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NOTE:  In addition to the factory installed Temperature-Pressure 

Relief Valve on the water heater, each remote storage tank that 

may be installed and piped to a water heating appliance must also 

have  its  own  properly  sized,  rated  and  approved  Temperature-

Pressure 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 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.
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.

Water Damage Hazard

• 

Temperature-Pressure Relief Valve discharge

  pipe must terminate at adequate drain.

CAUTION

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 building. In cold climates, it is recommended 

that discharge pipe be terminated at an adequate drain inside 

building.

• 

Shall not have any valve or other obstruction between the 

relief valve and the drain.

Burn hazard.

Hot water discharge.

Keep clear of Temperature-

Pressure Relief Valve

discharge outlet.

The Temperature-Pressure Relief Valve must be manually operated 

at least twice a year. Caution should be taken to ensure that (1) no 

one is in front of or around the outlet of the Temperature-Pressure 

Relief Valve discharge line, and (2) the water manually discharged 

will  not  cause  any  bodily  injury  or  property  damage  because 

the water may be extremely hot. If after manually operating the 

valve, it fails to completely reset and continues to release water, 

immediately close the cold water inlet to the water heater, follow the 

draining instructions in this manual, and replace the Temperature-

Pressure 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 11.
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.

FILLING THE WATER HEATER

Never use this water heater unless it is completely full of water. To 

prevent damage to the tank, the tank must be filled with water. Water 

must flow from the hot water faucet before turning “ON” gas to the 

water heater.

To fill the water heater with water:
1.  Close the water heater drain valve by turning the handle to the 

right (clockwise). The drain valve is on the lower front of the water 

heater.

2.  Open  the  cold  water  supply  valve  to  the  water  heater.  

 

NOTE: The cold water supply valve must be left open when the 

water heater is in use.

3.  To insure complete filling of the tank, allow air to exit by opening the 

nearest hot water faucet. Allow water to run until a constant flow is 

obtained. This will let air out of the water heater and the piping.

4.  Check all water piping and connections for leaks. Repair as 

needed.

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 

Summary of Contents for BL-80

Page 1: ...safety messages could result in death or serious injury This manual must remain with the water heater 500 Tennessee Waltz Parkway Ashland City TN 37015 Low Lead Content WARNING If the information in t...

Page 2: ...gs for Confined Spaces 13 Outdoor Air Through Two Openings 13 Outdoor Air Through One Opening 13 Outdoor Air Through Two Horizontal Ducts 14 Outdoor Air Through Two Vertical Ducts 14 Air From Other In...

Page 3: ...hazard what can happen if you do not follow the safety message and how to avoid the risk of injury DANGER WARNING CAUTION CAUTION DANGER indicates an imminently hazardous situation which if not avoide...

Page 4: ...4 GENERAL SAFETY INFORMATION...

Page 5: ...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 op...

Page 6: ...2 1 1 2 12 1 2 CM 157 6 147 3 74 9 64 1 40 3 10 2 38 7 40 6 5 1 NPT NPT 31 8 Model INPUT RATE F 30 40 50 60 70 80 90 100 110 120 130 140 GPH 246 184 147 123 105 92 82 74 67 61 57 53 C 17 22 28 33 39 4...

Page 7: ...vicing and proper operation of the water heater Installation of water heater must be accomplished in such a manner that if the tank or any connections should leak flow will not cause damage to the str...

Page 8: ...per and inefficient operation of the water heater producing carbon monoxide gas in excess of the safe limits This could result in serious injury or death Contact your local gas supplier for any specif...

Page 9: ...rtain it does not sag thereby obstructing the combustion air flow HARD WATER Where hard water conditions exist water softening or the threshold type of water treatment is recommended This will protect...

Page 10: ...manufacturer s specifications If a positive lock up regulator is required follow these instructions 1 Positive lock up gas pressure regulators must be rated at or above the input Btu hr rating of the...

Page 11: ...s 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...

