Bock Water heaters OT125 Installation And Operation Instruction Manual Download Page 53

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Page 53

SECTION VIII: PARTS LIST

Figure 41:

optiTHERM Burner Assembly Parts

Table 15:

optiTHERM Burner Assembly Parts

Gasket (transition tube to burner)

Burner

Gasket (burner to mounting flange)

Flange Assembly

** - includes mounting flange, insulation disk, retaining plate and bolts

Description

Blower
Gasket (blower to transition tube)

O-ring w/ Orifice (LP GAS models)

Gas Control

O-ring w/o Orifice (NAT GAS models)

Transition Tube

Summary of Contents for OT125

Page 1: ...ns thoroughly before attempting installation or operation of your water heater Keep these instructions for future reference Local plumbing and electrical codes must be followed in the installation of this water heater In the absence of a local code use the UNIFORM PLUMBING CODE and the NFPA Code Local codes may supersede instructions in this installation manual These instructions are a guide for t...

Page 2: ... injury NOTICE calls attention to observe a specified procedure SAVE THESE INSTRUCTIONS DANGER Water heaters utilizing Liquefied Petroleum gas LP are different from natural gas models A natural gas heater will not function safely on LP gas and vice versa To avoid possible equipment damage personal injury or fire DO NOT connect this water heater to a fuel type not in accordance with the rating labe...

Page 3: ...cations 4 Section II General Information 5 Section III Pre Installation 9 Section IV Installation 12 Section V Operation 38 Section VI Maintenance 42 Section VII Troubleshooting 46 Section VIII Parts List 51 Section IX Warranty 55 Page 3 ...

Page 4: ...OT150N OT199N H O T N P T C O L D N P T E x h a u s t V e n t P V C S h i p p i n g W e i g h t L B S k g H R E C I R C N P T G A S N P T CONNECTION SIZES A i r I n t a k e P V C NOTE Suffix N stands for NATURAL GAS For PROPANE GAS models change suffix N to LP For HIGH ALTITUDE models the following additional suffixes are defined as H25 Approved for altitudes greater than 2 000 up to 5 400 FT H58 ...

Page 5: ...o the temperature setpoint and controls the burner power on off and modulation accordingly The automatic reset temperature limiting safety function is managed by the main operating control In the event that the water temperature becomes excessive 193 F the control will shut off all gas to the water heater The temperature limit safety will automatically reset when the water temperature drops to bel...

Page 6: ...hot water system When 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 TEMPERATURE AND PRESSURE RELIEF VALVE T P CAUTION To reduce the risk of excessive pressures and temperatures in this water heater install temperature and pressure protectiv...

Page 7: ... 8 per foot This will allow the condensate in the vent to run back to the condensate drain on the water heater In some instances condensate may form in the intake piping during periods following burner operation Horizontal sections of air intake piping shall slope downward away from the water heater a minimum of 1 8 per foot A condensate drainage tube shall be installed on the intake piping near t...

Page 8: ...the water heater is properly braced to avoid movement or falling during a seismic event Bock recommends the Holdrite Quick Strap QS 120 or equivalent strapping system The Holdrite QS 120 is approved by the California Division State Architect and is UPC IPC IAMPO listed Figure 2 shows a water heater strapped against a wall Figure 2 Seismic Straps ...

Page 9: ...l be installed on a metal or wood panel extending beyond the full width and depth of the water heater by at least 3 inches 76 2 mm in any direction or if the water heater is installed in an alcove the entire floor shall be covered by the panel The panel must be strong enough to carry the weight of the heater when full of water Locate the heater so it is not subject to physical damage from moving v...

Page 10: ...r the water heater The gas meter must have adequate capacity to supply the rated maximum gas input of the water heater in addition to other gas fired equipment connected to the meter Minimum Gas Supply Pressure The gas supply must be capable of maintaining a minimum pressure at the inlet of the gas control during water heater operation at maximum input The pressure will be lowest at the gas contro...

Page 11: ...p and one within 12 inches of the bottom of the enclosure These openings shall lead directly to room s of sufficient volume so that the combined volume of all the space meets the criteria for unconfined space Each opening shall have a minimum free area of 1 square inch per 1000 Btu hr of the combined total input of all fuel burning appliances in the space Each opening shall have an area of not les...

Page 12: ... installed to the exhaust pipe prior to connection of the exhaust venting See instructions in Section IV Installation Vent Combustion Air Intake Condensate Elbow Assembly For the air intake side a 3 PVC 90 deg standard bend elbow is supplied and must be used as the termination fitting for either a direct vent or power vent system If a 4 vent system is specified use a 4 PVC 90 degree standard bend ...

