codes on the ignition module are as follows: 1 flash System lockout (retries or cycles exceeded) 2 flashes Pressure switch stuck close 3 flashes Pressure switch stuck open 4 flashes Open on high temperature limit switch (eco) 6 flashes 1 15 volt AC power reversed (check polarity) 7 flashes Low flame sense signal (mak[...]

25 SEQUENCE OF OPERA TION FLOW CHART Description of this flow chart can be found in the “SEQUENCE OF OPERA TION” section found on page 18. Switch power on to unit. Thermostat calls for heat. Ignition Control Board performs diagnostic check on components Ignition Control Board sends power to Exhaust Inducer Exhaust Inducer engages Prover Switch [...]

26 OPERA TIONAL CHECKLIST This checklist in conjunction with “TROUBLESHOOTING” and the “SEQUENCE OF OPERA TION” should be used as an on-the-job troubleshooting guide to identify the cause of incorrect system operation and suggest a remedy for its correction. Because improper piping and wiring can result in unsatisfactory system performance,[...]

27 Model BTR Limited Warranty A. O. Smith Corporation, the warrantor , extends the following LIMITED WARRANTY to the owner of this water heater . 1. THE T ANK If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable water therein, during the first THREE years aft[...]

28 A.O. SMITH WATER PRODUCTS COMPANY 5621 W. 115TH STREET • ALSIP, ILLINOIS 60803 PHONE: 1-800-433-2545 • FAX: 1-800-433-2515 www.aosmithwaterheaters.com • E-MAIL: parts@hotwater.com[...]