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GAS FIRED COMMERCIAL WATER HEATERS
25589, Highway 1
McBee, SC 29101
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.
PRINTED 1215
and
service
must
qualified
installer,
MAINTENANCE - LIMITED WARRANTY
be
Instruction Manual
MODELS: HWH
120, 160, 200, 225
SERIES 100, 101
INSTALLATION - OPERATION
INDOOR ONLY
327947-001
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Troubleshooting
Related Manuals for A.O. Smith Burkay 100 Series
Summary of Contents for A.O. Smith Burkay 100 Series
- Page 1 Instruction Manual GAS FIRED COMMERCIAL WATER HEATERS MODELS: HWH 120, 160, 200, 225 SERIES 100, 101 INSTALLATION - OPERATION 25589, Highway 1 MAINTENANCE - LIMITED WARRANTY McBee, SC 29101 INDOOR ONLY WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
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Page 2: Table Of Contents
TABLE OF CONTENTS Unusually Tight Construction ............15 SAFE INSTALLATION, USE AND SERVICE.........3 Confined Space ................15 GENERAL SAFETY................4 Direct Vent Water Heaters ...............15 Grounding Instructions ..............4 Exhaust Fans ..................15 Correct Gas ..................4 Louvers and Grilles .................15 Precautions ..................4 Fresh Air Openings for Confined Spaces ........16 Propane or Liquefied Petroleum (LP) Gas Models ...... -
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
GENERAL SAFETY GROUNDING INSTRUCTIONS HIGH ALTITUDE INSTALLATIONS This water heater must be grounded in accordance with the National Electrical Code, Canadian Electrical Code and/or local codes. This water heater is polarity sensitive; correct wiring is imperative for proper operation. This water heater must be connected to a grounded metal, permanent wiring system, or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the water heater. -
Page 5: Abbreviations Used
INTRODUCTION Thank You for purchasing this water heater. Properly installed Particular attention should be given to the installation and maintained, it should give you years of trouble free service. of thermometers at the locations indicated in the piping diagrams as these are necessary for checking the operation ABBREVIATIONS USED of the water heater. -
Page 6: Dimensions And Capacity Data
DIMENSIONS AND CAPACITY DATA TABLE 1. ROUGH-IN DIMENSIONS HWH-120 HWH-160 HWH-200 HWH-225 Models Inches Inches Inches Inches Dimensions 49 3/8 50 1/8 53 1/4 1254 1273 1353 1524 30 3/8 30 3/8 33 1/8 33 1/8 23 5/8 23 5/8 27 1/8 27 1/8 20 3/4... -
Page 7: Control Components
CONTROL COMPONENTS FIGURE 2. COMPONENT LOCATIONS... -
Page 8: Automatic Reset Limit Control
AUTOMATIC RESET LIMIT CONTROL FIGURE 4. IGNITION CONTROL THERMAL BALANCER FIGURE 3. AUTO RESET LIMIT CONTROL The thermal balancer (standard on Models HWH-200 and HWH-225) is a delay relay used to control the pump on the The automatic reset limit control, Figure 3, is an automatic safety water circulation system. -
Page 9: Tank Temperature Control (Not Supplied)
intermittent circulating operation is used per the recommended TANK TEMPERATURE CONTROL (NOT SUPPLIED) installation procedure. Constant circulation of water through The water temperature in the storage tank is controlled by the the building’s system main is permissible as long as the water Tank Temperature Control. - Page 10 Any part of the paddle must not touch the pipe or any restrictions To adjust the flow rate setting: in the pipe. Screw the flow switch in position so the flat of the 1. Remove the flow switch cover. paddle is at right angles to the flow. The arrow on the side case 2.