Page 13: ...hall not be interchanged with other vent systems or unlisted pipe fittings In Canada the primer and cement must be of the same manufacturer as the vent system do not mix primers and cements from one manufacturer with a vent system from a different manufacturer The supplied plastic pipe fittings are certified as part of the water heater Minimum and Maximum System Lengths The water heater should be ...

Page 14: ... on the water heater and the required 90 elbow termination fitting 4 Equivalent length is measured after the point of connection to the condensate assembly and includes the termination fitting if used Shown as a balanced system Vent length may exceed air intake length if total combined length does not exceed 240 ft Intake length cannot exceed exhaust length Model s Fuel Type Vent Arrangement Minim...

Page 15: ...een used Verify the maximum and minimum vent and combustion air intake equivalent lengths and terminal clearances meet the specifications in this manual Inspect the vent and combustion air intake systems for cracking Pay close attention to joints between elbows and straight pipe Inspect the system for misalignment of components This may lead to sagging and unwanted stresses in the joints If any co...

Page 16: ... portions labeled A Determine which direction minimizes the length of the condensate drain line and point the orienter in that direction Install the trap portion by connecting the union parts labeled B so that it is pointing in the proper direction See Figure 5 for a view of how the condensate trap is assembled and Figure 7 for the top view of both orientation options The orientation of the trap p...

Page 17: ...there is insufficient clearance between the connection point and the floor to maintain slope the heater should be installed on a concrete slab or use a low profile condensate pump Some installations require the use of a condensate neutralizer to reduce the acidity of the condensate prior to reaching the drain Figure 11 shows the connection of a condensate line to a neutralizer It is recommended th...

Page 18: ... intake pipes Minimum clearances between the terminals must be met as specified in Figure 13 All clearances must comply with local codes or the latest edition of NFPA 54 ANSI Z223 1 or CSA B149 See Figure 12 and Table 6 for terminal clearances SECTION IV INSTALLATION Figure 12 Terminal Clearances NOTICE When connecting exhaust vent take caution to not alter orientation of condensate trap assembly ...

Page 19: ...rance above grade veranda porch deck or balcony 12 inches 30 cm 12 inches 30 cm B Clearance to window or door that may be opened 6 inches 15cm for appliances 10 000 Btuh 3kW 12 inches 30 cm for appliances 10 000 Btuh 3kW and 100 000 Btuh 30kW 36 inches 91cm for appliances 100 000 Btuh 30kW 6 inches 15cm for appliances 10 000 Btuh 3kW 9 inches 23 cm for appliances 10 000 Btuh 3kW and 50 000 Btuh 15...

Page 20: ...e remainder of the vent and air intake system and attach to the water heater as shown in Figure 14 Horizontal sections of the exhaust vent shall slope upward away from the water heater a minimum of 1 8 per foot 10 mm per meter This will allow the condensate in the vent to run back to the condensate drain on the water heater Horizontal sections of air intake piping shall slope downward away from th...

Page 21: ...side the building for combustion air A single hole through the exterior of the building is required for the vent pipe Note If air from inside the building will be used for combustion air the require ments in Section III Unconfined Space must be met All clearances must comply with local codes or the latest edition of NFPA 54 ANSI Z223 1 or CSA B149 See Figure 15 and Table 7 for vent terminal cleara...

Page 22: ... Installations1 US Installations2 A Clearance above grade veranda porch deck or balcony 12 inches 30 cm 12 inches 30 cm B Clearance to window or door that may be opened 6 inches 15cm for appliances 10 000 Btuh 3kW 12 inches 30 cm for appliances 10 000 Btuh 3kW and 100 000 Btuh 30kW 36 inches 91cm for appliances 100 000 Btuh 30kW 4 feet 1 2 m below or to side of opening 1 foot 300 mm above opening ...

Page 23: ...educe the performance of the water heater and could cause nuisance control lockouts Complete the installation of the remainder of the vent and air intake system and attach to the water heater as shown in Figure 17 Horizontal sections of the exhaust vent shall slope upward away from the water heater a minimum of 1 8 per foot 10 mm per meter This will allow the condensate in the vent to run back to ...

Page 24: ...ake up air inlet such as a dryer or furnace area is considered to be a forced air inlet Minimum 24 inches 61 cm between the vent and combustion air intake terminal centerlines Note It is best practice to locate the intake and exhaust terminations on a common plane CAUTION Never install air intake terminal above vent exhaust terminal Install piping through the roof as shown in Figure 18 Adequate le...

