Table of Contents
Advertisement
Quick Links
To the Installer:
Please attach these instructions
next to the water heater.
Installation and Operation Instructions Manual
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.
WARNING
Improper installation, adjustment, alteration,
service or maintenance can cause serious injury
or property damage. Refer to this manual. For
assistance or additional information, consult a
qualified installer or service agency.
WARNING
Install in accordance with all local codes. In the
absence of local codes, refer to NFPA 54 or CSA
B149.1.
CAUTION
The recommended temperature for normal
residential use is 120°F. The dial on the aquastat
does not always reflect the out-coming water
temperature and it could occasionally exceed
120°F. Variation in out-coming temperature could
be based on factors including but not limited to
usage patterns and type of installation.
WARNING
Hotter water increases the risk of scald injury.
Before adjusting the water temperature setting,
read this instruction manual. Temperatures at
which injury occurs vary with the person's age
and the length of exposure. The slower reaction
time of children, elderly or physically or mentally
challenged persons increases the scalding hazard
to them. It is recommended that lower water
temperatures be used where these exposure hazards
exist. Households with small children or invalids
may require a temperature setting less than 120°F
to prevent accidental contact with hot water.
To produce less than 120°F, use point-of-use
temperature limiting devices.
23435 EN
To the Consumer:
High Efficiency Commercial Gas Water Heater
Models: OT200, OT250, OT299
Warranty, Registration Card and Parts List are included.
Owner: Please remember to return the Registration Card!
– Installation and service must be performed by a
Please read these and all component
instructions and keep for future reference.
• Immediately call your gas supplier from a neigh-
bor's phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire
department.
qualified installer, service agency or the gas supplier.
If higher water temperature is needed in part of
the water system, automatic temperature limiting
devices must be used on all lines to water taps.
WARNING
Water heater blankets may restrict air flow to the
water heater and cause fire, asphyxiation, personal
injury or death.
THIS MANUAL HAS BEEN PREPARED TO
ACQUAINT YOU WITH THE INSTALLATION,
OPERATION, AND MAINTENANCE OF YOUR
WATER HEATER AND TO PROVIDE IMPORTANT
SAFETY INFORMATION.
Read all instructions 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 the correct
installation of the water heater. The manufacturer
will not be liable for damages caused by failure to
comply with the installation and operating instruc-
tions outlined on the following pages.
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 any gas control
which has been under water.
FAILURE TO FOLLOW THESE INSTRUCTIONS OR
ALL APPLICABLE BUILDING CODES
AND REGULATIONS VOIDS THE WARRANTY ON
THIS WATER HEATER.
Rev4 4/21
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for BOCK OT200
Summary of Contents for BOCK OT200
- Page 1 Installation and Operation Instructions Manual High Efficiency Commercial Gas Water Heater Models: OT200, OT250, OT299 Warranty, Registration Card and Parts List are included. Owner: Please remember to return the Registration Card! 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 IMPORTANT SAFETY INSTRUCTIONS The proper installation, use and servicing of this water heater is very important to your safety and the safety of others. This is the safety alert symbol. Statements following this symbol contain important safety information. Obey all safety messages that follow this symbol to avoid possible injury or death.
-
Page 3: Table Of Contents
TABLE OF CONTENTS Section I: Specifications ..........4 Section II: General Information . -
Page 4: Section I: Specifications
“-H28” = Approved for altitudes greater than 2,000 up to 7,800 FT “-H25” = Approved for altitudes greater than 2,000 up to 5,400 FT All Bock products meet or exceed current ASHRAE standards. “-H58” = Approved for altitudes greater than 5,400 up to 7,800 FT These products are design certified by UL (Underwriters Laboratories) and meet ANSI Z21.10.3 / CSA 4.3... -
Page 5: Section Ii: General Information
CAUTION: Hot water in excess of 120°F can cause scalding! Bock recommends a tempering valve or anti-scald valve be installed and used according to the manufacturer’s directions to prevent scalding. Many state and local codes now require installation of these devices. - Page 6 SECTION II: GENERAL INFORMATION ANODE RODS The water heater is supplied with a factory installed powered anode system to prevent corrosion of internal tank components. Specifically, the type of anode system that is used is an impressed-cur- rent anode system. This system uses a power supply that regulates the protective current output based on actual conditions inside the tank.
