A.O. Smith BTN 120 THRU 400/A Series manual

1 MODELS BTN 120 THRU 400/A Series 108 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. 0603 P ART NO. 195714-000 A DIVISION OF A. O. SMITH CORPORA TION McBEE, SOUTH CARO[...]

2 ROUGH-IN-DIMENSIONS FRONT VIEW TOP VIEW BACK VIEW TA N K APPROX U.S Gallons/Hr . and Litres/Hr at TEMPERA TU RE RISE INDICA TED CAP ACITY E F F . F ° 36F° 40F° 50F° 54F° 60F° 70F° 72F° 80F° 90F° 100F° 108F° 110F° 120F° 126F° 1 30 F° 140F° Model Btuh K W U.S.Gal. Litres % C ° 20C° 22C° 2 8 C ° 30C° 33C° 39 C ° 40C° 44C° 5[...]

3 T ABLE OF CONTENTS ROUGH-IN-DIMENSIONS -------------------------------- 2 FOREWORD ------------------------------------------------- 3 GENERAL SAFETY INFORMA TION -------------------- 4 Precautions --------------------------------------------------- 4 Grounding Instructions ------------------------------------ 4 Chemical V apor Corrosion --------[...]

4 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[...]

5 HIGH AL TITUDE INST ALLA TIONS WARNING INST ALLA TIONS ABOVE 2000 FEET (610 METERS) REQUIRE REPLACEMENT OF THE BURNER ORIFICE IN ACCORDANCE WITH SECTION 8.1.2 OF THE NA TIONAL FUEL GAS CODE (ANSI Z223.1). F AILURE TO REPLACE THE ORIFICE WILL RESUL T IN IMPROPER AND INEFFICIENT OPERA TION OF THE APPLIANCE RESUL TING IN THE PRODUCTION OF INCREASED [...]

6 The exhaust inducer is equipped with a gravity controlled damper to reduce the amount of heat loss through the flue, improving efficiency . EXHAUST INDUCER FIGURE 4 CIRCULA TING PUMP A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the heater . Refer to the piping diagrams in[...]

7 length and width at least 2" greater than the diameter of the heater and must be piped to an adequate drain. The pan must not restrict combustion air flow . LEVELING If the unit is not level, insert the bolts which were used in crating into the legs to correct this condition. CLEARANCES These heaters are approved for installation on combusti[...]

8 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 DRAWN INTO THE ROOM THROUGH THE CHIMNEY , CAUSING POOR COMBUSTION. SOOTING MA Y RESUL T IN SERIOUS DAMAGE TO THE HEA TER [...]

9 TYPE B GAS VENT Multiple Gas Fired T ank-T ype Heaters When venting multiple tank type heaters using T ype B vent pipe, follow the installation diagram (figure 4) and tables below which give sizing and data based upon NFP A 54/ANSI Z223. 1992. T ABLE 6. TECHNICAL DA T A VENTING MODEL BTN-120 Input: 120,000 Btu/hr T otal V ent Height (Feet) V ent [...]

10 MODEL BTN-250 Input: 250,000 Btu/hr T otal V ent Height (Feet) V ent Connector Size: 6 inches 6 8 10 15 20 30 50 1 00 Input Btuh/hr Rise V ent Connector Diameter (Inches) 250,000 1 Ft 8 8 7 7 7 6 6 6 250,000 2 Ft 7 7 7 7 6 6 6 6 250,000 3 Ft 7 7 7 7 6 6 6 6 Number Combined Input BTN 250 of Heaters in Thousands of Btu/hr Manifold and Common V ent[...]

11 W A TER LINE CONNECTIONS This manual provides detailed installation diagrams (see pages 13-19 of this manual) for typical methods of application for the water heater(s). The water heater may be installed by itself, or with a separate storage tank, on both single and two-temperature systems. When used with a separate storage tank, the circulation[...]

12 INST ALLA TION DIAGRAMS-TOP INLET/OUTLET USAGE Use of the top inlet water connection requires installation of an inlet dip tube (refer to figure 8). 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. CODE RESTRICTIONS Use of the top i[...]

13 VERTICAL ST ORAGE T ANK AND FORCED CIRCULA TION DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERA TURE A T FIXTURES. SEE WA TER TEMPERA TURE CONTROL WARNING ON P AGE 25. IF HIGHER PREHEA T TEMPERA TURES ARE NECESSARY TO OBT AIN ADEQUA TE BOOSTER OUTPUT , ADD AN ANTI- SCALD V AL VE FOR HOT WA TER SUPPLIED T O FIXTURES. HORIZONT A L S[...]

14 DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERA TURE A T FIXTURES. SEE WA TER TEMPERA TURE CONTROL WARNING ON P AGE 25. IF HIGHER PREHEA T TEMPERA TURES ARE NECESSARY TO OBT AIN ADEQUA TE BOOSTER OUTPUT , ADD AN ANTI- SCALD V AL VE FOR HOT WA TER SUPPLIED TO FIXTURES. TWO TEMPERA TURE - ONE HEA TER HIGH TEMPERA TURE ST ORAGE WITH [...]