Page 25: ...Parapets can create stagnant zones that lead to accumulation of exhaust gas and eventual cross contamination of intake air Always terminate the vent above the parapet to allow for proper evacuation of exhaust gas See Figure 20 for details Figure 19 Vertical Direct Vent Arrangement CAUTION Annular spaces around vent pipe wall penetrations shall be permanently sealed using approved materials to prev...

Page 26: ...ce must be met All clearances must comply with local codes or the latest edition of NFPA 54 ANSI Z223 1 or CSA B149 As a basic guide the following minimum clearances shall be used Minimum 12 inches 30 cm above roof Minimum 12 inches 30 cm above anticipated snow level Maximum 24 inches 61 cm above roof level without additional support for vent 4 feet 1 2 m from any gable dormer or other roof struct...

Page 27: ...on to reduce the risk of rain snow or foreign objects entering the system Complete the installation of the remainder of the vent system and attach to the water heater Piping must be sufficiently supported At minimum it is recommended that a support is placed along the vent piping every 4 feet SECTION IV INSTALLATION Figure 21 Vertical Venting 1 pipe termination Figure 22 Vertical Power Vent Arrang...

Page 28: ...sily go 1 3 of the way into the fitting socket Liberally apply primer to inside of fitting socket and pipe joint area Over the wet primer apply a medium coat of cement to the fitting socket and pipe joint area Insert pipe into fitting with a slight twisting motion Ensure that the pipe is bottomed into the fitting Hold pipe and fitting for 30 seconds to prevent push off Wipe off excess cement Cure ...

Page 29: ...he end of the tube that was connected to the hose barb With the free end above the loop trap pour water into the tube until the loop is filled halfway Reconnect the tube to the hose barb and turn on electrical power to the water heater DANGER Failure to prime the condensate drain loop with water will result in combustion gas which may contain carbon monoxide entering the room To avoid the risk of ...

Page 30: ...alled pipe nipples at the cold and hot connections These pipes were tightened to proper orientation at the factory DO NOT ROTATE THESE PIPES WHEN CONNECTING FITTINGS IN THE FIELD The black indicator line on the side of the hot outlet pipe nipple must be facing up The black line on the side of the cold inlet nipple must be facing to the right in line with arrow on adjacent label If orientation is n...

Page 31: ...SECTION IV INSTALLATION Page 31 Figure 24 Piping Diagram One Unit Figure 25 Piping Diagram Two Units ...

Page 32: ...SECTION IV INSTALLATION Page 32 Figure 26 Piping Diagram Three Units Figure 27 Piping Diagram One Unit with 4 Port Storage Tank ...

Page 33: ...Page 33 Figure 28 Piping Diagram One Unit with 3 Port Storage Tank SECTION IV INSTALLATION ...

Page 34: ...shall not be connected to any heating system or component s previously used with a non potable water heating appliance If the space heating requires water at a temperature higher than required for other uses a tempering valve shall be installed to reduce the water temperature for those uses in order to lessen scald hazard potential This water heater cannot be used for space heating applications on...

Page 35: ...let and outlet connections on the regulator shall not be less than the minimum gas supply line size for the water heater The Maxitrol 325 7 1 1 4 1 1 2 or 325 5 3 4 1 series of regulators is recommended For ease of measurement install a tee with a pipe fitting and a manual shutoff valve between the main manual shut off valve to the water heater and the pressure regulator The pipe fitting should be...

Page 36: ... codes do not permit the use of the supplied cord disconnect the power cord from the junction box and replace with suitable power supply 120V 60 Hz wiring and connections The water heater draws less than 5 amps maximum Check for proper polarity at the main power connection prior to operating the water heater CAUTION Turn off or disconnect the electrical power supply to the water heater before serv...

Page 37: ...Page 37 SECTION IV INSTALLATION Figure 32 Schematic Wiring Diagram ...

Page 38: ...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 B C D WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions The gas contr...

Page 39: ...al been lost 10 times during one call for heat NO Gas valve is closed and blower goes to post purge speed for 25 seconds YES Blower is de energized and system goes to standby mode YES NO NO Gas valve is closed and blower goes to post purge speed for 25 seconds YES NO optiTHERM Sequence of Operation Are the blocked vent switches closed YES Has this error occurred 3 times in the last 10 minutes NO Y...

Page 40: ... at the factory Allow the water heater to warm up to the factory adjusted setpoint and wait until the main operating control has shut off gas to the burner Wait 30 seconds following shut off of gas then follow the procedure below to adjust the setpoint Figure 35 Steps to Adjust the Setpoint Temperature ...