- Page 7 SECTION II: GENERAL INFORMATION BACKFLOW PREVENTER (CLOSED SYSTEM) Some local municipal codes and ordinances require the use of these devices on potable (domestic) water lines. Where backflow preventers, check valves, or pressure regulating valves are required, it will be necessary to install a thermal expansion tank (designed for use with potable water) in order to prevent pressure build up in the water heater and associated piping, which could cause the T&P valve to discharge.
- Page 8 Regions of the United States and Canada that are considered earthquake zones require that 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.
-
Page 9: Section Iii: Pre-Installation
SECTION III: PRE-INSTALLATION LOCATION CAUTION This water heater must be located in an area where leakage of the tank, water line connections, or the temperature and pressure relief valve will not result in damage to the area adjacent to the water heater or to lower floors of the structure. When such location cannot be avoided, a suitable drain pan must be installed under the water heater. - Page 10 1,270 1,150 1,050 At minimum, use 3/4” gas supply pipe for models OT200 and OT250. For model OT299, use a minimum of 1” pipe. Maximum Gas Supply Pressure The gas supply pressure shall never be greater than 14” W.C. Pressures greater than 14” W.C. may damage the gas control which could cause a fire or explosion.
- Page 11 SECTION III: PRE-INSTALLATION COMBUSTION AND VENTILATION AIR The water heater can be installed to utilize combustion air from either inside or outside the building. Refer to “Section IV: Installation” for detailed venting specifications. If indoor air is used for combustion air it is imperative that the room has an adequate air supply. Inadequate air supplies may lead to unsafe levels of carbon monoxide (CO) and excessive levels of soot.
-
Page 12: Section Iv: Installation
The concentric vent kit must be purchased separately. The IPEX System 636® 3” and 4” concentric kits are approved by Bock Water Heaters. The connection size on the concentric vent cannot be smaller than the vent and intake pipe diameter. The vent and intake equivalent lengths must comply with minimum and maximum lengths specified in Tables 4 and 5. - Page 13 SECTION IV: INSTALLATION Note: DO NOT connect the water heater to an existing vent or chimney. It must be vented separately from all other appliances. The following materials are approved for use as the vent and combustion air intake piping: •...
- Page 14 SECTION IV: INSTALLATION Minimum and Maximum System Lengths The water heater should be located such that plastic vent pipe lengths and the number of connection fittings are minimized. Minimum and maximum equivalent pipe lengths for the vent and combustion air intake systems are given in Tables 4 and 5. Either 3 in. or 4 in. plastic piping may be used.
- Page 15 (ft) † † Direct Vent NAT or OT200, OT250, OT299 Power Vent Equivalent length is measured between the 4” pipe connection on the water heater and the required 90° elbow termination fitting. Equivalent length is measured after the point of connection to the condensate assembly and includes the termination fitting (if used).
- Page 16 SECTION IV: INSTALLATION The vent and combustion air intake systems must be sufficiently supported along vertical and horizontal sections. At minimum, it is recommended that a support is placed along the vent or air intake piping every 4 feet. For horizontal systems, the first support shall be located immediately adjacent to the first 90-deg.
- Page 17 SECTION IV: INSTALLATION Condensate Trap Assembly Prior to connecting the exhaust vent pipe, the condensate trap assembly (supplied) must be connected to the exhaust pipe on the water heater. The drain elbow shall be connected to the 3” exhaust pipe such that the arrow (showing flow direction on elbow) is pointing vertically (90°...
- Page 18 SECTION IV: INSTALLATION 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 7 for a view of how the condensate trap is assembled, and Figure 9 for the top view of both orientation options.
