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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 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.

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 15.
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.

temperature-pressure relief ValVe

Explosion Hazard

Temperature-Pressure Relief Valve

must comply with ANSI Z21.22-

CSA 4.4 and ASME code.

Properly sized temperature-

pressure relief valve must be

installed in opening provided.

Can result in overheating and

excessive tank pressure.

Can cause serious injury or death.

This  water  heater  is  provided  with  a  properly  rated/sized  and 

certified  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  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  Temperature-

Pressure  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 

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 

Summary of Contents for BTH-120 through BTH-500

Page 1: ...LLATION OPERATION SERVICE MAINTENANCE LIMITED WARRANTY WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury o...

Page 2: ...g Diagram 68 BTH 199 250 Wiring Diagram 69 Circulation Pump Wiring Diagrams 70 Water Piping Diagrams 71 Limited Warranty 78 Table Of Contents Safe Installation Use and Service 3 APPROVALS 3 General Sa...

Page 3: ...efects 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 defec...

Page 4: ...re 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 The...

Page 5: ...ment trap in accordance with NFPA 54 Use joint compound or Teflon tape compatible with propane gas Fire and Explosion Hazard Turn off gas lines during installation Contact a qualified installer or ser...

Page 6: ...ction Detailed installation diagrams are also found in this manual These diagrams will serve to provide the installer with a reference It is essential that all venting water piping gas piping and wiri...

Page 7: ...HOT SURFACE IGNITER 120 000 150 000 Btu hr MODELS COMBUSTION BLOWER FLAME SENSOR MAIN BURNER radial design BLOWER FLANGE INTAKE AIR combustion air CONNECTION 3 INCH PVC HOT SURFACE IGNITER COMBUSTION...

Page 8: ...p Views 3 2 4 5 6 8 10 12 11 2 13 14 16 1 17 15 9 7 FRONT 120 000 150 000 Btu hr MODELS TOP VIEW BTH 120 150 Components 1 Water Heater s 120 VAC on off switch 2 Powered anode rods The water heater s c...

Page 9: ...ration on page 44 3 2 4 5 6 8 10 12 11 2 13 14 16 1 17 15 9 7 FRONT 199 000 250 000 Btu hr MODELS TOP VIEW BTH 199 250 Components 1 Water Heater s 120 VAC on off switch 2 Powered anode rods The water...

Page 10: ...nch PVC drain connection See Figure 9 on page 17 and Condensate Drain Installation on page 38 Side Views 1 Cleanout access panel covers water heater cleanout opening 2 CCB enclosure see beginning on p...

Page 11: ...C L E A N O U T T P V A L V E D R A IN V A L V E 45 35 64 1 1 2 NPT WATER OUTLET SUPPLY GAS CONNECTION VERTICAL FRONT INTAKE AIR 3 INCH PVC V E N T 3 I N C H P V C 35 22 68 45 18 45 C L E A N O U T T...

Page 12: ...er heater in a new location observe the following critical points 1 The water heater must be located indoors 2 The water heater must not be located in an area where it will be subject to freezing temp...

Page 13: ...ation on page 30 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...

Page 14: ...trical Wiring on page 41 for installation instructions 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 PS...

Page 15: ...he 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...

Page 16: ...zed temperature pressure relief valve must be installed in opening provided Can result in overheating and excessive tank pressure Can cause serious injury or death This water heater is provided with a...

Page 17: ...n See Condensate Drain Installation on page 38 Combustible Material Storage Fire or Explosion Hazard Read instruction manual before installing using or servicing water heater Avoid all ignition source...

Page 18: ...rea 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...

Page 19: ...regate 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 d...

Page 20: ...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 Two Vertical Ducts The illustrations shown in...

Page 21: ...inal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size gas vent directly below Keep clear of all obstructio...

Page 22: ...take air connection Tee fitting is oriented properly on BTH 199 250 models see page 23 for instructions 20 Carefully read the Venting Requirements on page 24 and then proceed to the Venting Installati...