15 INST ALLA TION DIAGRAMS-SIDE INLET/OUTLET USAGE DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERA TURE A T FIXTURES. SEE WA TER TEMPERA TURE CONTROL WARNING ON P AGE 25. IF HIGHER PREHEA T TEMPERA TURES ARE NECESSARY TO OBT AIN ADEQUA TE BOOSTER OUTPUT , ADD AN ANTI- SCALD V AL VE FOR HOT WA TER SUPPLIED T O FIXTURES. A listed tempe[...]

16 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) WA TER CIRCULATION. INST AL L ON OR CLOSE TO DISHWASHING MACHINE. TOGGLE SWITCH MUST BE CLOSED (ON) DURING THE RINS[...]

17 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 W ATER TEMPERA TURE CONTROL W ARNING ON P AGE 25. IF HIGHER PREHEA T TEMPERA TURES [...]

18 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 WA TER TEMPERA TURE CONTROL W ARNING ON P AGE 25. IF HIGHER PREHEA T TEMPERA TURES ARE NECESSAR Y[...]

19 MODEL DIMENSION “A” BTN-120 63” BTN-154 68” BTN-180 72” BTN-199 72” BTN-200/A 7 2” BTN-250/A 7 2” BTN-275/A 7 2” BTN-310/A 7 3” BTN-366/A 7 3” BTN-400/A 7 3” MANIFOLD KITS TWO UNIT MANIFOLD KIT (P ART NO. 78692) THREE UNIT MANIFOLD KIT (P ART NO. 78593) FOUR UNIT MANIFOLD KIT (P ART NO. 78694)[...]

20 HEA TER WIRING All electrical work must be installed in accordance with the latest version of the National Electrical Code ANSI/NFP A No. 70, 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[...]

21 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 3. 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. N[...]

22 correct water column pressure allowing for a nominal pressure drop through the controls. The minimum gas supply pressure for input adjustment must not be less than 4.5" w .c. (1.12 kPa) for natural gas. Do not subject the combination gas valve to inlet gas pressures of more than 14.0" W .C. (3.48 kPa) - natural gas. A service regulator[...]

23 SEQUENCE OF OPERA TION The following information will describe the Sequence of Operation for this appliance. 1. Switch power on to unit. 2. Thermostat calls for heat. 3. Ignition Control Board performs diagnostic check on system components. 4 . On completion of diagnostics check, the Ignition Control Board sends signal to Exhaust Inducer . 5. Ex[...]

24 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[...]

25 W A TER TEMPERA TURE CONTROL DANGER THIS W A TER HEA TER IS EQUIPPED WITH AN ADJUST ABLE THERMOST A T TO CONTROL W A TER TEMPERA TURE. HOT W A TER TEMPERA TURES REQUIRED FOR A UT OMA TIC DISHWASHER AND LAUNDRY USE CAN CAUSE SCALD BURNS RESUL TING IN SERIOUS PERSONAL INJURY AND/ OR DEA TH. THE TEMPERA TURE A T WHICH INJUR Y OCCURS V ARIES WITH TH[...]

26 Servicing of the ignitor assembly includes keeping the ignitor free of lint, scale or any other foreign debris. FIGURE 1 1, IGNIT OR MAIN BURNER The main burner , fig.12, should display the following characteristics: • Cause rapid ignition and carry across entire burner . • Give reasonably quiet operation during ignition, burning, and extinc[...]

27 When the heater is operating at full capacity , or full gas input, it should consume 1 cu. ft. of gas in time indicated on T able 9. VENTING SYSTEM Examine the venting system every six months for obstructions and/or deterioration of the vent piping. Remove all soot or other obstructions from chimney which will retard free draft. REMOTE STORAGE T[...]

28 Hydrochloric base acids are not recommended for use on glass lined tanks. CAUTION Observe handling instructions on label of product being used. T ANK CLEANOUT PROCEDURE The following practices will ensure longer life and enable the unit to operate at its designed efficiency: 1. Once a month the heater should be flushed. Open the drain valve and [...]

29 Note: If your container does not have the vent cap and vent boss, drill a 3/16" hole in the handle. When you have finished deliming you will be able to plug this drilled vent with the stainless steel screw that is supplied with the kit. 2. Remove the container's cap and cut the plastic membrane located in the 3/4" IPT opening in t[...]

30 REPLACEMENT P ARTS, SERVICE HANDBOOKS AND TRAINING AIDS Replacement parts may be ordered through A.O. Smith dealers, authorized servicers or distributors. Refer to the Y ellow Pages f or where to call or contact the A.O. Smith Water Product s Company , Product Service Division, 5621 W est 1 15th Street, Alsip, IL 608 03, 1-800- 433-2545. When or[...]

31 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,[...]

32 Model BTN Limited Warranty A. O. Smith Corporation, the warrantor, extends the following LIMITED W ARRANTY 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 af[...]