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A.O. Smith 101 Series Instruction Manual

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http://waterheatertimer.org/How-to-troubleshoot-gas-water-heater.html
500 Tennessee Waltz Parkway
Ashland City, TN 37015
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.
•
Do not touch any electrical 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.
•
If you cannot reach your gas supplier,
call the fire department.
Installation
performed by a
service agency or the gas supplier.
Thank you for buying this energy efficient water heater.
We appreciate your confidence in our products.
place these instructions adjacent to heater and notify owner to keep for future reference.
PRINTED IN THE U.S.A. 0310
commercial gas water heaters
ASME CRN
ANSI / NSF 5
and
service
must
qualified
installer,
models Bth-300a/400a/500a
installation - operation - serVice
- maintenance - limited warranty
be
instruction manual
series 100 & 101
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
197373-005

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Summary of Contents for A.O. Smith 101 Series

  • Page 1 http://waterheatertimer.org/How-to-troubleshoot-gas-water-heater.html instruction manual commercial gas water heaters models Bth-300a/400a/500a series 100 & 101 installation - operation - serVice - maintenance - limited warranty 500 Tennessee Waltz Parkway Ashland City, TN 37015 ASME CRN ANSI / NSF 5 WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

  • Page 2: Table Of Contents

    taBle of contents SAFE iNSTALLATiON, USE AND SErViCE.......... 3 Supply Gas Line Installation ............37 GENErAL SAFETy iNFOrmATiON ............4 Supply Gas Regulator Installation ........... 38 Precautions ..................4 Electrical Wiring ................39 iNTrODUCTiON ..................6 Power Supply Connections ..............39 Qualifications ..................

  • Page 3: Safe Installation, Use And Service

    safe installation, use and serVice The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others. many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard.

  • Page 4: General Safety Information

    general safety information precautions hydrogen gas flammaBle DO NOT USE THiS APPLiANCE iF ANy PArT HAS BEEN UNDEr WATEr. immediately call a qualified service agency to inspect the appliance and to make a determination on what steps should be taken next. Explosion Hazard if the unit is exposed to the following, do not operate heater until all corrective steps have been made by a qualified...
  • Page 5 general safety information Fire or Explosion Hazard Fire Hazard Do not store or use gasoline or other flammable vapors and For continued protection against liquids in the vicinity of this or any other appliance. risk of fire: Avoid all ignition sources if you smell gas. Do not install water heater on Do not expose water heater controls to excessive gas carpeted floor.

  • Page 6: Introduction

    introduction Thank you for purchasing this water heater. Properly installed Detailed installation diagrams are also found in this manual. and maintained, it should give you years of trouble free service. These diagrams will serve to provide the installer with a reference.

  • Page 7: Features And Components

    features and components Basic operation Blower/Burner assemBly detail The water heaters covered in this manual have a helical coil INTAKE AIR COMBUSTION shaped heat exchanger that is submerged in the storage tank. (combustion air) BLOWER The water heater’s main Burner is a radial design burner, it CONNECTION is mounted on the top and fires downward through the heat 4 INCH PVC...

  • Page 8: Top View

    top View FRONT figure 3 top View components Blower is operating properly. The control system monitors this switch and will disable heating operation if its contacts 1. Water Heater’s 120 VAC on/off switch. are closed before the Combustion Blower is energized or 2.

  • Page 9: Side Views

    side Views 1. Cleanout access panel, covers water heater cleanout operational buttons. Used to adjust various user settings and opening. view operational information. See Control System Operation on page 42. 2. CCB enclosure - see Figure 3 on page 8 for description. 11.

  • Page 10: Installation Considerations

    installation considerations rough in dimensions 4” PVC 35° 1 1/4” SUPPLY GAS INTAKE AIR CONNECTION CONNECTION 20° 70° 69” BACK FRONT (175.3 cm) T & P WATER OUTLET 69” HEIGHT 33.12” (84.1 cm) (175.3 cm) 63 INCHES OUTSIDE (160 cm) 75.50”...

