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A.O. Smith 120 trough 500 manual

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  • Page 1

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  • Page 2

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 1 BTR HA NDBOOK TABLE OF CONTENTS PAGE PAG E Troubleshooting (continued) Introduction 1-2 Troubleshooting the Efflk al 30-31 Wire Harness Test 32 Installation IID Module 33 Clearances 3-4 Pilot Spark 34 Air Requirements 5-9 [...]

  • Page 3

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 2 Qualifications: Installation or service of this water heater requires ability equivalent to that of a licensed tr adesman in the field invol ved. Plumbing, air suppl y, venti ng, gas supply and electrical testing skills ar[...]

  • Page 4

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 3 INSTALLATION This portion of the handbook will review some often overlooked installation considerations, taki ng note of necessary install ation requir ements for the BTR 120 through 500 model heater s. The instal lation m[...]

  • Page 5

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 4 EXTERIOR CLEARANCE This illustrates t he exterior roo f clearance s for BTR units with na tural draft ve nting. The vent shall extend at least 3 feet above the highest point w here it passes thr ough a roof of a building, [...]

  • Page 6

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 5 AIR FOR COMBUSTION 10 CUBIC FEET OF AIR PER 1, 000 BTU Stoichiometr ic or theoretical complete com bustion requir es 10 cubic feet of air per 1000 BTUH input of the gas input. The National Fuel Gas Code al so recommends an[...]

  • Page 7

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 6 MAKE-UP AIR DIRECT COMMUNICATION A fresh supply of make-up air for com bustion can be suppli ed to the heater through make-up air ducts which directly com municate wi th the out of doors. Tw o openings are required - one w[...]

  • Page 8

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 7 MAKE-UP AIR VERTICAL DUCTS Often it is mor e practical to install ver tical make-up air ducts to the out doors. Again, two openings are r equired - one w ithin 12 i nches of the top of the enclosur e and one within twelve [...]

  • Page 9

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 8 MAKE-UP AIR HORIZONTAL DUCTS When the heater is installed in an inter ior room with no roof access for vertical ducts, horizontal m ake-up air ducts should be installed. W hen using horizontal ducts, tw o openings are r eq[...]

  • Page 10

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 9 INSUFFICI ENT MAKE-UP AIR BACKDRAFT Insufficient make-up air is a major cause of c ombustion probl ems. One c ommon example is in a restaurant i nstallation wher e exhaust vent equipm ent was not consider ed in sizing make[...]

  • Page 11

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 10 CONTAMINATED AIR Along with adequate m ake-up air , the quality of the air is important. Contaminants i n combustion air can lead to pr emature heater fai lure. Vapor s from bl eaches, soaps, waxes, salts, etc. are drawn [...]

  • Page 12

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 11 GAS PRESSURE REQUIREMENTS Natural Gas Propane Gas Maximum Suppl y Pressure 13.8" w.c. 13.8" w.c. Minimum Supply Pressure 4.5" w.c. 11" w.c. Manifold Pressur e 3.5 " w.c. 10" w.c. The supply g[...]

  • Page 13

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 12 BTR GAS VALVE The gas valves used on all BTR water heaters ar e 24 volt AC combi nation step opening gas val ves. They incorpor ate the pilot val ve, main val ve, and gas pressure regul ators into one body. The inlet view[...]

  • Page 14

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 13 VENTING Atmospheric Multi ple Heaters All BTR water heater s are classified by ANSI as category I ( non-condensing, negative pressure venting) appliances. They ar e approved for type B vent. For larger appli cations, BTR [...]

  • Page 15

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 14 DRAFT INDUCER Draft inducer s can be used wit h BTR water heater s to mechanical ly aid a l azy chimney in vertical vent applications. They are not designed to allow “through-the- wall” vent installations. (See Power [...]

  • Page 16

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 15 POWER VENT KITS FOR SIDEWALL VENTING Water Heater Models Part Number BTR-120-200 193933-0 BTR-250-500 193933-1 BTR water heater s can be used with power vent kits for sidewal l venting. A.O. Smith offers power vent kits f[...]