- Page 19 SECTION IV: INSTALLATION A detailed view of the condensate trap is shown in Figure 12. The discharge portion of the trap is designed with a vent and threaded ¾” female NPT connection. The trap may be cleaned by disconnecting union ‘B’ and the threaded connection, then running water through the trap.
- Page 20 SECTION IV: INSTALLATION Horizontal Venting, Direct Vent 2-pipe termination This water heater may be vented horizontally (through a sidewall) with a two-pipe termination. Two holes through an exterior wall are required for the vent and combustion air intake pipes. Minimum clearances between the terminals must be met as specified in Figure 9. All clearances must comply with local codes or the latest edition of NFPA 54/ANSI Z223.1 or CSA B149.
- Page 21 SECTION IV: INSTALLATION Table 8: Direct Vent Terminal Clearances Canadian Installations US Installations A = Clearance above grade, veranda, 12 inches (30 cm) 12 inches (30 cm) porch, deck, or balcony 6 in (15 cm) for appliances ≤ 10,000 6 in (15 cm) for appliances ≤ 10,000 Btuh (3 kW), 12 in (30 cm) for Btuh (3 kW), 9 in (23 cm) for appliances >...
- Page 22 SECTION IV: INSTALLATION Install piping through the wall as shown in Figure 15. Adequate length of pipe must protrude beyond the exterior wall for attachment of the termination fitting. The recommended distance between the terminal fitting and the exterior wall is 1 in. (2.5 cm). A 90° elbow is supplied with the water heater for the termination fitting on the air intake.
- Page 23 SECTION IV: INSTALLATION Horizontal Venting, Power Vent 1-pipe termination This water heater may be vented horizontally (through a sidewall) with a one-pipe termination. In this case, the water heater will be utilizing air from inside 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”...
- Page 24 SECTION IV: INSTALLATION Table 9: Power Vent Terminal Clearances Canadian Installations US Installations A = Clearance above grade, veranda, 12 inches (30 cm) 12 inches (30 cm) porch, deck, or balcony 6 in (15 cm) for appliances ≤ 10,000 Btuh (3 kW), 12 in (30 cm) for 4 feet (1.2 m) below or to side appliances >...
- Page 25 SECTION IV: INSTALLATION Install piping through the wall as shown in Figure 18. Adequate length of pipe must protrude beyond the exterior wall for attachment of the termination fitting. The recommended distance between the terminal fitting and the exterior wall is 1 in. (2.5 cm). A 90° elbow is supplied with the water heater for the termination fitting on the air intake.
- Page 26 SECTION IV: INSTALLATION Vertical Venting, Direct Vent 2-pipe termination This water heater may be vented vertically (through a roof) with a two-pipe termination. Two holes through the roof are required for the vent and combustion air intake pipes. All clearances must comply with local codes or the latest edition of NFPA 54/ANSI Z223.1 or CSA B149.
- Page 27 SECTION IV: INSTALLATION CAUTION Annular spaces around vent pipe wall penetrations shall be permanently sealed using approved materials to prevent entry of combustion products into the building. Figure 21: Vertical Direct Vent Arrangement A 2-pipe system may also be vertically vented through a flat roof. In addition to minimum clearances above the roof and for snow levels, attention must be given to building features such as a parapet.
- Page 28 SECTION IV: INSTALLATION Vertical Venting, Power Vent 1-pipe termination This water heater may be vented vertically (through a roof) with a one-pipe termination. In this case, the water heater will be utilizing air from inside the building for combustion air. A single hole through the roof of the building is required for the vent pipe.
- Page 29 SECTION IV: INSTALLATION Install piping through the roof as shown in Figure 23. Adequate length of pipe must protrude beyond the exterior of the roof (see dimension Y). Two 90° elbows are recommended for the exhaust termination 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.
- Page 30 SECTION IV: INSTALLATION Assembling Vent and Air Intake Joints WARNING Cements and primers are highly flammable. Assemble joints in an adequately ventilated area away from heat sources or open flames. Do not smoke. Read cautions and warnings on material containers. CAUTION DO NOT use cement that is lumpy or thick.
