background image

62

fault and alert messages

Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualified service agent 

in your area.

possiBle causes - check/repair

displayed fault/alert message

•  The water heater’s control system is polarity sensitive and will lock 

out and disable heating operation if the polarity of the power supply 

is reversed. The control system will display the “AC reversed” 

Fault message on the LCD in this condition. See Power Supply 

Connections on page 41 for instructions on how to properly connect 

the power supply.

note:

 Electronic flame sensing requires correct power supply 

polarity AND a proper earth ground to the water heater and the 

main Burner. The control system does not verify earth ground 

but this should be checked first if ignition failure occurs. See the 

Ignition Failure Fault message information below.

 

CHANGE

 

BACK 

ADVANCED

AC Reversed

Fault occurred 2 mins ago

Power supply to water heater

has reversed polarity.

Call a service professional:

Your Company Name Here

(press [DOWN] for more....)

•  The control system has failed to ignite the main Burner.
•  Water heater is not properly grounded, loose or open ground wire 

to the main Burner - see Power Supply Connections on page 41.

•  Corroded flame sensor, clean flame sensor with fine steel wool 

(replace if damaged) - see Figure 2 on page 7.

•  Loose or open wiring to the flame sensor.
•  Loose or open wiring to the 24 Volt Gas Valve.
•  24 Volt Gas Valve on/off switch in the "off" position - see Figure 57 

and Figure 58 on page 53.

•  Supply gas turned off, low gas volume - see page 39.
•  Intake air and/or vent piping is restricted or improperly installed - 

see Venting Installation on page 22.

•  Low or no manifold gas pressure to the main Burner - see Initial 

Start Up on page 52.

 

CHANGE

 

BACK 

ADVANCED

Ignition Failure

Fault occurred 2 mins ago

The water heater has failed to

ignite the burner.

Call a service professional:

Your Company Name Here

(press [DOWN] for more....)

•  The control system has detected the Low Gas Pressure Switch 

contacts are open.

•  Loose or open wiring to the Low Gas Pressure Switch - see 

beginning on page 8 for location.

•  Supply gas pressure is 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 line are operating.

•  Low volume of supply gas - see Supply Gas Line Installation on 

page 39 and the requirements for the Gas Supply Systems on 

page 14 and Supply Gas regulator on page 14.

 

CHANGE

 

BACK 

ADVANCED

Low Gas Pressure

Fault occurred 2 mins ago

The supply gas pressure to the

water heater is low.

Call a service professional:

Your Company Name Here

(press [DOWN] for more....)

•  The control system has detected low current (AC amps) from the 

Hot Surface Igniter. The control system monitors igniter current 

and will declare this Fault condition if the current is not at or above 

the programmed minimum requirement - see the Sequence Of 

Operation on page 58 for minimum igniter amp requirements.

•  Loose or open wiring to the Hot Surface Igniter - see Figure 2 on 

page 7 for igniter location.

•  Damaged, worn or open circuit Hot Surface Igniter.

note:

 Hot surface igniters are wearing parts. Wear is directly 

related to heating cycle count. Heating cycle count can be viewed 

in the Heater Information menu - see Heater Information on page 

49. Increasing the Differential setting reduces heating cycle count - 

see Operating Set Point And Differential Adjustment on page 47.

 

CHANGE

 

BACK 

ADVANCED

Low Igniter Current

Fault occurred 2 mins ago

Igniter current is low.

Call a service professional:

Your Company Name Here

(press [DOWN] for more....)

•  The control system has detected the Blocked Exhaust Switch 

contacts are open.

•  The condensate drain is blocked filling the exhaust elbow with 

water - clear the condensate drain - see Figure 9 on page 17.

•  Loose or open wiring to the Blocked Exhaust Switch - see 

beginning on page 8 for switch location.

•  restricted/blocked vent piping - condensate trapped in low point.
•  Excessive equivalent pipe length, exceeded the maximum number 

of 90° elbows or wrong pipe size used in the vent piping system - 

see Venting requirements on page 24.

•  Excessive wind outdoors pressurizing the vent system piping.
•  Excessive negative air pressure in the installed space.

 

CHANGE

 

BACK 

ADVANCED

Blocked Exhaust

Fault occurred 2 mins ago

The exhaust is blocked or

restricted. Ensure

condensate hose is draining.

Call a service professional:

Your Company Name Here

(press [DOWN] for more....)

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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