Page 12: ...ature 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 th...

Page 13: ...eater and the risk of fire or explosion may result It can also create a risk of asphyxiation LOUVERS AND GRILLES Thefreeareasofthefreshairopeningsintheinstructionsthatfollowdonot takeintoaccountthepre...

Page 14: ...e 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 commun...

Page 15: ...er heater unless it is vented to the outdoors and has adequate air supply to avoid risks of improper operation explosion or asphyxiation Align the legs of the draft hood with the holes provided Insert...

Page 16: ...IN INCHES MAXIMUM CAPACITY OF PIPE IN CUBIC FEET PER HOUR LENGTH IN FEET NOMINAL IRON PIPE SIZES INCHES INPUT IN THOUSANDS BTU HR 1 2 3 4 1 1 1 4 1 1 2 2 2 1 2 3 4 10 175 360 680 1400 2100 3960 6300 1...

Page 17: ...allation shown in the Figures 15 and 16 Contaminants in the gas lines may cause improper operation of the gas control valve that may result in fire or explosion Before attaching the gas line be sure t...

Page 18: ...ter several tries turn the gas control knob clockwise to OFF and call your service technician or gas supplier SEE FIGURE A DANGER Hotter water increases the risk of scald injury Consult the instructio...

Page 19: ...r at the water heater Mixing valves are available at plumbing supply or hardware stores see Figure 6 Follow manufacturer s instructions for installation of the valves Before changing the factory setti...

Page 20: ...See Condensation in this section OPERATIONAL CONDITIONS SMELLY WATER In each water heater there is installed at least one anode rod for corrosion protection of the tank Certain water conditions will c...

Page 21: ...replaced At least once a year a visual inspection should be made of the main burner and pilot burner see Figure 19 Inspect burner fl ames through viewport Flames should be very small with a blue haze...

Page 22: ...ter temperature and usage see chart The higher the water temperature or water usage the more lime deposits are dropped out of the water This is the lime scale which forms in pipes heaters and on cooki...

Page 23: ...drained before opening cleanout To clean heater through cleanout opening proceed as follows 1 Drain heater 2 Remove outer cover plate from lower side of heater jacket 3 Remove six 6 hex head screws se...

Page 24: ...er is no longer hot 4 Close the cold water inlet valve to the water heater 5 Connect a hose to the water heater drain valve and terminate it to an adequate drain 6 Open the water heater drain valve an...

Page 25: ...an condense on the cooler surfaces of the tank Droplets form and drip onto the burner or run on the floor This is common at the time of start up after installation and when incoming water is cold I Wa...

Page 26: ...Gas Control Replace Gas Control PILOT OUTAGE Dirty pilot burner Clean pilot assembly Thermocouple malfunction Replace pilot assembly and or thermocouple Defective Gas Control Replace Gas Control Ther...

Page 27: ...ocal codes shall govern their usage 4 The Tank Temperature Control should be wired to and control the pump between the water heater s and the storage tank s 5 The water heater s operating thermostat s...

Page 28: ...trol should be wired to and control the pump between the water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Cont...

Page 29: ...Control should be wired to and control the pump between the water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature C...

Page 30: ...ired to and control the pump between the water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control SINGLE FLUE...

Page 31: ...rature Control should be wired to and control the pump between the water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temper...

Page 32: ...he pump between the water heater s and the storage tank s 5 The water heater s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control SINGLE FLUE 2 UNITS TWO TEMPERATU...

Page 33: ...33 NOTES...

Page 34: ...34 NOTES...

Page 35: ...gas type venting connections combustion air voltage wiring or fusing Failure to follow applicable codes Failure to follow printed instructions Improper installation sizing delivery or maintenance Cla...

Page 36: ...36 500 Tennessee Waltz Pkwy Ashland City TN 37015 Technical Support 800 527 1953 Parts 800 433 2545 www hotwater com Copyright 2014 A O Smith Corporation All rights reserved...

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