- Page 31 SECTION IV: INSTALLATION Intake Drain An intake drain port is included from the factory to drain moisture buildup from the intake vent. When proper pitching of the vent is not possible or a vertical direct vent arrangement is used, install a drain line. Follow these steps to properly install the drain line: •...
- Page 32 SECTION IV: INSTALLATION WATER CONNECTIONS CAUTION This water heater incorporates fittings that contain a nonmetallic lining. DO NOT apply heat to these fittings when making sweat connections to the heater. Sweat tubing to an adapter before securing adapter to any fittings on water heaters. ALL PIPING SHOULD CONFORM TO LOCAL CODES AND ORDINANCES.
- Page 33 SECTION IV: INSTALLATION Figure 27: Piping Diagram One Unit Figure 28: Piping Diagram Two Units Page 33...
- Page 34 SECTION IV: INSTALLATION Figure 29: Piping Diagram Three Units Figure 30: Piping Diagram One Unit with Storage Tank Page 34...
- Page 35 SECTION IV: INSTALLATION WATER (POTABLE) HEATING AND SPACE HEATING CONNECTIONS If this heater is used for water (potable) heating and space heating, the following requirements apply: - Piping and components to the water heater for the space heating application must be suitable for use with potable water.
- Page 36 Check the rating label on the front of the water heater and make sure the gas to be used matches the gas stated on the rating label. Consult your local gas company or Bock Water Heaters with any questions. ...
- Page 37 SECTION IV: INSTALLATION WIRING All electrical wiring and connections must be in accordance with local codes. In the absence of local codes, wiring must conform to the National Electric Code ANSI/NFPA No. 70 or the Canadian Electrical Code C22.1. This water heater must be electrically grounded. Electrical power should be supplied through a fused disconnect switch located near the water heater.
- Page 38 SECTION IV: INSTALLATION Figure 34: Schematic Wiring Diagram Page 38...
-
Page 39: Section V: Operation
SECTION V: OPERATION FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. This appliance does not have a pilot. It is equipped If you cannot reach your gas supplier, call with an ignition device which automatically lights the fire department. - Page 40 SECTION V: OPERATION SEQUENCE OF OPERATION Figure 36 gives a step-by-step description of the sequence of operations for this water heater. See Troubleshooting section of this manual for solutions to error codes. Is a request for heat present? ...
- Page 41 SECTION V: OPERATION ADJUSTING THE CONTROLS The temperature setpoint has been adjusted to 120°F 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 adjust the setpoint to a higher temperature.
- Page 42 SECTION V: OPERATION Following adjustment of the setpoint to a higher temperature (see Figure 37), the main burner should relight. Next, adjust the setpoint to a lower temperature (i.e. back to 120° F) and the gas valve will close, extinguishing the burner flame. The thermostat should be adjusted to the minimum setting that will meet the hot water needs of the application.
-
Page 43: Section Vi: Maintenance
SECTION VI: MAINTENANCE NOTICE TO THE OWNER: If you are having a mechanical problem with your water heater, contact your service company or installer. The required maintenance schedule for this water heater is shown in Table 10. Further detail is given in this section for each component. - Page 44 • Measure the products of combustion in the exhaust vent. At maximum input, the % O in the exhaust gas should be in the range of 3.0 - 4.5%. CO should be less than 25 ppm. If measurements are not within range, contact Bock Technical Support for adjustment instructions.
- Page 45 SECTION VI: MAINTENANCE INSPECT THE VENTING SYSTEM AND BURNER The vent and combustion air intake system should be checked at least once a year for damage and blockage. Make sure all joints are secure and that the system is properly supported. Inspect the outdoor terminals to make sure they are free of obstructions.
