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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.
23404 EN
To the Consumer:
High Efficiency Commercial Gas Water Heater
Models: OT600-A, OT700-A, OT800-A, OT900-A
Warranty, Registration Card and Parts List are included.
Owner: Please remember to return the Registration Card!
• Immediately call your gas supplier from a neigh-
• If you cannot reach your gas supplier, call the fire
– Installation and service must be performed by a
qualified installer, service agency or the gas supplier.
Please read these and all component
instructions and keep for future reference.
bor's phone. Follow the gas supplier's instructions.
department.
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.
Rev0 05/2022
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Related Manuals for Bock Water heaters OT600-A
Summary of Contents for Bock Water heaters OT600-A
- Page 1 Installation and Operation Instructions Manual High Efficiency Commercial Gas Water Heater Models: OT600-A, OT700-A, OT800-A, OT900-A 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS Section I: Specifications ..........4 Section II: General Information . -
Page 4: Section I: Specifications
SECTION I: SPECIFICATIONS Figure 1: All Models Table 1: Dimensions CONNECTION SIZES DIMENSIONS, INCHES (cm) Model 600,000 OT600*-A (175) (2,675) (3,017) 700,000 OT700*-A (205) (3,121) (3,464) 140,000 1,700 2” 2” 1” 2” 6” 6” 800,000 1,032 (492) (41) (199) (86) (173) (38) (33) -
Page 5: Section Ii: General Information
SECTION II: GENERAL INFORMATION WHEN YOU RECEIVE YOUR NEW WATER HEATER Check the new equipment to see if all components are in good condition. If damage is observed or parts appear to be missing, contact your wholesaler. WATER TREATMENT/FILTRATION In areas where poor water conditions are suspected (i.e. lime, iron, and other minerals), it is essential that the water be tested and appropriate action taken to prevent damage to the water heater and ensure the quality of the water. - 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 LOW WATER CUTOFF A low water cutoff device is optional, and available for factory or field installation. For field installation, reference the control panel figure in Section VIII (Parts List) for the location of the device and the 24V power supply. Reference the wiring diagrams in Section IV (Installa- tion) for proper connections.
- Page 8 SECTION II: GENERAL INFORMATION SEISMIC RESTRAINT 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. Figures 2 and 3 show common approaches to bracing and are provided only as concepts. Refer to state and local codes and follow specific instructions for correct installation.
- Page 9 Mechanical draft controls shall only be utilized when vent lengths exceed the limits specified in this manual. Consult Bock Water Heaters and the manufacturer of the mechanical draft system for recommendations on pressure sensor location and setpoint in the exhaust vent.
- Page 10 SECTION II: GENERAL INFORMATION HIGH LIMIT COMMISSIONING To prove functionality, the temperature limiting safety function may be tested by selecting the High Limit Commissioning Test via the display. The high limit temperature is factory set at 190°F. For safety reasons, the factory set high limit will automatically lower to equal the operating setpoint when the test is started.
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Page 11: 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 12 SECTION III: PRE-INSTALLATION Minimum clearance from combustible material is 0” for the sides, top, and back of this water heater, as shown in Figure 4. This water heater is approved for installation in an alcove with the clearances shown in Figure 4. For ease of access and proper maintenance, the clearances in Figure 5 are recommended.
- Page 13 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.
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Page 14: Section Iv: Installation
SECTION IV: INSTALLATION VENT & COMBUSTION AIR INTAKE DANGER Failure to properly install the vent and combustion air intake system as outlined in this manual can result in unsafe operation of the water heater. To avoid the risk of fire, explosion, or asphyxiation from carbon monoxide, never operate this water heater unless it is properly vented and has adequate air supply for combustion. - Page 15 SECTION IV: INSTALLATION The following materials are approved for use as the vent and combustion air intake piping: • PVC (DWV, ASTM-D2665 or CSA B181.2) • PVC (Schedule 40, ASTM-D1785 or CSA B137.3) • PVC (SDR Series, ASTM-D2241 or CSA B137.3) •...
- Page 16 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 Table 4. 6” diameter piping must be used.
- Page 17 SECTION IV: INSTALLATION Table 4: Minimum and Maximum Vent and Air Intake Pipe Lengths (6” Pipe) Minimum Equivalent Pipe Maximum Equivalent Pipe Length (per pipe run) Length (per pipe run) Fuel Vent Model(s) Type Arrangement Air Intake (ft) Vent (ft) Air Intake (ft) Vent...
- Page 18 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 19 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 8 for a view of both orientation options.
- Page 20 SECTION IV: INSTALLATION The orientation of the trap portion of the drain is critical for proper venting of gas and drainage of condensate. This portion must be level after both unions are fully tightened. See Figure 9 for proper final orientation of the assembly. DETAIL H SCALE 1 : 16 4"...