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Page 11: Installation Considerations
INSTALLATION CONSIDERATIONS GENERAL HARD WATER If the system is to be filled with water for testing or other purposes Where hard water conditions exist, water softening or the during cold weather and before actual operation, care must be threshold type of water treatment is recommended. This will taken to prevent freezing of water in the system. -
Page 12: Installation Requirements
INSTALLATION REQUIREMENTS LOCATION MIXING VALVES When installing the water heater, consideration must be given to Water temperature over 125°F (52°C) proper location. The location selected should provide ade quate air can cause severe burns instantly supply and be as centralized with the piping system as possible. resulting in severe injury or death. -
Page 13: Dishwashing Machines
must use field supplied regulators to lower the gas pressure to DISHWASHING MACHINES less than 14" W.C. (3.5 kPa) (1/2 PSI Gauge). Appliances require All dishwashing machines meeting the National Sanitation gas regulators that are properly sized for the water heater input Foundation requirements are designed to operate with water flow and deliver the rating plate specified pressures. -
Page 14: Combustible Material Storage
COMBUSTIBLE MATERIAL STORAGE Explosion Hazard Fire or Explosion Hazard Relief Valve must comply with Do not store or use gasoline or other flammable vapors and ASME code. liquids in the vicinity of this or any other appliance. Properly sized Relief Valve must Avoid all ignition sources if you smell gas. -
Page 15: Installation Clearances
Never obstruct the flow of ventilation air. If you have any doubts INSTALLATION CLEARANCES or questions at all, call your gas supplier. Failure to provide the These water heaters are approved for installation on combustible proper amount of combustion air can result in a fire or explosion flooring in an alcove with minimum clearance to combustibles or and cause property damage, serious bodily injury or death. -
Page 16: Fresh Air Openings For Confined Spaces
communicate with the outdoors and shall have a minimum free FRESH AIR OPENINGS FOR CONFINED SPACES area of the following: The following instructions shall be used to calculate the size, number and placement of openings providing fresh air for 1 square inch per 3000 Btu/hr (733 mm per kW) of the total input rating of all appliances located in the enclosure, and combustion, ventilation and dilution in confined spaces. -
Page 17: Air From Other Indoor Spaces
The confined space shall be provided with two permanent vertical of all appliances installed in the enclosure. Each opening shall ducts, one commencing within 12 inches (300 mm) of the top and not be less than 100 square inches (645 cm one commencing within 12 inches (300 mm) of the bottom of the GAS CONNECTIONS enclosure. - Page 18 It is important to guard against gas control valve fouling two threads. Use compounds resistant to the action of liquefied from contaminants in the gas ways. Such fouling may cause petroleum gases. The water heater and its gas connection must improper operation, fire or explosion.
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Page 19: Venting
VENTING STANDARD VENTING FIGURE 14. VENT PIPE INSTALLATION Where a continuous or intermittent back draft is found to exist the cause must be determined and corrected. A special vent cap may Type B venting may be used with these water heaters. All be required. -
Page 20: Venting System
Test for spillage at the draft hood relief opening after five minutes VENTING SYSTEM of main burner operation. Use the flame of a match or candle. Have venting system checked every six months for After it has been determined that each appliance remaining obstructions and/or deterioration in vent piping. - Page 21 TABLE 9. COMBINED VENT SIZING TABLES Model HWH-120 Input: 120,000 btu/hr Total Vent Height (Feet) Draft hood outlet diameter: 6 inches Input (btu/hr) Rise Vent Connector Diameter (Inches) 1 Ft. 120,000 2 Ft. 120,000 3 Ft. 120,000 Combined Input (btu/hr) Number of Heaters Manifold and Common Vent Diameter (Inches) 240,000...