  • Page 11: Locating The Water Heater

    locating the water heater Carefully choose a location for the new water heater. The placement is a very important consideration for the safety of the Fire or Explosion Hazard occupants in the building and for the most economical use of the appliance.

  • Page 12: Insulation Blankets

    extended Vent terminations insulation Blankets The water heaters covered by this manual can be installed using 4 inch pipe for the intake air and/or vent piping up to a maximum of 70 equivalent feet (21.3 m). The intake air and/or vent piping Breathing Hazard - Carbon Monoxide Gas can be extended up to 120 equivalent feet (36.5 m) by installing 6 inch pipe.

  • Page 13: Installation Requirements

    installation reQuirements gas pressure reQuirements taBle 4 *mANiFOLD PrESSUrE †miNimUm SUPPLy PrESSUrE ‡mAximUm SUPPLy PrESSUrE moDEL NATURAL GAS PRoPANE GAS NATURAL GAS PRoPANE GAS NATURAL GAS PRoPANE GAS bTH 300 4” W. C. (1.0 kPa) 10” W. C. (2.49 kPa) 5.2”...

  • Page 14: Mixing Valves

    mixing ValVes HOT WATER OUTLET Water temperature over 125°F (52°C) can cause severe burns instantly 12” TO 15” resulting in severe injury or death. (30-38 cm) Children, the elderly and the TEMPERED WATER physically or mentally disabled are at OUTLET highest risk for scald injury.

  • Page 15: Temperature-Pressure Relief Valve

    temperature-pressure relief ValVe CAUTION Water Damage Hazard Explosion Hazard • Temperature-Pressure Relief Valve discharge pipe must terminate at adequate drain. Temperature-Pressure Relief Valve must comply with ANSI Z21.22- CSA 4.4 and ASME code. t&p Valve discharge pipe requirements: Properly sized temperature- •...

  • Page 16: Condensate Drain

    condensate drain comBustiBle material storage The water heaters covered in this manual are condensing appliances and require a building drain to be located in close proximity to allow the condensate to drain safely. Fire or Explosion Hazard Condensate drains from the water heater at the exhaust elbow located at the bottom.

  • Page 17: Air Requirements

    air reQuirements unusually tight 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 Breathing Hazard - Carbon Monoxide Gas barrier, etc.) additional air must be provided using the methods described in the Confined Space section that follows.
  • Page 18 fresh air openings for confined spaces Alternatively a single permanent opening, commencing within 12 inches (300 mm) of the top of the enclosure, shall be provided. The following instructions shall be used to calculate the size, See Figure 11. The water heater shall have clearances of at number and placement of openings providing fresh air for least 1 inch (25 mm) from the sides and back and 6 inches (l50 combustion, ventilation and dilution in confined spaces.
  • Page 19 outdoor air through two Vertical ducts air from other indoor spaces 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.

  • Page 20: Commonwealth Of Massachusetts

    installation reQuirements - commonwealth of massachusetts commonwealth of massachusetts inspection The state or local gas inspector of the side wall horizontally For all side wall terminated, horizontally vented power vent, direct vented gas fueled equipment shall not approve the installation vent, and power direct vent gas fueled water heaters installed in unless, upon inspection, the inspector observes carbon every dwelling, building or structure used in whole or in part for...

  • Page 21: Venting Installation

    Venting installation provide an adequate supply of fresh air the water heater must be installed in a Direct Vent configuration. 2. if the water heater is to be installed in a beauty shop, barber shop, cleaning establishment, a laundry with dry Breathing Hazard - Carbon Monoxide Gas cleaning equipment or any space with contaminated air it is •...

  • Page 22: Venting Requirements

    Venting reQuirements (exhaust) and intake air piping shall be 0 inches. Vent or intake air piping passing through a combustible wall or ceiling must be approVed materials a continuous run (no joints). Approved vent and intake air pipe materials that may be used in minimum eQuiValent lengths the United States: four inch pipe...

