A.O. Smith BTR 500 Page 50 Instruction Manual Download

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limited warranty

Summary of Contents for BTR 500

Page 1: ...ES 120 121 INSTALLATION 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 or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance ...

Page 2: ...g Diagrams 34 Manifold Kits 49 Limited Warranty 50 notes 51 Table Of Contents Safe Installation Use and Service 3 APPROVALS 3 General Safety Information 4 Precautions 5 Grounding Instructions 5 Hydrogen Gas Flammable 5 Introduction 6 Abbreviations Used 6 Qualifications 6 features and components 7 The Eliminator self cleaning system 7 High Limit Switch 7 Electronic Ignition Control 7 Exhaust Induce...

Page 3: ...cause cancer birth defects 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 defects or other reproductive harm This appliance can cause low level exposure to some of the substances listed in the Act DANGER WARNING CAUTION CAUTION DANGER indicates an imminently ...

Page 4: ...iment 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 service agency for installation and service Excessive gas pressure to gas valve can cause serious injury or death Do not use water heater with any gas other than the gas shown on the rating label Turn o...

Page 5: ...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 There should be no smoking or open flame near the faucet at the time it is open General Safety Information Verify the power to the water heater is turned off before performing any service procedures Read and understand this instruction manual and the safety messag...

Page 6: ...gas supply and electrical supply are required in addition to electrical testing skills when performing service ANSI Z223 1 2006 Sec 3 3 83 Qualified Agency Any individual firm corporation or company that either in person or through a representative is engaged in and is responsible for a the installation testing or replacement of gas piping or b the connection installation testing repair or servici...

Page 7: ...d manual resetting of high limit control preceded by higher than usual water temperature is evidence of high limit switch operation The following is a possible reason for high limit switch operation A malfunction in the thermostatic controls would allow the gas valve to remain open causing water temperature to exceed the thermostat setting The water temperature would continue to rise until high li...

Page 8: ...0 1 50 1 50 1 50 1 50 812 857 BTR500 147 322 207 44 196 171 69 53 3 171 20 70 1 50 1 50 1 50 1 50 1 50 1 50 368 389 Model Input Rate Btu Hr Kw Hr Approximate Tank Cap G L Recovery Rating Capacities GPH and LPH at temperature rise indicated 30 F 40 F 50 F 60 F 70 F 80 F 90 F 100 F 110 F 120 F 130 F 140 F 17 C 22 C 28 C 33 C 39 C 44 C 50 C 56 C 61 C 67 C 72 C 78 C BTR 500 500 000 85 1616 1212 970 80...

Page 9: ...E 5 MINIMUMCLEARANCESTONONCOMBUSTIBLECONSTRUCTION MODEL A RIGHT SIDE B LEFT SIDE C BACK D CEILING BTR 500 0 0 0 12 30 5 cm Locating the Water Heater Property Damage Hazard All water heaters eventually leak Do not install without adequate drainage CAUTION When installing the heater consideration must be given to proper location Location selected should be as close to the stack or chimney as practic...

Page 10: ... flow to the burners DO NOT allow insulation to come within 9 inches 23 cm of floor within 2 inches 5 cm of bottom cover to prevent blockage of combustion air flow to the burners DO NOT cover the instruction manual Keep it on the side of the water heater or nearby for future reference DO obtain new warning and instruction labels from the manufacturer for placement on the blanket directly over the ...

Page 11: ... Call the local gas or utility company to verify Btu per cubic foot content before calling for technical assistance and have that information available Note The actual firing rate of the water heater must not exceed the input rating on the water heater s rating label under any circumstances Note Due to the input rating reduction at high altitudes the output rating of the appliance is also reduced ...

Page 12: ...60 C Less than 5 seconds 130 F 54 C About 30 seconds 120 F 49 C More than 5 minutes Gas Pressure Requirements Natural gas models require a minimum gas supply pressure of 4 5 W C Propane gas models require a minimum gas supply pressure of 11 W C The minimum supply pressure is measured while gas is not flowing static pressure AND while gas is flowing dynamic pressure The supply pressure static and d...

Page 13: ...mal expansion tank installed See Water Line Connections on page 19 and the Water Piping Diagrams beginning on page 34 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 c...

Page 14: ...tems and Thermal Expansion on page 13 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 Contaminated Air Breathing Hazard Carbon Monoxide Gas Install water heater in accordance with the Instruction Manual and NFPA 54 or CAN CSA B149 1 To avoid i...

