Table of Contents
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Table of Contents
Related Manuals for A.O. Smith 120 trough 500
Summary of Contents for A.O. Smith 120 trough 500
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Page 2: Table Of Contents
Normal Operation 28-29 This service handbook is designed to aid in servicing and troubleshooting A.O. Smith BTR water heaters in the field. No duplication or reproduction of this book may be made without the express written authorization of the A.O. Smith Water Products Company. - Page 3 Revised Part Numbers on Page 15 Revision 3: • Adds information unique to the Efflkal damper equipped (Series 110, 111 and Retrofit) models A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK Service Handbook Training Department...
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Page 4: Clearances
A 24 inch clearance for all serviceable parts is recommended. Clearances may vary between BTR models – See instruction manual or the label on the heater, for clearances applicable to your specific model. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK 1”... -
Page 5: Clearances
10 feet (for vents of 12" in diameter or less). (NFPA 54 ANSI Z 223.1 SEC 7.5.2a). (Sec 7.6.2a may allow reduction to 8 feet with a “ Listed vent cap”). A.O. Smith Water Products Irving, Texas ©2000... - Page 6 The National Fuel Gas Code also specifies minimum make-up air opening sizes for various building installations. (Ref: NFPA 54, ANSI Z223.1, sec 5.3) A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS...
- Page 7 1 sq. in. per 3000 BTU per hr (7 cm located in the enclosure, and b. Not less than the sum of the areas of all vent connectors in the confined space. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS...
- Page 8 Each opening shall have a free area of not less than 1 square inch per 4000 BTUH of the total input of all appliances within the enclosure. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS...
- Page 9 Each opening shall have a free area of not less than 1 square inch per 2000 BTUH of the total input of all appliances within the enclosure. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS...
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Page 10: Air Requirements
This may result in air being backdrafted by the restaurant exhaust equipment through the heater causing flue gas spillage, flame roll out, improper combustion, inconsistent pilot operation, and/or erratic heater shut down. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS... -
Page 11: Contaminated Air
Flammable items, pressurized containers or any other potentially hazardous articles must never be placed on or adjacent to the heater. Open containers of flammable material should not be stored or used in the same room with the heater. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS... -
Page 12: Gas Pressure
This reading must be measured with 'flowing' gas. The manifold gas pressure is measured at the manifold pressure tap of the gas valve when the gas is flowing. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK... -
Page 13: Gas Valve
See step 18 for BTR-500 gas valve illustration A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK... -
Page 14: Venting
(Follow National Fuel Gas Code requirements for sizing and installation.) BTRs may be common vented only with other category I appliances. (See venting section in the National Fuel Gas Code). A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK... - Page 15 When mechanically venting, the following items are required: Draft Inducer (up to 300,000Btuh) Draft Inducer (up to 305,000 thru 500,000 Btuh) Draft Prover Switch Relay Switch A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK DRAFT INDUCER...
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Page 16: Venting
BTR-120-200 BTR-250-500 BTR water heaters can be used with power vent kits for sidewall venting. A.O. Smith offers power vent kits for use on installations with a maximum of 100 equivalent feet of vent piping. The power vent kits also use type B vent materials. - Page 17 IID, the sparking is stopped and the main gas valve is opened, allowing gas flow to the main burner. When the thermostat satisfie’s, main and pilot gas is shut off. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK 9.