Page 41: ...e installed on all domestic hot water lines MEASURING THE POINT OF USE WATER TEMPERATURE The thermostat is factory set at 120 F for domestic use It is the responsibility of the building owner to verify that the installer follows the recommended quantitative testing for measuring the point of use water temperature To make sure that the system works properly after installa tion and in the future it ...

Page 42: ... control enclosure cover The status LED is located on the right side of the panel When the tank is filled with water and the heater is connected to the power supply the status LED will be green If the LED is flashing red this indicates a system error Refer to Table 14 in Section VII Troubleshooting for possible causes and remedies when the LED is flashing red Check the status LED every three month...

Page 43: ...hin acceptable parameters Gas pressures and combustion measurements can be used to verify proper operation Check the inlet gas pressure to the gas control The pressure should be greater than 3 5 W C natural gas and 8 W C LP gas when the burner is operating at high fire Gas pressure shall not exceed 14 W C when the burner is off Measure the products of combustion in the exhaust vent At maximum inpu...

Page 44: ...ter utilizes a forced draft combustion system to draw combustion air to the burner and remove exhaust gas from the vent The combustion air intake is under a negative pressure which may cause unwanted objects to be pulled into the intake vent pipe Over time these objects may collect in the burner and affect burner ignitions and water heater performance While not required as a periodic maintenance i...

Page 45: ...air may be used to blow out any buildup Reassemble the burner carefully placing all gaskets back to their original locations Remount the blower assembly to the mounting flange with the nuts and lock washers Reconnect the elbow to the gas control with the four screws and reattach the air intake piping to the blower Finally reinstall the ignitor and flame rod Connect the wiring harnesses to the blow...

Page 46: ...build up in tank 1 Drain the water heater to remove scale and sediment Insufficient hot water 1 Heater undersized for load 1 Reduce hot water usage rate 2 Check display for error code 2 See Tables 10 and 11 3 Temperature setting of control is too low 3 Adjust setting as required Water too hot or not hot enough 1 Control temperature setting is too high or low 1 Adjust setting as required T P relief...

Page 47: ...ƵĂůŝĨŝĞĚ ĂŐĞŶĐǇ ƚŽ ŝŶƐƉĞĐƚ ƚŚĞ ĐŽŶƚƌŽů ĞƐĐƌŝƉƚŝŽŶ ŶƚĞƌŶĂů ƐŽĨƚǁĂƌĞ ĞƌƌŽƌ ĂƵƐĞƐ Θ ĐƚŝŽŶƐ ŽŶƚĂĐƚ Ă ƋƵĂůŝĨŝĞĚ ĂŐĞŶĐǇ ƚŽ ŝŶƐƉĞĐƚ ƚŚĞ ĐŽŶƚƌŽů ĞƐĐƌŝƉƚŝŽŶ ŶƚĞƌŶĂů ƐŽĨƚǁĂƌĞ ĞƌƌŽƌ ĂƵƐĞƐ Θ ĐƚŝŽŶƐ ŽŶƚĂĐƚ Ă ƋƵĂůŝĨŝĞĚ ĂŐĞŶĐǇ ƚŽ ŝŶƐƉĞĐƚ ƚŚĞ ĐŽŶƚƌŽů ĞƐĐƌŝƉƚŝŽŶ dŚĞ ĨůĂŵĞ ŝƐ Ɛƚŝůů ƉƌĞƐĞŶƚ ϭϬ ƐĞĐŽŶĚƐ ĂĨƚĞƌ ĐůŽƐŝŶŐ ƚŚĞ ŐĂƐ ǀĂůǀĞ ĂƵƐĞƐ Θ ĐƚŝŽŶƐ dŚĞ ŐĂƐ ǀĂůǀĞ ŝƐ ŶŽƚ ĐůŽƐŝŶŐ ƉƌŽƉĞƌůǇ Ͳ ĐŽŶƚĂĐƚ Ă ƋƵĂůŝĨŝĞĚ ĂŐĞŶĐǇ ĞƐĐƌŝƉ...