  • Page 23: Venting Installation Sequence

    Venting installation seQuence exhaust elbow on the water heater. 11. if installing 6 inch pipe transition to 4 inch pipe as shown in 1. read the General Venting instructions on page 21 and Figure 15. The field installed 4” pipe between the exhaust Venting requirements on page 22 before proceeding.

  • Page 24: Vertical Termination Installation

    14. BTH 500 NATUrAL GAS mODELS ONLy: install the balance plate (removed in the previous step) on the intake Air INSTALL TEE FITTING AS CLOSE TO WATER HEATER INTAKE INTAKE AIR CONNECTION AS POSSIBLE Termination if the installed equivalent length of the intake air FACTORY PIPING INTAKE AIR...
  • Page 25 10. install the factory supplied intake air and/or vent termination(s) configuration vertically through the roof the following using field supplied pipe and one field supplied 90° elbow as instructions must be followed: shown in Figure 19. The short section of pipe that connects The intake air and vent pipes must penetrate the same side between the field supplied 90°...

  • Page 26: Sidewall Termination Installation

    sidewall termination installation 7. Cut a 5 inch (13 cm) diameter hole for 4 inch pipe or 7 inch (18 cm) diameter hole for 6 inch pipe where the pipe(s) will 1. Determine the location for the termination(s). pass through the wall. 2.

  • Page 27: Concentric Termination Installation

    concentric termination installation termination. Use only Schedule 40 PVC to extend the 6 inch concentric termination. 1. Determine which concentric termination will be installed. BTH When shortening the length of the termination carefully 300 models installed using 4 inch vent/intake air piping use measure and cut the larger (intake air) pipe first.
  • Page 28 4 inch concentric termination installation VENT MAINTAIN 12” (30 cm) 18” (45 cm) FOR CANADA INTAKE AIR CONNECTION INTAKE AIR PIPE MINIMUM CLEARANCE 3 INCH PVC ABOVE HIGHEST ANTICIPATED VENT PIPE COMBUSTION 3” x 3” x 4” SNOW LEVEL. MAXIMUM OF Y FITTING 24”...
  • Page 29 6 inch concentric termination installation 11. Push the vent cap/vent pipe assembly into the intake air y fitting assembly until the vent cap seats properly on the large diameter intake air pipe. Ensure the vent pipe is cemented 6” x 4” STANDARD INTAKE AIR CONNECTION REDUCER BUSHING 6”...

  • Page 30: Multiple Concentric Termination Clearances

    multiple concentric termination clearances four concentric terminations When installing multiple concentric terminations vertically through 1. When installing four concentric terminations through a roof or a roof or horizontally through a sidewall ensure the required through a sidewall in close proximity they may be arranged clearances (separation) between terminations are maintained.

  • Page 31: Multiple Concentric Termination Arrangements

    multiple concentric termination arrangements four concentric terminations The illustrations on this page show some of the installation Four concentric terminations may be installed in close proximity arrangements for multiple concentric terminations that are as shown in Figure 38. See Figure 34 and Figure 35 on page 30 for allowed.

  • Page 32: Venting Arrangements

    Venting arrangements power Vent Vertical power Vent horizontal figure 40 figure 41 direct Vent Vertical direct Vent horizontal figure 42 figure 43...
  • Page 33 Venting arrangements direct Vent Vertical Vent horizontal intake direct Vent horizontal Vent Vertical intake figure 44 figure 45 direct Vent Vertical concentric direct Vent horizontal concentric figure 46 figure 47...

  • Page 34: Termination Clearances Sidewall Power Vent

    termination clearances sidewall power Vent POWER VENT (using room air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION F IX E D C L O S E D O P E R A B L F IX E D C L O S E D O P E R A B L VENT TERMINAL AIR SUPPLY INLET...