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Page 18: Electrical
BTR TANK TYPE HEATERS SERVICE HANDBOOK BTR ELECTRICAL SEQUENCE 100 – 109 Series A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department... -
Page 19: Electrical
R elay (4 ) In teru p ted D am p er M otor E n erg ized an d D am p er C los ed A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK 1 2 0 V ac to J u n c tion B ox O n / O F F S witch "O N "... -
Page 20: Transformer
STEP 1 - TO TEST THE TRANSFORMER - Using a multimeter, test for 24 VAC between the secondary transformer terminals. The meter does not read 24 VAC: The meter reads 24 VAC: A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK... -
Page 21: High Limit
Note: The high limit (Energy Cut Off) opens if the tank water temperature exceeds 205 degrees. The control is resettable (manually) when the tank water temperature drops below 185 degrees. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS... -
Page 22: High Limit
There is also a black wire connecting to the damper motor assembly. This black wire supplies power to the motor to close the damper during periods of standby. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS... -
Page 23: Pc Board
STEP 5. CHECK THE PC BOARD. Test for 24 VAC between the black PC board wire connection and ground. 24 VAC is not present: 24 VAC is present: A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK... -
Page 24: Pc Board
WARNING - In the event of damper motor failure, verify that the damper is in the "open" position before utilizing the service switch. (BTR Series 106/107 and some prior series – changed from momentary push button to service switch). A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS... -
Page 25: Thermostat
Note: If the high limit to thermostat jumper wire was disconnected earlier to simulate a satisfied thermostat, reconnect the jumper to the terminals. Note: A yellow wire from this thermostat terminal connects to the damper PC board. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS... - Page 26 STEP 9 STEP 9. TEST THE DAMPER . Visually check the damper blade position. The damper does NOT open fully: The damper DOES open fully: A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK DAMPER INPUT TEST THEN •...
- Page 27 The meter reads 24 VAC Note: The spring rotates the damper blade assembly to the open position. This closes an end switch. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK TEST DAMPER OUTPUT...
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Page 28: Effikal Damper
Yellow – 24V To damper if the thermostat is closed Red – 24V From damper to IID if damper closes end switch White – Neutral (common) From Heater Male Plug A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK EFFIKAL DAMPER Service... -
Page 29: Normal Operation
TEST FOR 24VAC BETWEEN BLACK (COMMON) STEP A AND BROWN STEP A. TEST FOR 24VAC BETWEEN BLACK (COMMON) AND BROWN 24VAC is present 24VAC is not present A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK HARNESS CHART Function... -
Page 30: Normal Operation
• Thermostat closed, damper fully open STEP C TEST FOR 24VAC BETWEEN BLACK AND YELLOW 24VAC is present 24VAC is not present A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK THEN Continue to Step C. - Page 31 Condition: Thermostat closed, damper in process of opening. STEP A2 24VAC is present 24VAC is not present A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK TEST BETWEEN BLACK (COMMON) AND BROWN ON THE DAMPER BOARD...
- Page 32 Thermostat closed, damper is open fully STEP A3 TEST FOR 24VAC BETWEEN BLACK AND YELLOW 24VAC is present 24VAC is not present A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK THEN This is correct – continue to Step 11 •...
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Page 33: Wire Harness Test
Note: This test may be easier to conduct by removing the red wire from the IID terminal. Test for 24 VAC between the red wire and ground. Reconnect the red wire to the 24V terminal after the test. A.O. Smith Water Products Irving, Texas ©2000... -
Page 34: Iid Module
24 VAC between terminal PV and 24V (GND) on the IID during the 90 second trial for ignition. The meter does not read 24 VAC and the IID module is not between ignition trials: The meter does read 24 VAC: A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK IID MODULE TEST THEN •... -
Page 35: Pilot Spark
Power To Module May Be Interrupted To Reset . 90 sec. 5 min. Call for Sparking heat Sparking A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK PILOT SPARK TEST THEN Check for: • A 7/64” spark gap •... -
Page 36: Pilot Valve
20* ohms resistance +/- 5 through the solenoid coil. The meter dose not read 20 ohms plus or minus 5: The meter does read 20 ohms plus or minus 5: A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK PILOT VALVE - OHM TEST BTR 120 –... -
Page 37: Pilot Valve