Page 48: ...ƚŚĞ ŵĂŝŶ ƉŽǁĞƌ ƐƵƉƉůǇ ŝƐ ƌĞǀĞƌƐĞĚ ĂƵƐĞƐ Θ ĐƚŝŽŶƐ dŚĞ ŚŽƚ ĂŶĚ ŶĞƵƚƌĂů ǁŝƌĞƐ ĂƌĞ ƌĞǀĞƌƐĞĚ Ͳ ŽŶƚĂĐƚ Ă ƋƵĂůŝĨŝĞĚ ĂŐĞŶĐǇ ƚŽ ŝŶƐƉĞĐƚ ƚŚĞ ŝŶƐƚĂůůĂƚŝŽŶ ĞƐĐƌŝƉƚŝŽŶ ĨĂƵůƚǇ ĞĂƌƚŚ ŐƌŽƵŶĚ ĐŽŶŶĞĐƚŝŽŶ ŝƐ ĚĞƚĞĐƚĞĚ ĂƵƐĞƐ Θ ĐƚŝŽŶƐ ŵƉƌŽƉĞƌ ǁŝƌŝŶŐ Ͳ ĐŚĞĐŬ Ăůů ŐƌĞĞŶ ǁŝƌĞƐ ĞƐĐƌŝƉƚŝŽŶ dŚĞ ǁĂƚĞƌ ƚĞŵƉĞƌĂƚƵƌĞ ƐĞŶƐŽƌ ŝƐ ŽƉĞŶ ĂƵƐĞƐ Θ ĐƚŝŽŶƐ ĂƵůƚǇ Žƌ ůŽŽƐĞ ǁŝƌŝŶŐ Ͳ ĐŚĞĐŬ ƐĞŶƐŽƌ ǁŝƌĞƐ ĂŶĚ ĐŽŶŶĞĐƚŝŽŶƐ ĞƐĐƌŝƉƚŝŽŶ dŚĞ ǁĂƚĞƌ ƚĞŵƉĞ...

Page 49: ...tinuity If continuity is not indicated the ignitor must be replaced If the ignitor is working properly and the burner lights but goes out right away check the flame rod The rod may be dirty or it could be damaged and a replacement will be required Start by turning off power to the water heater and remove the flame rod Inspect the ceramic insulator for cracks replace if cracked Clean the rod with f...

Page 50: ...m and troubleshooting information such as fan speeds flame signal ignition attempts and error history is available in the Installer Menu Refer to Figure 38 for instructions to access this menu and useful tips Page 50 Figure 38 Using the Installer Menu ...

Page 51: ... Valve Hand Hole Access Cover Hand Hole Cover Plate Hand Hole Gasket Blocked Exhaust Switch Description Description Exhaust Gas Sensor Trim Plate Condensate Elbow Assembly T P Relief Valve Hot Surface Ignitor Flame Rod Sight Glass Baffle Control Panel Cover Knob Insulation Tank Top Air Intake Assembly Power Supply Junction Box Blocked Intake Switch w bracket Flue Pass 2 Sensor Powered Anode Rod 16...

Page 52: ...l Panel Parts 1 7 2 8 3 9 4 10 5 11 6 Powered Anode Status LED Standoff 2 5 in length Power Switch Bracket Power Switch for main control Terminal Block Main Operating Control Control Display Display Bracket Description Description Powered Anode Power Supply Anode LED Bracket Standoff 3 5 in length ...

Page 53: ...Gasket transition tube to burner 2 7 Burner 3 8 Gasket burner to mounting flange 4 9 Flange Assembly includes mounting flange insulation disk retaining plate and bolts Description Description Blower Gasket blower to transition tube O ring w Orifice LP GAS models Gas Control O ring w o Orifice NAT GAS models Transition Tube ...

Page 54: ...1669 19925 Gas Control Gas Control 21677 J Box to Terminal Block Junction Box Terminal Block 21665 Plug in Power Cord Junction Box Standard 3 Prong 120VAC Plug 21667 Power Switch Power Switch Terminal Block 21675 Power to Anode Controller Terminal Block Anode Power Supply 21671 Flue Gas Temperature Sensor Safety Switch Harness 21655 Harness 21664 Flue Gas Sensor Blocked Exhaust Switch 15155 Anode ...

Page 55: ...acement If a replacement tank is provided it will remain warranted under this section as if it were the original tank For example if we send you a replacement tank under this limited warranty two years after the original installation date then the replacement tank will remain warranted for the remaining three years after the original installation date HOW DO YOU GET SERVICE UNDER THE LIMITED WARRA...

Page 56: ...er Transfer or sell the water heater Remove the water heater from its original location and install it somewhere else Fail to follow the care and maintenance instructions provided with the water heater Alter disable or in any way cause the Impressed Current Cathodic Protection system to be inoperable Fail to maintain in continuous good working condition the Impressed Current Cathodic Protection sy...

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