- Page 21 SECTION IV: INSTALLATION Some installations require the use of a condensate neutralizer to reduce the acidity of the condensate prior to reaching the drain. Figure 12 shows the connection of a condensate line to a neutralizer. It is recommended that a low profile condensate pump is installed between the heater and neutralizer to facilitate flow through the neutralizer.
- Page 22 SECTION IV: INSTALLATION Table 5: Direct Vent Terminal Clearances Canadian Installations US Installations A= Clearance above grade, veranda, porch, deck, or 12 in (30 cm) 12 in (30 cm) balcony B= Clearance to window or 6 in (15 cm) for appliances ≤ door that may be opened 6 in (15 cm) for appliances ≤...
- Page 23 SECTION IV: INSTALLATION In addition to the clearances specified, the following items shall be accounted for during installation: • The minimum distance from adjacent public walkways, adjacent buildings, open able windows, and building openings shall not be less than those values specified in the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the National Gas and Propane Installation Code, CSA B149.1.
- Page 24 SECTION IV: INSTALLATION Install piping through the wall as shown in Figure 14. 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 single 90°...
- Page 25 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.
- Page 26 SECTION IV: INSTALLATION Table 6: Power Vent Terminal Clearances Canadian Installations US Installations A= Clearance above grade, veranda, porch, deck, or 12 in (30 cm) 12 in (30 cm) balcony B= Clearance to window or - 4 feet (1.2M) below or to side of 6 in (15 cm) for appliances ≤...
- Page 27 SECTION IV: INSTALLATION In addition to the clearances specified, the following items shall be accounted for during installation: • The minimum distance from adjacent public walkways, adjacent buildings, openable windows, and building openings shall not be less than those values specified in the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the National Gas and Propane Installation Code, CSA B149.1.
- Page 28 SECTION IV: INSTALLATION Install piping through the wall as shown in Figure 17. 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 single, 4” 90° elbow is supplied with the water heater for the termination fitting on the air intake.
- Page 29 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. Multi-story venting is allowed provided maximum vent lengths are not exceeded. 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 30 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. TERMINATE EXHAUST VENT WITH STRAIGHT PIPE, OR FACTORY SUPPLIED TEE AIR INTAKE TERMINAL 90° (FACTORY SUPPLIED) CONNECT 4"X6"...
- Page 31 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. Note: If air from inside the building will be used for combustion air, the require- ments in Section III, “Unconfined Space”...
- Page 32 SECTION IV: INSTALLATION TERMINATE EXHAUST VENT WITH STRAIGHT PIPE OR FACTORY SUPPLIED TEE. POWER VENT REQUIRES 4" PVC ELBOW (FACTORY SUPPLIED) CONNECT VERTICAL PIPE TO FACTORY SUPPLIED EXHAUST ASSEMBLY Figure 23: Vertical Power Vent Arrangement Assembling Vent and Air Intake Joints WARNING Cements and primers are highly flammable.
- Page 33 SECTION IV: INSTALLATION • Insert pipe into fitting with a slight twisting motion. Ensure that the pipe is bottomed into the fitting. • Hold pipe and fitting for 30 seconds to prevent push off. • Wipe off excess cement. Cure time may be at least 8 hours for Ø6” pipe at 60°F. Longer cure time is required for larger diameter pipe and/or lower temperatures.
- Page 34 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 35 SECTION IV: INSTALLATION Figure 26: Piping Diagram One Unit Figure 27: Piping Diagram Two Units Page 35...
- Page 36 SECTION IV: INSTALLATION Figure 28: Piping Diagram Three Units Figure 29: Piping Diagram One Unit with Storage Tank Page 36...
- Page 37 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 38 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. REGULATED GAS SUPPLY LINE...
- Page 39 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 40 SECTION IV: INSTALLATION Figure 32: Component Wiring Diagram Page 40...
- Page 41 SECTION IV: INSTALLATION Figure 33: Schematic Wiring Diagram Page 41...
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Page 42: 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 43 SECTION V: OPERATION SEQUENCE OF OPERATION Figure 35 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. ...
- Page 44 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 45 SECTION V: OPERATION Following adjustment of the setpoint to a higher temperature (see Figure 36), 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.
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Page 46: 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 7. Further detail is given in this section for each component. - Page 47 SECTION VI: MAINTENANCE FLUSH THE TANK Elements in the water such as lime and iron may accumulate in the heater. Accumulation of these elements can keep your water heater from operating at peak efficiency and may lead to premature tank failure. It is recommended that the tank is drained and flushed thoroughly twice a year to prevent buildup.