Test DC Amperage through Pilot coil of gas valve .75 to .85 DCA is not present: .75 to .85 DCA is present Power off, reattach blue gas valve wire to PV terminal of module. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK PILOT VALVE TEST –... -
Page 38: Main Burner Test
STEP 15. MAIN BURNER TEST. Visually check for main burner. The main burner ignites: The main burner does not ignite A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK MAIN BURNER TEST THEN •... -
Page 39: Flame Rectification
Sparking at the pilot will continue if an insufficient signal is received by the module. Sparking at the pilot will stop almost immediately after the ignition module senses the pilot flame. Sparking continues after pilot is established: Sparking stops: A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK FLAME RECTIFICATION THEN •... -
Page 40: Iid Module
STEP 17. IID MODULE TEST (Power to the Main Valve). Using a multimeter, test for 24 VAC between terminal MV on the IID and 24V (GND). 24 VAC is not present: 24 VAC is present: A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK... -
Page 41: Main Gas Valve
Using a multimeter, test for 68 ohms plus or minus 5 between TH and TR on the main valve coil. The meter reads ‘O’ or infinity The meter reads 68* ohms plus or minus 5 A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK MAIN GAS VALVE CHECK BTR 120 –... -
Page 42: Main Gas Valve
.25 to .35 DC Amps is not present .25 to .35DCA is present Be certain to correct you meter wire connections and setting before performing further tests. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK... -
Page 43: Natural And Propane Gas
Honeywell Ignition System (110 – 109 Series) IF ANY OF THE ORIGINAL WIRE AS SUPPLIED MUST BE REPLACED, USE ONLY TYPE 105° C THERMOPLASTIC OR EQUIVALENT. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE HANDBOOK BLUE... -
Page 44: Service Charts
SHAFT SPRING WEAK/BROKEN DAMPER MOTOR NO SPARK AT PILOT - DAMPER ASSEMBLY DAMPER FULLY OPEN IID MODULE SPARK CABLE A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE WORKBOOK GENERAL SERVICE CHART CAUSE .EFFIKAL – REPLACE DAMPER CONTROL ASSEMBLY . -
Page 45: General Questions & Answers
Anode rods provide additional protection against corrosion. replaced? When large gouges or pits appear in the anodes, replace them. It is recommended that these be inspected every 6 months. A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE WORKBOOK... - Page 46 BTR TANK TYPE HEATERS SERVICE WORKBOOK BTR MODELS 197 AND 198 Series 100-101 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department...
- Page 47 BTR TANK TYPE HEATERS SERVICE WORKBOOK BTR MODELS 197 AND 198 (continued) Series 100-101 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department...
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Page 48: Parts List
T & P Relief Valve ... 99465-7 Transformer ... 193444 Inlet Tube ... 192626 Gas Valve Natural... 192827-2 Gas Valve Propane... 192827-3 Off/On Switch ... 193243 A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE WORKBOOK BTR 197 BTR 198... - Page 49 BTR TANK TYPE HEATERS SERVICE WORKBOOK BTR MODELS 120 through 500 Series 104-105 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department...
- Page 50 BTR TANK TYPE HEATERS SERVICE WORKBOOK BTR MODELS 120 through 500 (continued) Series 104-111 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department...
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Page 51: Parts List
Transformer Inlet Tube Gas Valve, Natural Gas Valve, LP Off/On Switch ∗ For complete parts list call 1-800-433-2545 A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE WORKBOOK on 104 thru 109 series heaters.) BTR-120 BTR-154 BTR-180 BTR-199 BTR-200... -
Page 52: Component Part Information
NATURAL GAS IGNITION DEVICE PROPANE CONTROL DAMPER COMPLETE ASSEMBLY P.C. BOARD W/RELAY TRANSFORMER A.O. Smith Water Products Irving, Texas ©2000 BTR TANK TYPE HEATERS SERVICE WORKBOOK NAME SPECIFICATIONS 120-180 RANGE, + 4 DIFFERENTIAL, LIQUID FILLED, ANTI- OPENS - 205 (ECO) RESET BELOW 185 BTR 120-400;24VAC, 60hz,... -
Page 53: Service Check List
(This service checklist may be photo copied to assist with BTR service call.) This checklist is intended to aid the Service Agent in determining that the A.O. Smith BTR Water Heater has been properly installed and is operating correctly. Because the circumstances of each installation may vary greatly, it is not intended to be an all- inclusive list of the problems that the Service Agent may encounter. -
Page 54: Service Check List
Are flammable materials located in the area of the water heater? Are flammable vapors located in the area of the water heater? Comments: (This service checklist may be photo copied to assist with BTR service call.) A.O. Smith Water Products Irving, Texas © BTR TANK TYPE HEATERS SERVICE WORKBOOK... -
Page 55: Comments
BTR TANK TYPE HEATERS SERVICE WORKBOOK COMMENTS Author: Terry Mulder A.O. Smith Water Products Service Handbook Irving, Texas © 1999 Training Department...