Page 15: ... Construction In unconfined spaces in buildings infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases However in buildings of unusually tight construction for example weather stripping heavily insulated caulked vapor barrier etc additional air must be provided using the methods described in the Confined Space section that follows Confined Space A Confine...

Page 16: ...0 square inches 645 cm2 Outdoor Air Through One Opening Figure 15 Alternatively a single permanent opening commencing within 12 inches 300 mm of the top of the enclosure shall be provided See Figure 15 The water heater shall have clearances of at least 1 inch 25 mm from the sides and back and 6 inches l50 mm from the front of the appliance The opening shall directly communicate with the outdoors o...

Page 17: ...e 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 this section of the manual are a reference for the openings that provide fresh air into confined spaces only Do not refer to these illustrations for the purpose of vent installation See Venting Installa...

Page 18: ... 8 8 7 500 000 2 Ft 10 10 10 9 9 8 8 7 500 000 3 Ft 10 10 9 9 9 8 7 7 Multiple Fan Assisted Water Heaters Total Vent Height Feet Number of 500 Heaters Combined Input btu hr 6 8 10 15 20 30 50 100 Manifold and Common Vent Diameter Inches 2 1 000 000 14 14 12 12 10 10 9 8 3 1 500 000 16 16 14 14 14 12 12 10 4 2 000 000 18 18 16 16 14 14 12 12 Combination of Multiple Fan Assisted and Natural Draft Wa...

Page 19: ...ation diagrams on pages 34 48 are typical The discharge opening of the temperature and pressure relief valve must be piped to an open drain and should not be subject to freezing temperatures Install in accordance with all local codes Water Line Connections This manual provides detailed installation diagrams see pages 34 48 of this manual for typical methods of application for the water heater s Wa...

Page 20: ...allations in the state of North Carolina due to the material of the tube Polypropylene Where such code restrictions exist use only lower inlet tank connection This may also require a heat trap check local codes The Top Outlet connection may still be used on these applications Plug or cap all unused openings in the tank before filling with water TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPER...

Page 21: ...ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF ELECTRICAL SHOCK OR POSSIBLE ELECTROCUTION If any of the original wire as supplied with the appliance must be replaced use only type 105 C thermoplastic or equivalent and 2500 C type F must be used for the flame sensor and igniter leads The controls of this water heater are polarity sensitive Be certain to properly wire the hot and neutral connection...

Page 22: ...VERSION OF THE NATIONAL FUEL GAS CODE To prevent damage care must be taken not to apply too much torque when attaching gas supply pipe to gas valve inlet Apply joint compounds pipe dope sparingly and only to the male threadsofpipejoints Donotapplycompoundstothefirsttwothreads Use compounds resistant to the action of liquefied petroleum gases BEFORE PLACING THE HEATER IN OPERATION CHECK FOR GAS LEA...

Page 23: ... and avoid unnecessary service calls However the user should not attempt repairs which are not listed under the USER column General NEVER OPERATE THE HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER AND A TEMPERATURE AND PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE OPENING OF THE HEATER SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MANUAL GAS CONTROL ...

Page 24: ...rt of the control system and any gas control which has been under water Do not touch any electric switch do not use any telephone in your building Immediately call your gas supplier from a neighbor s telephone Follow the gas suppliers instructions FOR YOUR SAFETY READ BEFORE OPERATING STOP Read the safety information above on this label Set thermostat to lowest setting 5 1 3 3 4 Turn off all elect...

Page 25: ...by the normal method or if a suitable draft cannot be obtained a blower type flue gas exhauster must be employed to assure proper venting and correct combustion Check the Igniter Assembly At least once a year check the igniter assembly Figure 23 and the main burner Figure 24 for proper operation Refer to the following igniter assembly and main burner sections Igniter Assembly For access to igniter...

Page 26: ...ng BTR 500 heater T 7 56 seconds H 1050 Btu Btuh 3600 7 56 X 1050 500 000 Btuh Compare with the BTR 500 model and rating Should it be necessary to adjust the gas pressure to the burners to obtain the full input rate the steps below should be followed 3 Remove the regulator adjustment sealing cap fig 25 and adjust the pressure by turning the adjusting screw with a screwdriver Clockwise to increase ...

Page 27: ...ting properly Expansion on page 13 The Temperature Pressure Relief Valve is not intended for the constant relief of thermal expansion Temperature Pressure Relief Valve leakage due to pressure build up in a closed system that does not have a thermal expansion tank installed is not covered under the limited warranty Thermal expansion tanks must be installed on all closed water systems DO NOT PLUG TH...