  • Page 17

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 16 BTR SEQUENCE OF OPERATION 1. Thermostat calls for heat 2. Flue dam p er o p ens 3. Intermittent I g nition Control 5. Main gas valve opens 7. Thermostat satisfies 4. Pilot gas opens, Pilot sparks and flame p roves 6. Main[...]

  • Page 18

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 17 BTR ELECTRICAL SEQUENCE 100 – 109 Series[...]

  • Page 19

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 18 BTR ELECTRICAL SEQUENCE OF OPERATI ON Mo t o r Ope n s Da m pe r Po w e r t o Da m pe r #2 I nt e r r upt e d Se r i e s 11 0 a nd 111 Ef f i k a l Ser i es 1 10 a nd 111 Ef f i k a l I I D M o dul e ( 2 4 V ) Rec ei v es[...]

  • Page 20

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 19 TROUBLESHOOTING BTR WATER HEATERS To troubleshoot a BTR water heater check that: • 120 VAC i s supplied to the heater • the tank is full of wate r • gas is supplied to the unit STEP 1 TEST THE TRANSFORMER STEP 1 - T[...]

  • Page 21

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 20 STEP 2 HIGH LIMI T, LEFT TERMINAL TEST STEP 2. HIGH LIMIT, LEFT TERMINAL TEST. Test for 24 VAC between the left high limi t terminal and ground. IF THEN The meter does not r ead 24 VAC: • Check w iring between transform[...]

  • Page 22

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 21 STEP 3 TEST HIGH LIMI T RIGHT TERMINAL STEP 3. TO TEST HIGH LIMIT RIGHT TERMINAL . Ensure that the jumper wire between the high lim it and thermostat is connected, and the dam per motor pow er line i s connected. Test for[...]

  • Page 23

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 22 STEP 4 INSPECT THE DAMPER STEP 4. INSPECT THE DAMPER. Lower the thermo stat setting so the unit will not b e calling for heat, then inspect the damper. IF THEN If the damper is open: • Go to step 5. If the damper is clo[...]

  • Page 24

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 23 STEP 6 PC BOARD MOTOR TEST STEP 6. PC BOARD/MOTOR TEST. Check for 24 VAC between the tw o motor lead terminal s of the PC board. Disconnect the wires for thi s test. IF THEN 24 VAC is not present: • Repl ace the board ([...]

  • Page 25

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 24 STEP 7 THERMOSTAT TEST STEP 7. THERMOSTAT TEST. Set the thermostat to call for heat. Using your multim eter, test for 24 VAC between right term inal and ground. IF THEN The meter does not read 24 VAC and the jumper wir e [...]

  • Page 26

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 25 GO TO PAGE 27 FO R DAMPER TESTS O F EFFIKAL EQUI PPED (SERIES 110, 111 AND RET ROFIT ) MODEL S STEP 8 DAMPER INPUT TEST STEP 8. DAMPER INPUT TEST. Test for 24 VAC between the yel low wi re on the PC board and ground. Effi[...]

  • Page 27

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 26 STEP 10 TEST DAMPER OUTPUT STEP 10. TEST DAMPER OUTPUT. On a call for heat, the damper relays recei ves power through the y ellow w ire and power to the motor is interrupted. Then, the motor clutch is disengaged and the d[...]

  • Page 28

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 27 Damper 1 23 4 Bl ack Red Ye llo w Wh i te Or ange Br own Yello w Black Male P lug From Heater 2 1 3 4 Female Plug EFFIKAL DAMPER BTR Series 110 and 111 began using the motor open; motor close, Effikal D amper. T he wiri n[...]

  • Page 29

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 28 HARNESS CHART Heater Harness Function Damper Harness Black 24V Hot 1-Brown Yellow 24V from Therm 2-Orange Red 24V from damper 3-Yellow White 24V commo n 4-Black Series 110 and 111 heaters and convert ed model BTR(C) and B[...]