- Page 48 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 and vents to make sure they are free of obstructions.
- Page 49 SECTION VI: MAINTENANCE (cont.) REMOVE FLAME ROD TRANSITION TUBE REMOVE BURNER NUT AND ASSEMBLY LOCK MOUNTING WASHER (4X) FLANGE BLOWER DROPS OFF. REMOVE IGNITOR DISCONNECT AIR INTAKE CLOSE GAS PIPING FROM BLOWER SUPPLY HERE OR AT MAIN SHUTOFF VALVE. REMOVE SCREW FROM GAS CONTROL...
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Page 50: 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 8: General Troubleshooting Problem Possible causes Recommended Action 1) Check display for error code. 1) See Tables 9 and 10. 2) Contact qualified agency to purge the air Unable to light the burner 2) Air in the gas line. - Page 51 SECTION VII: TROUBLESHOOTING Table 9 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 52 SECTION VII: TROUBLESHOOTING Table 10 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 10: Blocking Error Codes BLOCKING ERRORS (automatic reset once error is cleared) Description:...
- Page 53 SECTION VII: TROUBLESHOOTING SECTION VII: TROUBLESHOOTING Table 14 should be referenced when troubleshooting the powered anode system. If the status Table 11 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 54 SECTION VII: TROUBLESHOOTING USING THE DISPLAY System and troubleshooting information such as fan speeds, flame signal, ignition attempts, and error history is available from the display. Refer to Figure 39 (below) for instructions to access this information and understanding the display. The Home screen displays valuable information for the given state of the water heater (standby, demand, or error).
- Page 55 SECTION VII: TROUBLESHOOTING SYSTEM TEST The System Test feature allows for constant operation (for up to one hour) at the maximum, ignition, or minimum fan speed. This feature is useful for troubleshooting or establishing a proper fuel/air mixture at a specific input rate. Use of this feature is typically done under the guidance of Bock Technical Support and data collection requires a combustion analyzer.
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Page 56: Section Viii: Parts List
SECTION VIII: PARTS LIST 32 26 PARTS NOT BALLOONED ARE SHOWN IN THE BURNER ASSEMBLY Figure 40: optiTHERM Parts Table 12: optiTHERM Parts ITEM 14 SEE CONTROL PANEL PARTS FINDER. ITEM ITEM DESCRIPTION PART NUMBER DESCRIPTION PART NUMBER Insulation, Tank Top 18229 Condensate Assembly Running Trap 19987... - Page 57 SECTION VIII: PARTS LIST Items attached to enclosure cover Figure 41: optiTHERM Control Panel Parts Table 13: optiTHERM Control Panel Parts ITEM ITEM PART NUMBER DESCRIPTION PART NUMBER DESCRIPTION 11 19860 Fuse BLK, 300V 30A 19912 Display, OT600-900 ITEM NO. PART NUMBER DESCRIPTION 12 19857 Relay, SPDT, 120V, 5 TRM...
- Page 58 SECTION VIII: PARTS LIST 18 19 11 14 Figure 42: optiTHERM Burner Assembly Parts Table 14: optiTHERM Burner Assembly Parts ITEM ITEM PART NUMBER DESCRIPTION PART NUMBER DESCRIPTION 18008 Burner Bracket Refractory Disc 17850 Switch, High Gas Pressure, Dungs GA 17900 Gasket, Flange, Burner Mounting 17850...
- Page 59 SECTION VIII: PARTS LIST Table 15: optiTHERM Wiring Harnesses Connections Part # Description From 17437-1 Control Power Wiring High Voltage Main Control Blower, Relays, Fuses, High Voltage components 17437-2 Modbus and Touchscreen 850 IF Control Modbus and Touchscreen 17437-3 Low Water Cut Off & Safety Switches Main Control LWCO board, Pressure Sensors and switches.
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Page 60: Section Ix: Warranty
SECTION IX: WARRANTY LIMITED WARRANTY FOR GAS-FIRED WATER HEATER Bock Water Heaters, Inc. 110 S. Dickinson Street Madison, WI 53703 Phone: 608-257-2225 WHAT DOES THIS LIMITED WARRANTY COVER? This limited warranty applies only to the original consumer purchaser. General Defects and Malfunctions: This warranty covers defections and malfunctions in your new water heater for a period of one year from the original installation date. - Page 61 INDIRECT, AND WHETHER ARISING IN CONTACT OR TORT. Some states do not allow the exclusion of incidental or consequential damages, so the above exclusion may not apply to you. Bock Water Heaters, Inc. • 110 South Dickinson Street • Madison, WI 53703 Telephone 608 -257-2225 • Fax 608-257-5304 www.bockwaterheaters.com...
- Page 62 Page 62...
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