Page 23: ...e air Fernco coupling 6 Reconnect the Blocked Intake Air switch sensing tube making sure the sensing tube is securely connected at both ends and is not kinked INTAKE AIR CONNECTION PIPE 199 000 250 00...

Page 24: ...to order Concentric Vent Termination Part Numbers 4 Concentric Termination 9006328005 Venting Requirements Approved Materials Approved vent and intake air pipe materials that may be used in the Unite...

Page 25: ...h humidity The drain hose should be routed to an adequate floor drain separate from any other condensate drains See Figure 21 on page 26 Note Snow being pulled into the intake air piping and then melt...

Page 26: ...pe to the exhaust elbow on the water heater 12 If installing 4 inch vent pipe transition to 3 inch pipe at the exhaust elbow on the water heater as shown in Figure 18 on page 25 The field installed 3...

Page 27: ...nations must have a minimum separation of 24 61 cm measured on center line as shown in Figure 25 on page 28 In colder climates this separation should be increased to at least 48 inches 122 cm The bott...

Page 28: ...CES 60 cm ABOVE ANY PARAPET VERTICAL WALL OR STRUCTURE WITHIN 10 FEET 3 m HORIZONTALLY VERTICAL TERMINATION S FLAT ROOF CLEARANCE INTAKE AIR AND OR VENT EXHAUST 24 INCHES 60 cm MINIMUM HEIGHT ABOVE IF...

Page 29: ...diameter hole for 3 inch pipe or 5 inch 13 cm diameter hole for 4 inch pipe where the pipe s will pass through the wall Note Beware of concealed wiring and piping when cutting through the wall 8 Cut a...

Page 30: ...the length of a concentric termination do not use couplings The use of couplings will restrict flow through the termination and may cause improper combustion The termination s intake air and vent pipe...

Page 31: ...t cap onto the vent pipe Alternately a field supplied stainless steel screw may be used to secure the 2 components together when field disassembly is desired for cleaning A pilot hole must be drilled...

Page 32: ...tions are maintained Ensure multiple terminations are arranged or grouped as required Note These clearances must be maintained to prevent the recirculation of vent exhaust gases to the intake air Clea...

Page 33: ...learances on page 32 for detailed information on clearances and additional arrangement options Note When multiple concentric terminations are installed through a roof in the same location all terminat...

Page 34: ...34 Venting Arrangements Power Vent Vertical Figure 40 Direct Vent Vertical Figure 42 Power Vent Horizontal Figure 41 Direct Vent Horizontal Figure 43...

Page 35: ...g Arrangements Direct Vent Vertical Vent Horizontal Intake Figure 44 Direct Vent Vertical Concentric Figure 46 Direct Vent Horizontal Vent Vertical Intake Figure 45 Direct Vent Horizontal Concentric F...

Page 36: ...other appliance 6 inches 15 cm for appliances up to 10 000 Btu hr 3 kW 12 inches 30 cm for appliances between 10 000 Btu hr 3 kW and 100 000 Btu hr 30kW 36 inches 91cm for appliances above 100 000 Btu...

Page 37: ...ny other appliance 6 inches 15 cm for appliances up to 10 000 Btu hr 3 kW 12 inches 30 cm for appliances between 10 000 Btu hr 3 kW and 100 000 Btu hr 30 kW 36 inches 91 cm for appliances above 100 00...

Page 38: ...PVC cement and PVC primer 1 2 inch PVC pipe minimum length to equal the distance between the water heater and a suitable building drain 1 2 inch PVC fittings elbows and couplings necessary to install...

Page 39: ...PE CAP SEDIMENT TRAP Figure 52 Ensure all gas pipe is clean on the inside before installation To trap any dirt or foreign material in the gas supply line a sediment trap must be installed as shown in...

Page 40: ...e 5 Use a standard pipe wrench Stillson wrench as a back up on the first pipe nipple installed above when connecting other fittings and pipe in the supply gas line to prevent the 24 Volt Gas Valve on...

Page 41: ...r caused by freezing temperatures is not covered under the limited warranty Electrical Wiring All electrical work must be installed in accordance with the National Electrical Code ANSI NFPA 70 or the...