Page 28: ...ater Do not smoke or have open flame or sparks in vicinity of heater Do not mix UN LIME with other chemicals Do not allow contact with magnesium aluminum or galvanized metals RecommendedProcedureforPeriodicRemoval of Lime Deposits from Tank Type Commercial Water Heaters The amount of calcium carbonate lime released from water is in direct proportion to water temperature and usage see chart The hig...

Page 29: ...tion for contact with eyes Keep out of reach of children NOTE THE USE OF RUBBER OR NEOPRENE GLOVES IS RECOMMENDED ESPECIALLY IF YOU HAVE ANY OPEN SORES OR CUTS TO AVOID UNNECESSARY IRRITATION OR DISCOMFORT 1 Turn off fuel and or power supply to heater Also turn off power to any electrical device or equipment which is attached or part of the system 2 Open hot water side of faucet closest to heater ...

Page 30: ...EL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING Start Up Conditions SMOKE ODOR It is not uncommon to experience a small amount of smoke and odor during the initial start up This is due to burning off of oil from metal parts and will disappear in a short while STRANGE SOUNDS Possible noises ...

Page 31: ...ox Turn on the water heater If this fails to correct the problem contact your plumber or service representative further information regarding anode replacement and this chlorination treatment If the smelly water persists after the anode replacement and chlorination treatment we can only suggest that chlorination or aeration of the water supply be considered to eliminate the water problem Do not re...

Page 32: ...32 Sequence of Operation Flow Chart Description of this flow chart can be found in the SEQUENCE OF OPERATION section found on page 23 FIGURE 29 ...

Page 33: ...outside of tank normal Rumbling Sediment accumulation on bottom of tank Drain a quantity of water through drain valve If rumbling persists call a service agent Delime heater Ticking or metallic sounds Expansion and contraction normal Pounding Air chambers in piping have become waterlogged Drain piping system and refill Heater must be off while this is being done Combustion noises Too much primary ...

Page 34: ... s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control MULTI FLUE 1 UNIT WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WIT...

Page 35: ...mostat should be set 5 degrees F higher than the Tank Temperature Control MULTI FLUE 1 UNIT WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES A...

Page 36: ...s and the storage tank s MULTI FLUE 1 UNIT WITH MIXING VALVE TWO TEMPERATURE LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS TE...

Page 37: ...ump between the water heater s and the storage tank s MULTI FLUE 2 UNITS LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS HOT WA...

Page 38: ...stat should be set 5 degrees F higher than the Tank Temperature Control MULTI FLUE 2 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ...

Page 39: ...stat should be set 5 degrees F higher than the Tank Temperature Control MULTI FLUE 2 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ...

Page 40: ...at should be set 5 degrees F higher than the Tank Temperature Control MULTI FLUE 2 UNITS WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ...

Page 41: ...TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS BOOSTER WATER RETURN PRE HEATED WATER TO BOOSTER BOOSTER WATER TO FIXTURES HOT WATER T...

Page 42: ...F VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS EXPANSION TANK BOOSTED WATER OUTLET TYPICAL BOOSTER HEATER PRE HEATER PRE HEATER MUST BE IDENTICAL HEATERS FINISHED FLOOR COLD WATER S...

Page 43: ... LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS HOT WATER TO FIXTURES HOT WATER RETURN COLD WATER SUPPLY EXPANSION TANK PIPE T...

Page 44: ... than the Tank Temperature Control MULTI FLUE 3 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENT...

Page 45: ...er than the Tank Temperature Control MULTI FLUE 3 UNITS WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIRE...

Page 46: ...URE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS EXPANSION TANK COLD WATER SUPPLY HOT WATER TO FIXTURES FINISHED FLOOR HOT WATER RETURN PIPE T ...

Page 47: ...Temperature Control MULTI FLUE 4 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS HOT WATER TO ...

Page 48: ...k Temperature Control MULTI FLUE 4 UNITS WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS HOT WATER...

Page 49: ...49 Manifold Kits MANIFOLD KITS TWO UNIT MANIFOLD KIT PART NO 9003426205 THREE UNIT MANIFOLD KIT PART NO 9003427205 FOUR UNIT MANIFOLD KIT PART NO 9003428205 MODEL DIMENSION A BTR 500 81 5 ...

Page 50: ...50 Limited Warranty ...

Page 51: ...notes ...

Page 52: ...500 Tennessee Waltz Pkwy Ashland City TN 37015 Technical Support 800 527 1953 Parts 800 433 2545 Fax 800 644 9306 www hotwater com Copyright 2010 A O Smith Corporation All rights reserved ...

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