background image

61

alert conditions

When the control system declares an Alert condition it will display 

an Alert message on the control system's LCD with a question "?" 

mark. The water heater will continue to operate during an Alert 

condition but the water heater must be serviced by a qualified 

service agent as soon as possible.

resetting control system lock outs

To reset the control system from a lock out condition; turn the 

power supply off for approximately 20 seconds and then back on. 

Keep in mind; if the condition that caused the Fault has not been 

corrected, the control system will continue to lock out.

diagnostic checks

Turn off power to the water heater

before performing any service.

Electrical Shock Hazard

Label all wires prior to disconnecting

when performing service. Wiring errors

can cause improper and dangerous

operation.

Verify proper operation after servicing.

Failure to follow these instructions can

result in personal injury or death.

The  following  section,  Fault And Alert  messages  on  page  62, 

lists some of the messages the control system will display on the 

LCD when there are operational problems. This is not a complete 

list. Along with each of the Fault and Alert messages described 

there will be a list of possible causes and things to check and 

repair.
Only  qualified  service  agents,  as  defined  in  Qualifications  on 

page 6, using appropriate test equipment, should perform any 

service procedures on the water heater. 

note:

  If  you  are  not  qualified  and  licensed  or  certified  as 

required by the authority having jurisdiction to perform a given 

task do not attempt to perform any of the diagnostic or service 

procedures described in the following section. 
If you do not understand the instructions in the following section 

do not attempt to perform any procedures.
Call the technical support phone number listed on the back cover 

of  this  manual  for  further  technical  assistance  or  to  locate  a 

qualified service agent in your area.

Jumping out control circuits or components can

result in property damage, personal injury or death.

Service should only be performed by a qualified service

agent using proper test equipment.

Altering the water heater controls and/or wiring in any way

could result in permanent damage to the controls or water

heater and is not covered under the limited warranty.

Any bypass or alteration of the water

heater controls and/or wiring will result

in voiding the appliance warranty.

Altering the water heater controls and/or wiring in any way

could result in altering the ignition sequence allowing gas to

flow to the main burner before the hot surface igniter is at

ignition temperature causing delayed ignition which can

cause a fire or explosion.

•  Colder incoming water temperature lengthening 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 

heater operation. See maintenance on page 64 for sediment 

and lime scale removal procedures.

•  Water heater not firing at full input rating. Check manifold 

gas pressure, see instructions on page 54. Check actual firing 

rate of the water heater, see instructions on page 55.

water is too hot

•  Operating Set Point is set too high. See Operating Set Point 

And Differential Adjustment on page 47.

•  Upper and/or Lower Probe Offset settings improperly set - 

see Temperatures menu (cont) on page 48.

•  Improper water piping - see diagrams beginning on page 71.

noisy operation

•  Sediment or lime scale accumulations can cause rumbling 

and pounding noises during heating cycles. See the 

maintenance section of this manual beginning on page 64 for 

sediment and lime scale removal procedures.

•  Normal operating noise of electrical components; 

Combustion Blower, transformer hum, relay contact closure.

water leakage is suspected

•  Ensure the water heater drain valve is tightly closed.
•  Check cleanout opening for leaks - see Figure 5 on page 10.
•  Check inlet/outlet water connections and system piping.
•  Check the Temperature-Pressure relief Valve.

•  Excessive water temperature.
•  Excessive water pressure.
•  Defective Temperature-Pressure relief Valve.

note:

 Excessive water pressure is the most common cause of 

Temperature-Pressure  relief  Valve  leakage.  Excessive  water 

system pressure is most often caused by "thermal expansion" 

in a "closed system." See Thermal Expansion and Closed Water 

Systems on page 15. 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.

replacement parts

replacement  parts  may  be  ordered  from  the  manufacturer, 

authorized service agencies or distributors. When ordering parts 

be sure to have the complete water heater model Number, Serial 

Number and Series Number available. This information can be 

found on the rating label affixed to the water heater.
refer  to  the  parts  list  included  with  the  water  heater  from  the 

factory  for  more  information  or  call  the  parts  department  or 

technical support phone number listed on the back cover of this 

manual for further assistance.

fault and alert conditions

fault conditions

When the control system declares a Fault condition it will display 

a Fault message on the control system's LCD with an exclamation 

"!"  mark. The  control  system  will  lock  out  and  disable  heating 

operation until the condition is corrected. The water heater must 

be serviced by a qualified service agent before operation can be 

restored.

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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