- Page 46 SECTION VI: MAINTENANCE Figure 39: Removing the blower for burner inspection With the blower disassembled from the burner assembly, lift the burner straight up and through the burner assembly mounting flange. Carefully set aside all gaskets when disassembling the burner assembly. The gaskets must be used when reassembling. Inspect the inside of the burner for blockage.
-
Page 47: Section Vii: Troubleshooting
SECTION VII: TROUBLESHOOTING CAUTION For your safety, the repair and servicing of this equipment shall only be performed by a qualified agency. Table 11: General Troubleshooting Problem Possible causes Recommended Action 1) Check display for error code. 1) See Tables 12 and 13. 2) Contact qualified agency to purge the air Unable to light the burner 2) Air in the gas line. - Page 48 SECTION VII: TROUBLESHOOTING Table 12 shows a list of lockout error codes. A lockout code will be visible on the control display in the form of a code (letter “A” followed by a number) and a short message. Lockout errors require a manual reset to resume operation after the root cause of the problem has been solved.
- Page 49 SECTION VII: TROUBLESHOOTING Table 13 shows a list of blocking error codes. A blocking code will be visible on the control display in the form of a code (letter “E” followed by a number) and a short message. Blocking errors automatically reset once the error is corrected. Table 13: Blocking Error Codes BLOCKING ERRORS Code...
- Page 50 SECTION VII: TROUBLESHOOTING SECTION VII: TROUBLESHOOTING Table 14 should be referenced when troubleshooting the powered anode system. If the status Table 14 should be referenced when troubleshooting the powered anode system. If the status LED is off or flashing red, a problem has occurred and service is required. When the LED is a LED is off or flashing red, a problem has occurred and service is required.
- Page 51 SECTION VII: TROUBLESHOOTING INSTALLER MENUS System and troubleshooting information such as fan speeds, flame signal, ignition attempts, and error history is available in the Installer Menu. Refer to Figure 40 for instructions to access this menu and useful tips. Figure 40: Using the Installer Menu Page 51...
-
Page 52: Section Viii: Parts List
SECTION VIII: PARTS LIST Figure 41: optiTHERM Parts Table 16: optiTHERM Parts Table 16: optiTHERM Parts Description Description Control Panel Cover Power Supply Junction Box Knob Baffle Sight Glass Outlet Pipe Nipple Assembly Flame Rod Tank Temperature Sensors (2-in-1) Flame Rod Gasket T&P Relief Valve Hot Surface Ignitor Condensate Elbow Assembly... - Page 53 SECTION VIII: PARTS LIST Figure 42: optiTHERM Control Panel Parts Figure 42: optiTHERM Control Panel Parts Table 17: optiTHERM Control Panel Parts Status LED Bracket Page 53 Page 53...
- Page 54 SECTION VIII: PARTS LIST Figure 43: optiTHERM Burner Assembly Parts Table 18: optiTHERM Burner Assembly Parts Table 18: optiTHERM Burner Assembly Parts Description Description Gas Control Flange (w/ gasket) Gasket (blower to transition tube) Gas Control (NAT GAS_0-2,000 FT ALT) Transition Tube Gas Control (LP GAS_0-2,000 FT ALT) Gasket (transition tube to burner)
- Page 55 SECTION VIII: PARTS LIST Table 19: optiTHERM Wiring Harnesses Page 55...
-
Page 56: Section Ix: Warranty
Bock model available at the time of replacement. 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... - Page 57 SECTION IX: WARRANTY WHAT DOES THIS LIMITED WARRANTY NOT COVER? This limited warranty does not cover water heaters that are or were: • Incorrectly installed, especially where the installation violates state or local plumbing, housing or building codes • Operated at inappropriate settings, excessive pressures or temperatures. •...
- Page 58 NOTES...
- Page 59 NOTES...
- Page 60 Bock Water Heaters, Inc. • 110 South Dickinson Street • Madison, WI 53703 Telephone 608-257-2225 • Fax 608-257-5304 www.bockwaterheaters.com...
Need help?
Do you have a question about the OT200 and is the answer not in the manual?
Questions and answers