Page 42: ...g Machines on page 15 3 Temperature Pressure Relief Valve on page 16 4 Closed Systems and Thermal Expansion on page 15 5 For multiple water heater installations see Water Piping Diagrams beginning on...

Page 43: ...on a rise in temperature The ECO is located inside the Upper Temperature Probe two red wires see pages 8 and 9 for location The ECO switch contacts will open when the water temperature reaches approxi...

Page 44: ...storage tank Heating cycles and ignition are managed by the control system The ECO energy cut out flame sensor pressure switches and temperature probes are monitored by the control system The Combust...

Page 45: ...See beginning on page 8 for Blower Prover Switch location The Hot Surface Igniter is being energized See Figure 2 on page 7 for Hot Surface Igniter location The igniter has been energized and the con...

Page 46: ...s from the combustion chamber at the end of a heating cycle Fault The control system has detected a Fault condition Heating operation is disabled until the Fault condition is corrected Power to the wa...

Page 47: ...ll control system menus from the Main Menu With Temperatures menu selected highlighted in black in the Main Menu screen press the Operational Button under SELECT to enter the Temperatures menu If the...

Page 48: ...obe Offset 0 F CHANGE BACK HELP Temperatures Bottom of Menu Differential 8 F Tank Temperature 120 F Upper Temperature 122 F Lower Temperature 118 F Heater Regulated to Tank Upper Probe Offset 0 F Lowe...

Page 49: ...ulated time the control system water heater has been energized Burner On Time Total accumulated time the control system has been in the heating operating state burner run time Cycle Count Total accumu...

Page 50: ...event will replace the oldest Press the Operational Button under VIEW to view details for each Fault or Alert message stored 1 Blocked Air Intake A7 51 mins ago 2 Blocked Exhaust A8 54 mins ago 3 Low...

Page 51: ...is menu item Show Contact Information Yes Change Contact Name Change Contact Phone Current Contact Info 000 000 0000 Access Code UPDATE CANCEL Service Contact Information Using the UP and DOWN buttons...

Page 52: ...ly gas line tighten all supply gas line connections 4 Check for gas leaks see Gas Line Leak Testing on page 40 and repair any leaks found Initial Start Up Required Test Equipment Two U tube manometers...

Page 53: ...up sequence is complete 4 Using the control system menus and UIM user interface module change the Operating Set Point to a setting higher than the current tank temperature displayed on the control sy...

Page 54: ...ents and installation instructions are maintained Manifold Gas Pressure Adjustment Fire and Explosion Hazard Gas and carbon monoxide detectors are available Overfiring could result in fire or explosio...

Page 55: ...n page 47 2 When the water heater has completed its shut down sequence and enters the standby mode turn the water heater s on off switch to the off position 3 Close the Main Gas Shutoff Valve see Figu...

Page 56: ...fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and...

Page 57: ...than air and will settle on the floor 2 Set the ON OFF switch on the control panel to the ON position 8 Set the ON OFF switch on the control panel to the ON position 1 Set the thermostat to lowest se...

Page 58: ...re and the state of other system devices If the tank temperature drops below the Operating Set Point minus the Differential setting the control will automatically return to Step 2 and repeat the opera...

Page 59: ...tem Igniter is energized for warm up period 24 Volt Gas Valve is energized gas flows to Main Burner Is flame sensed at the Main Burner control system monitors the flame sensor Control System Locks Out...

Page 60: ...disable circuit disabling heating operation See Enable Disable Circuit on page 41 The heating capacity of the water heater has been exceeded the water heater is unable to meet demand Operational Probl...

Page 61: ...thening the time required to heat water to desired temperature Hot water piping leaks open faucets water heater drain valve leaking or open Sediment or lime scale accumulation may be affecting water h...

Page 62: ...below the required minimum pressure see Table 3 on page 12 Supply gas is turned off at the Main Shutoff Valve Supply gas pressure is dropping when other gas fired appliances on a common supply gas li...

Page 63: ...in the intake air piping system see Venting Requirements on page 24 Intake air screen was not removed prior to connecting the intake air piping to the water heater and is clogged blocked with debris...

