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22

2.  If  the  water  heater  is  to  be  installed  in  a  beauty  shop, 

barber  shop,  cleaning  establishment,  a  laundry  with  dry 

cleaning equipment or any space with contaminated air it is 

imperative  that  the  water  heater(s)  be  installed  in  a  Direct 

Vent  configuration  so  that  all  air  for  combustion  is  derived 

from the outdoor atmosphere.

3.  The vent and intake air piping must terminate outdoors.
4.  The minimum clearance from combustible materials for the 

vent (exhaust) and intake air piping shall be 0 inches. Vent 

piping passing through a combustible wall or ceiling must be 

a continuous run (no joints).

5.  The water heater must be protected from freezing downdrafts 

during shutdown periods.

6.  The vent (exhaust) pipe must not be combined or connected 

to any other appliance’s vent system or chimney.

7.  The intake air pipe must not be combined or connected to 

any other appliance’s intake air piping.

8.  Locate the water heater where the vent (exhaust) and intake 

air piping will remain within the maximum equivalent lengths 

allowed. See Venting requirements on page 24.

9.  Do not install the vent or intake air piping in a manner that will 

allow water to be trapped in the piping.

10. Vent pipes must be pitched a minimum of a 1/4 inch per foot 

back to the water heater (to allow drainage of condensate).

11. Do not anchor the vent or intake air pipe directly to framed 

walls, floors or ceilings unless rubber isolation pipe hangers 

are used to prevent vibration noise from being transmitted.

12. Use only approved vent/intake air pipe sizes and materials. 

See Venting requirements on page 24.

13. Use only factory supplied vent and intake air or concentric 

terminations. See the Venting requirements on page 24.

14. Do  not  locate  the  vent  (exhaust)  or  intake  air  terminations 

where  they  would  be  objectionable  due  to  noise  at  the 

termination(s). This includes locations close to or across from 

windows and doors.

15. Direct venting into dead air spaces such as alleys, atriums, 

and  inside  corners  can  cause  recirculation  of  flue  gases. 

recirculation  of  flue  gases  will  cause  sooting,  premature 

failure  of  the  heat  exchanger  and  icing  of  the  combustion 

air  intake  during  severe  cold  weather.  To  prevent  the 

recirculation  of  flue  gases,  maintain  as  much  distance  as 

possible between the intake air and vent terminations.

16. Do not locate the vent termination over a public area where 

condensate or vapor can cause a nuisance or ice hazard.

17. Ensure the screens in the factory supplied terminations are 

securely installed to prevent blockage in the vent system.

18. Stress levels in pipe/fittings can be significantly increased by 

improper  installation.  If  rigid  pipe  clamps  are  used  to  hold 

the pipe in place, or if the pipe cannot move freely through a 

wall penetration, the pipe may be stressed, or high thermal 

stresses may be formed when the pipe heats up and expands. 

Install accordingly to minimize such stresses.

19. Ensure the intake 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 Installation Sequence on page 25.

Venting installation

Breathing carbon monoxide can cause brain damage or death.

Always read and understand the instruction manual.

Install vent system in accordance with codes. 
Do not operate water heater if flood damaged.
Special consideration must be taken with installations

above 10,000 feet (3,048 m) refer to high altitude

section of this manual.

Breathing Hazard - Carbon Monoxide Gas

Do not operate if soot buildup.

Do not obstruct water heater air intake with insulating

jacket or blanket.

Do not place chemical vapor emitting products near

water heater.

Gas and carbon monoxide detectors are available.

Never operate the heater unless it is vented to the

outdoors and has adequate air supply to avoid risks

of improper operation, fire, explosion or asphyxiation.

Analyze the entire vent system to make sure that

condensate will not become trapped in a section of

vent pipe and therefore reduce the open cross

sectional area of the vent.

Never operate the water heater unless it is vented to the outdoors. 

The instructions in this section of the manual must be followed 

to avoid choked combustion or recirculation of flue gases. Such 

conditions  cause  sooting  of  the  combustion  chamber,  burners 

and flue tubes and creates a risk of asphyxiation.

general Venting information

The  water  heaters  covered  in  this  manual  are  operationally 

equivalent  to  Category  IV  appliances  and  may  be  installed  in 

either a Power Vent or Direct Vent configuration.

category iV appliance

Category  IV  appliances  operate  with  a  positive  vent  (exhaust) 

static pressure and with vent gas temperatures low enough to 

produce condensate in the vent piping.

power Vent configuration

Power  Vent  configurations  derive  all  combustion  air  from  the 

room  where  they  are  installed  and  discharge  all  flue  gases  to 

the outdoor atmosphere through a sealed vent (exhaust) pipe. 

Power vent configurations have one vent pipe connected to the 

water heater which can be terminated in a vertical or horizontal 

arrangement. See Figure 40 and Figure 41 on page 34.

direct Vent configuration

Direct Vent configurations derive all combustion air directly from 

the  outdoor  atmosphere  through  a  sealed  intake  air  pipe  and 

discharge  all  flue  gases  to  the  outdoor  atmosphere  through  a 

sealed vent (exhaust) pipe. Direct Vent configurations have two 

pipes  connected  to  the  water  heater,  one  vent  pipe  and  one 

intake air pipe. Direct Vent configurations can be terminated in 

one  of  six  different  arrangements.  See  Figure  42  on  page  34 

through Figure 47 on page 35.

general Venting instructions

These instructions must be followed on all installations.
1. 

Do NoT

 install the water heater in a Power Vent configuration 

unless  there  is  adequate  supply  of  fresh  air,  see  Air 

requirements  on  page  18.  If  the  installation  space  does 

not provide an adequate supply of fresh air the water heater 

must be installed in a Direct Vent configuration.

Содержание BTH-120 through BTH-500

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 79: ...79...

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

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