  • Page 30

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 29 NORMAL OPERATION (conti nued) Condition: • Thermostat closed, damper in process of opening STEP B TEST FOR 24VAC BETWEEN BLACK AND ORANGE IF THEN 24VAC is pr esent Continue to Step C. 24VAC is not pr esent See Troublesh[...]

  • Page 31

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 30 TROUBLESHOOTING THE EFFIKAL STYLE DAMPER Condition: Thermostat closed, dam per STEP A1 TEST BETWEEN BLACK (COMMON) AND BROWN ON THE DAMPER BOARD IF THEN 24VAC is present This i s correct 24VAC is not present • S e eS t [...]

  • Page 32

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 31 TROUBLESHOOTING THE EFFIKAL STYLE DAMPER (continued) Condition: Thermostat closed, dam per is open fully STEP A3 TEST FOR 24VAC BETWEEN BLACK AND YELLOW IF THEN 24VAC is pr esent This is cor rect – continue to Step 11 2[...]

  • Page 33

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 32 STEP 11 WIRE HARNESS TEST STEP 11. WIRE HARNESS TEST. Test for 24 VAC between terminal 24V on the IID module, and 24V (GN D). IF THEN 24 VAC is not present: • Check the w iring harness. 24 VAC is present: • Go to step[...]

  • Page 34

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 33 STEP 12 IID MODU LE TEST STEP 12. IID MODULE TEST ( Power to the Pilot Valve). Using a multimeter, test for 24 VAC between terminal PV and 24V (GND) on the IID during the 90 second trial for ignition. IF THEN The meter do[...]

  • Page 35

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 34 STEP 13 PILOT SPARK TEST STEP 13. PILOT SPARK TEST. Visually check for spark at the pilot assembly. Note: The pilot burner mounts on the left side of the main burner . IF THEN The igniter is not sparki ng: Check for: • [...]

  • Page 36

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 35 STEP 14A PILOT VALVE - OHM TEST BTR 120 – 400 GA S VALVE STEP 14A. PILOT VALVE - OHM TEST. If pilot assembly is sparking but no pi lot flame is establis hed, disconnect the pilot valve solenoid leads. Using a multimeter[...]

  • Page 37

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 36 STEP 14B PILOT VALVE TEST – BTR 500 ONLY STEP 14B. PILOT VALVE TEST – BTR 500 ONLY. Testing the two co ils of the Honeywell VR 8404P 5004 gas valve used on the model BTR 500 only. Because of built in diodes, it is dif[...]

  • Page 38

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 37 STEP 15 MAIN BURNER TEST Note: BTR seri es 108 and 109 implemented a new mai n burner stamping process – burners appear the same as illustrated. STEP 15. MAIN BURNER TEST. Visually check for main burner . IF THEN The ma[...]

  • Page 39

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 38 STEP 16 FLAME RECTIFICATI ON STEP 16. FLAME RECTIFICATION Note: Flame rectific ation means that an alternating cur rent (AC) signal is changed to a direc t current ( DC) signal. The pilot flame is the ' switch' [...]

  • Page 40

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 39 STEP 17 IID MODU LE TEST Pilot is lit - Sparking has stopped. STEP 17. IID MODULE TEST (Power to th e Main Valve). Using a multimeter, test for 24 VAC between term inal MV on the IID and 24V (GND ). IF THEN 24 VAC is not [...]

  • Page 41

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 40 STEP 18A MAIN GAS VALVE CHECK BTR 120 – 400 GA S VALVE STEP 18A. MAIN GAS VALVE CHECK. Disconnect wires fr om gas valve TH and TR terminals. Using a multimeter , test for 68 ohms pl us or minus 5 between TH and TR on t [...]

  • Page 42

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 41 STEP 18B MAIN GAS VALVE COIL CHECK STEP 18B. MAIN GAS VALVE COIL CHECK – BTR 500 ONLY Condition: • Pilot lights • Sparking stops • No main bur ner ignition Test Procedure: • Power off • Disconnect red, m ain v[...]