  • Page 35: Termination Clearances Sidewall Direct Vent

    termination clearances sidewall direct Vent DIRECT VENT (using outdoor air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION F IX E D C L O S E D O P E R A B L F IX E D C L O S E D O P E R A B L VENT TERMINAL AIR SUPPLY INLET...

  • Page 36: Water Heater Installation

    water heater installation condensate drain installation than 1/2 inch PVC in size. 3. do not remove, modify or alter the factory condensate trap. installation must conform with these instructions and local installation instructions building codes. 1. Ensure the water heater’s on/off switch is in the “off” position. Field supplied materials required for installation include: 2.

  • Page 37: Supply Gas Line Installation

    supply gas line installation gas line siZing do not use flexible gas piping. Contact your local gas utility company to ensure that adequate minimum required supply gas line sizes are shown in Table 5 on gas service is available and to review applicable installation page 13.

  • Page 38: Supply Gas Regulator Installation

    gas line connection gas line leak testing 1. The water heaters covered by this manual are shipped from the factory with a 1 1/4” supply gas connection, see Table 1 on page 10. Short pipe nipples and reducer couplings are factory installed to increase the size of the water heater’s 24 Fire and Explosion Hazard VAC Gas Valve inlet, see Figure 53.

  • Page 39: Electrical Wiring

    electrical wiring board and is not covered under the limited warranty. connecting an external supervisory control All electrical work must be installed in accordance with the The enable/disable circuit is accessed from the CCB’s J6 plug National Electrical Code, ANSi/NFPA 70 or the Canadian inside the CCB enclosure, see Figure 3 on page 8 to locate the Electrical Code, CSA C22.1 and local requirements.

  • Page 40: Water Line Connections

    water line connections t&p ValVe discharge pipe The water piping installation must conform to these instructions and to all local and national code authority having jurisdiction. Good practice requires that all heavy piping be supported. Explosion Hazard read and observe all requirements in the following sections before installation of the water piping begins: Temperature-Pressure Relief Valve 1.

  • Page 41: Temperature Regulation

    temperature regulation high temperature limit control (eco) Setting the Operating Set Point at 120°F (49°C) will reduce the risk of scalds. Some States require settings at specific lower This water heater is equipped with an ECO (energy cut off) non temperatures.

  • Page 42: Control System Operation

    control system operation oVerView the desktop screen During normal operation the control system will display the The water heaters covered in this manual are equipped with an "Desktop" screen on the LCD which is the default screen. The electronic control system that regulates water temperature inside control system will return to the Desktop screen when there are the storage tank.

  • Page 43: Status Icons

    status icons The Status icons are displayed on the Desktop screen and convey operational and diagnostic information. The icons are described in the table below. See Figure 55 on page 42 and the Sequence Of Operation on page 54. taBle 11 icon description Water temperature in the tank has fallen.
  • Page 44 operating states The current operational state of the water heater is displayed on the Desktop screen as the "Status." The common operational states are described in the table below. See Figure 55 on page 42 and the Sequence Of Operation on page 54. taBle 12 state description...

  • Page 45: User Settings & Control System Menus

    user settings & control system menus temperatures menu operating set point and differential adjustment The Operating Set Point is adjustable from 90°F (42°C) to 180°F (82°C). The factory setting is 120°F (49°C). The Differential is adjustable from 2° to 20°. The factory setting is 8°. These user settings are accessed from the Temperatures menu. The following instructions will explain how to adjust these settings and navigate the control system menus.

  • Page 46: Heater Status Menu

    temperatures menu (cont) description/action display • tank temperature - non adjustable - control system Top of menu sensed temperature (averaged from upper and lower Temperatures temperature probes). Operating Set Point 140°F • upper temperature - non adjustable - control system Differential 8°F sensed temperature from the Upper Temperature Probe.