Page 64: ...et the water run until the water is no longer hot Then close the hot water faucet 4 Connect a hose to the drain valve and terminate it to an adequate drain Maintenance General Keep water heater area c...

Page 65: ...water heater drain valve to flush the storage tank 7 Flush the water heater storage tank to remove sediment and allow the water to flow until it runs clean 8 Close the water heater drain valve when fl...

Page 66: ...pped with a powered anode system The anode rods 2 are of a permanent design and do not need replacing unless damaged Inspection and cleaning should be performed once a year Note Follow the instruction...

Page 67: ...numbers 1 4 On the other side of the dipswitch is the word OPEN The dipswitches are rocker type switches if one side of the rocker is down the other side will be up Pressing a rocker down on the side...

Page 68: ...ALVE B CENTRAL CONTROL BOARD C C 6 J 5 J 4 J 7 J 5 1 J 6 1 J 0 1 J 3 1 J 2 J 3 J 1 J TRANSFORMER INSIDE CCB ENCLOSURE 50VA GROUND STRIP BURNER GROUND BURNER BOLT ON OFF SWITCH GROUND 120 VAC NEUTRAL 1...

Page 69: ...STRIP BURNER GROUND BURNER BOLT ON OFF SWITCH GROUND 120 VAC NEUTRAL 120 VAC HOT LOW GAS PRESSURE SWITCH 1 BLACK 2 WHITE RED 1 BLACK 2 BLACK 1 BLACK 2 WHITE M USER INTERFACE MODULE I U 1 2 15 4 14 5...

Page 70: ...UIT DO NOT SHARE POWER WITH WATER HEATER AS THIS MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION CIRCULATING PUMP WIRING DIAGRAM DISHWASHER LOOP WITH TOGGLE SWITCH FIELD S...

Page 71: ...eview the following 1 See Mixing Valves on page 15 2 See Dishwashing Machines on page 15 3 See Temperature Pressure Relief Valve on page 16 ONE WATER HEATER SINGLE TEMPERATURE WITH BUILDING RECIRCULAT...

Page 72: ...es on page 15 3 See Temperature Pressure Relief Valve on page 16 ONE WATER HEATER TWO TEMPERATURE WITH HIGH TEMPERAURE LOOP RECIRCULATION WITH BUILDING RECIRCULATION LEGEND TEMPERATURE PRESSURE RELIEF...

Page 73: ...alve on page 16 ONE WATER HEATER SINGLE TEMPERATURE WITH VERTICAL STORAGE TANK FORCED RECIRCULATION WITH BUILDING RECIRCULATION LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATI...

Page 74: ...ONE WATER HEATER SINGLE TEMPERATURE WITH HORIZONTAL STORAGE TANK FORCED RECIRCULATION WITH BUILDING RECIRCULATION LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP DRAIN...

Page 75: ...llowing 1 See Mixing Valves on page 15 2 See Dishwashing Machines on page 15 3 See Temperature Pressure Relief Valve on page 16 TWO WATER HEATERS SINGLE TEMPERATURE WITH BUILDING RECIRCULATION LEGEND...

Page 76: ...Mixing Valves on page 15 2 See Dishwashing Machines on page 15 3 See Temperature Pressure Relief Valve on page 16 THREE WATER HEATERS SINGLE TEMPERATURE WITH BUILDING RECIRCULATION LEGEND TEMPERATURE...

Page 77: ...ves on page 15 2 See Dishwashing Machines on page 15 3 See Temperature Pressure Relief Valve on page 16 FOUR WATER HEATERS SINGLE TEMPERATURE WITH BUILDING RECIRCULATION LEGEND TEMPERATURE PRESSURE RE...

Page 78: ...stalled at the heater s and operational at all times The temperature and pressure relief valve installed on the heater is not an acceptable method 4 SERVICE AND REPAIR EXPENSES Under the limited warra...

Page 79: ...79...

Page 80: ...500 Tennessee Waltz Parkway Ashland City TN 37015 www hotwater com...

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