  • Page 43

    BTR TANK TYPE HEATERS SERVICE HANDBOOK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 42 BTR WIRING DI AGRAM - NATURAL AND PROPANE GAS Honeywell Ignition Syst em (110 – 109 Series) IF ANY OF THE ORI GINAL WIRE AS S UPPLI ED MUST BE REPLACE D, USE ONLY TYPE 105° C THERM OPLASTI C OR EQUIVALEN T. BLUE WHITE [...]

  • Page 44

    B T RT A N KT Y P EH E A T E R S SERVICE WORKBO OK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 43 GENERAL SERVICE CHART CONDITION CAUSE SOLUTION DAMPER OPENS NO POWER TO IID MODULE . DAMPER NOT FULLY OPEN . DEFECTIVE PROTECTOR SWITCH .EFFIKAL – REPLACE DAMPER CONTROL ASSEMBLY . REPLACE DAMPER . REPLACE P[...]

  • Page 45

    B T RT A N KT Y P EH E A T E R S SERVICE WORKBO OK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 44 GENERAL QUESTIONS AND ANSWERS Q. What chan ges caused series 106/107 and 108/109 t o be implement ed? A. The 106 and 107 series units changed from the momentary push button to a slide switch. The 108 and 109 s[...]

  • Page 46

    B T RT A N KT Y P EH E A T E R S SERVICE WORKBO OK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 45 BTR MODELS 197 AND 198 Series 100-101[...]

  • Page 47

    B T RT A N KT Y P EH E A T E R S SERVICE WORKBO OK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 46 BTR MODELS 197 AND 198 (continued) Series 100-101[...]

  • Page 48

    B T RT A N KT Y P EH E A T E R S SERVICE WORKBO OK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 47 PARTS LIST for BTR Models 197 and 198 Series 100 & 101 Item Parts Description BTR 197 BTR 198 1 Bracket For Main Burner Orifice............... 098044(5) 098044(5) 2 Main Burner ............................[...]

  • Page 49

    B T RT A N KT Y P EH E A T E R S SERVICE WORKBO OK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 48 BTR MODELS 120 through 500 Series 104-105[...]

  • Page 50

    B T RT A N KT Y P EH E A T E R S SERVICE WORKBO OK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 49 BTR MODELS 120 through 500 (continued) Series 104-111[...]

  • Page 51

    B T RT A N KT Y P EH E A T E R S SERVICE WORKBO OK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 50 PARTS LIST FOR BTR Models 120 Thr ough 500(A) Series 104 Through 109 Ser ies (Series 106/107 have a service sw itch on Circuit Board 6522; Series 108/109 have new main burner production method. Both parts will[...]

  • Page 52

    B T RT A N KT Y P EH E A T E R S SERVICE WORKBO OK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas ©2000 Training Depart ment 51 COMPONENT PART INFORMATIO N NA ME SPECIFICA TIONS A OS PART NUMBERS DUAL CONTROLLER THERMOSTAT 120-180 O RANGE, + 4 O ,5 O DIFFERENTIAL, LIQUID FILLED, ANTI- STACKING AOS # 192828 HIGH LIMIT (ECO) OPENS - 205 [...]

  • Page 53

    B T RT A N KT Y P EH E A T E R S SERVICE WORKBO OK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas © 1999 Training Depart ment 52 BTR SERVICE CHECKLIS T (This service checklist may be photo copied to assist with BTR service call.) This checklist is intended to aid the Servi ce Agent in determ ining that the A.O. Sm ith BTR Water Heater [...]

  • Page 54

    B T RT A N KT Y P EH E A T E R S SERVICE WORKBO OK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas © 1999 Training Depart ment 53 Is the system properly si zed? yes no Is the system properly i nstalled? yes no Are there any water leaks? yes no Does th e inst all ation ha ve a recircu lating syst em? yes no If so, is it operational? yes [...]

  • Page 55

    B T RT A N KT Y P EH E A T E R S SERVICE WORKBO OK A.O. Smith Water Pr oducts Servic e Handbook Irving, Texas © 1999 Training Depart ment 54 COMMENTS Author: Terr y Mulder[...]