  • Page 47: Display Settings

    display settings description/action display Select Display Settings from the main menu and press the Display Settings Operational Button under "SELECT" to enter this menu. This Temperature Units °F menu contains adjustable display options for viewing information on the Uim’s LCD screen. Use the Up & Down Buttons to Backlight Delay navigate the menu.

  • Page 48: Current Fault

    current fault description/action display Select Current Fault from the main menu and press the Operational Button under "SELECT" to enter this menu. This menu contains non adjustable operational information. Use the Blocked Exhaust Up & Down Buttons to navigate the menu. Fault occurred 2 mins ago This menu contains the current Fault or Alert error message.

  • Page 49: Service Contact Information

    serVice contact information The control system has a discrete menu that installing contractors and/or service agents can access to enter contact information for their customers. This contact information will be displayed with all Fault and Alert messages. description/action display From the Desktop Screen (see Figure 55 on page 42) press and Service Contact Information hold down the middle (unmarked) Operational Button for 30 seconds and then release it.

  • Page 50: Start Up

    start up prior to start up 3. When all air has been purged from the supply gas line, tighten all supply gas line connections. installation and start up of this water heater requires abilities 4. Check for gas leaks, see Gas Line Leak Testing on page 38, and skills equivalent to that of a licensed tradesman in the field and repair any leaks found.

  • Page 51: Supply Gas Pressure Adjustment

    6. Compare the actual manifold gas pressure reading recorded to a common gas main firing at full capacity. above to the required minimum/maximum values given in note: A pressure drop of more than 1.5” W. C. (0.37 kPa) when Table 4 on page 13. Adjust manifold gas pressure as necessary, the main Burner ignites is an indication of an inadequate supply see the instructions that follow.

  • Page 52: Checking The Firing Rate

    to turn off gas GAS CONTROL MANIFOLD GAS 1. Change the Operating Set Point to the lowest temperature PRESSURE TAP KNOB 1/8’ NPT PLUG setting, see Operating Set Point And Differential Adjustment on page 45. 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”...

  • Page 53: Lighting The Water Heater

    lighting the water heater lighting & operation laBel The instruction label below is affixed to the water heater's covered by this manual at the factory and must be followed when lighting and operating the water heater. FOR YOUR SAFETY READ BEFORE OPERATING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION WARNING MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

  • Page 54: Troubleshooting

    trouBleshooting seQuence of operation installation checklist read the Sequence of Operation below before attempting to The list below represents some of the most critical installation correct any operational problems. refer to the Features And requirements that, when overlooked, often result in operational Components section beginning on page 7 for the location of problems, down time and needless parts replacement.

  • Page 55: Sequence Of Operation Flow Chart

    seQuence of operation flow chart If tank temperature drops below Operating Set Point minus Differential setting a heating cycle is activated Control System performs diagnostic checks Normal State of all pressure switches and ECO are checked Control System Locks Out Blower Prover pressure switch verified open Displays Fault Msg All other pressure switches and ECO are verified closed...

  • Page 56: Operational Problems

    operational proBlems • Excessive manifold gas pressure - see Table 4 on page 13 and manifold Gas Pressure Adjustment on page 51. • Vent (exhaust) gas recirculation at the vent and intake air pipe terminations on Direct Vent installations - see Direct Vent Installation on page 23.

  • Page 57: Fault And Alert Conditions

    • Colder incoming water temperature lengthening the time alert conditions required to heat water to desired temperature. When the control system declares an Alert condition it will display • Hot water piping leaks, open faucets, water heater drain an Alert message on the control system's LCD with a question "?" valve leaking or open.

  • Page 58: Fault And Alert Messages

    fault and alert messages Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualified service agent in your area. possiBle causes - check/repair displayed fault/alert message • The water heater’s control system is polarity sensitive and will lock AC Reversed out and disable heating operation if the polarity of the power supply is reversed.
  • Page 59 fault and alert messages (cont) Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualified service agent in your area. possiBle causes - check/repair displayed fault/alert message • The control system has detected the Blower Prover Switch Blower Prover Failure contacts are closed when they should be open at the beginning of a heating cycle - see the Sequence Of Operation on page 54.

  • Page 60: Maintenance

    maintenance general maintenance schedule keep appliance area clear and free from combustible materials, taBle 14 gasoline and other flammable vapors and liquids. See Locating component operation interVal reQuired The Water Heater on page 11. Tank Sediment Semi Annually Flushing Water heater maintenance includes periodic tank flushing and Removal cleaning, and removal of lime scale.
  • Page 61 5. Ensure the drain hose is secured before and during the entire flushing procedure. Flushing is performed with system water CLEANOUT pressure applied to the water heater. TANK ACCESS PANEL 6. Open the water heater drain valve to flush the storage tank. CLEANOUT CLEANOUT OPENING...
  • Page 62 taBle 15 TEMPERATURE-PRESSURE un-lime® professional delimer RELIEF VALVE part number description 9005416105 4 - 1 gallon (case) 9005417105 1 - 5 gallon powered anode rods DISCHARGE PIPE To insure a long, trouble-free operating life, the water heaters Figure 60 covered in this manual are factory equipped with a powered if the Temperature-Pressure relief Valve on the water heater anode system.

  • Page 63: Diagrams

    diagrams ccB - central control Board layout CCB (CENTRAL CONTROL BOARD) 1 Retry Retries Input Type Tstat Vent Spare Spare S1 DIPSWITCH S1 DIPSWITCH DETAIL 1 Retry Retries Input Type Tstat Vent Spare Spare Dipswitch Operation: Along one side of the dipswitch array there are numbers, 1-4. On the other side of the dipswitch is the word “OPEN.”...

  • Page 64: Bth 300 Wiring Diagram

    Bth 300 wiring diagram LOW GAS 24 VAC BLOCKED BLOCKED BLOWER PRESSURE SWITCH GAS VALVE AIR INTAKE PROVER EXHAUST ENABLE/DISABLE CIRCUIT JUMPER WIRE BETWEEN PINS 8 AND 11 ON J6 PLUG HOT SURFACE IGNITER 1 BLACK 2 WHITE FLAME SENSOR 1 RED (ECO) 2 BLACK 3 BLACK...

  • Page 65: Bth 400, 500 Wiring Diagram

    Bth 400, 500 wiring diagram LOW GAS 24 VAC BLOCKED BLOWER BLOCKED PRESSURE SWITCH GAS VALVE INTAKE AIR EXHAUST PROVER ENABLE/DISABLE CIRCUIT JUMPER WIRE BETWEEN PINS 8 AND 11 ON J6 PLUG HOT SURFACE IGNITER 1 BLACK 2 WHITE FLAME SENSOR 1 RED (ECO) 2 BLACK 3 BLACK...

  • Page 66: Circulation Pump Wiring Diagrams

    circulation pump wiring diagrams CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK OR BUILDING RECIRCULATION FIELD SUPPLIED TEMPERATURE CONTROL INSTALLED IN THE STORAGE TANK OR CIRCULATING LOOP RETURN LINE NOTE: USE SEPARATE 120 VAC POWER SUPPLY FOR PUMP CIRCUIT. DO NOT SHARE POWER WITH APPLIANCE AS THIS MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION.
  • Page 69 STORAGE TANK...

  • Page 74: Limited Warranty

    limited warranty A. O. Smith Corporation, the warrantor, extends the following LimiTED WArrANTy to the owner of this water heater. 1. THE TANK if the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable water therein, during the first THrEE years after initial installation, the warrantor will supply a replacement tank less burner and controls or a complete new A.
  • Page 76 500 Tennessee Waltz Parkway, Ashland City, TN 37015 Technical Support: 800-527-1953 • Parts: 800-433-2545 • Fax: 800-644-9306 www.hotwater.com...

This manual is also suitable for:

100 seriesBth-300aBth-400aBth-500a

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