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Page 22: Gas Supply Connections
GAS SUPPLY CONNECTIONS After installing the positive lock-up gas pressure regulator(s), GAS SUPPLY PIPE CONNECTIONS an initial nominal supply pressure setting of 7 inches w.c. Make sure to install ground joint union for servicing. (1.7 kPa) for Natural Gas or 12" W.C. (3.0 kPa) for Propane In Canada: When using the manual main shutoff valve to while the water heater is operating is recommended and support the weight of the piping, ensure that it is identified... -
Page 23: Gas Manifold Pressure
Clockwise to increase pressure. GAS MANIFOLD PRESSURE • Counterclockwise to decrease pressure. The gas manifold pressure regulator is included in the • combination gas control valve, Figure 17, and is set to operate 5. Set primary system temperature control dial (thermostat) to on the gas specified on the water heater model and rating plate. -
Page 24: Water Heater Start Up And Operations
WATER HEATER START UP AND OPERATIONS Before operating the water heater, the entire system must be IMPORTANT It is recommended that a qualified service agency perform filled with water, purged of air and checked for leaks. The gas the initial firing of the water heater. At this time the user piping should also be leak tested. -
Page 25: Checking And Adjusting Input
EXAMPLE: CHECKING AND ADJUSTING INPUT T = 31.5 seconds H = 1050 Btu/ft (natural gas) Btuh = ? Gas flow through meter: Fire and Explosion Hazard x 1050 = 120,000 Btuh 3600 Under no circumstances should the 31.5 input exceed the rate shown on the Small changes in the input rate may be made by adjusting the water heater’s rating label. -
Page 26: Sequence Of Operation Flowchart
SEQUENCE OF OPERATION FLOWCHART START THERMOSTAT (CONTROLLER) CALLS FOR HEAT STAGE 1 SPARK GENERATOR POWERED TRIAL FOR First valve (pilot) operator opens IGNITION PILOT BURNER OPERATION Pilot burner lights. Pilot burner does not light Ignition Control Module Response senses flame S-8600M After 15 sec. -
Page 27: Operating Instructions
OPERATING INSTRUCTIONS (NATURAL AND PROPANE FOR HWH120 - HWH225) OPERATING INSTRUCTIONS... -
Page 28: Troubleshooting
TROUBLESHOOTING Before any extensive troubleshooting, perform the following: • Voltage (24 vac) is supplied by transformer. • Water heater is wired according to wiring diagram. Ensure that: Note: Cross wiring the 24 volt circuit of the relay will short the •... - Page 29 CHECKING INTERMITTENT IGNITION CONTROLS NO SPARK AT PILOT BURNER Turn off gas supply. Is voltage (24 Vac) across the 24 V terminals Replace ignition control. on ignition control during “Call for heat”? Is voltage (24 Vac) across the PV & MV/PV terminals on “call for heat”? NOTE: S-8600M will automatically reset every 5 minutes.
- Page 30 CHECKING INTERMITTENT IGNITION CONTROLS SPARK AT PILOT BURNER BUT PILOT WILL NOT LIGHT Ensure all manual shutoff valves are fully open; all filters are clean; all gas connections are gas tight; pilot tubing is not damaged, obstructed or kinked; and pilot orifice is unclogged. Check for air in gas line, purge (bleed) line if necessary.
- Page 31 CHECKING INTERMITTENT IGNITION CONTROLS PILOT BURNER LIGHTS BUT MAIN BURNER DOES NOT LIGHT Correct the situation by consulting the Does the pilot flame cover 3/8” to 1/2” instruction manual on how to adjust of igniter/sensor rod? pilot flame. Replace Does spark stay on for more than Is voltage (24 Vac) across terminals ignition 15 seconds after the pilot is “proven”...
- Page 32 CHECKING INTERMITTENT IGNITION CONTROLS NO SPARK AT PILOT BURNER BUT PILOT WILL NOT LIGHT Turn off gas supply. Fix connection and/or Is there a good connection between terminals? tighten ignition control to the water heater. Is ignition control securely attached to water heater for good ground connection? Check the circuit providing Is voltage (24VAC) across transformer positive terminal and...
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Page 33: Led Status And Troubleshooting
LED STATUS AND TROUBLESHOOTING The following procedures are provided as a general guide. Any control should be replaced if it does not perform properly on checkout or troubleshooting. In addition, replace any control if it is wet or looks like it has ever been wet. The control has one LED used for flame sensing and system status: FIGURE 18. - Page 34 TABLE 12. CONTINUOUS RETRY MODELS C, M, E AND K ONLY - GREEN LED STATUS CODES Green LED Indicates Next System Action Recommended Service Action Flash Code No “Call for Heat” Not applicable None Power up - internal check Not applicable Flash Fast None Normal startup - ignition sequence started...
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Page 35: Flame Current Measurement
FLAME CURRENT MEASUREMENT Flame current of the device can be measured using a standard micro-ammeter by simply inserting the meter probes into the holes labeled FLAME CURRENT, as shown in Figure 19. — Flame current must be measured with pilot valve lit but no main gas flowing. —... -
Page 36: General Maintenance
GENERAL MAINTENANCE These water heaters are designed to give many years of relief valve. The discharge pipe should terminate at an adequate efficient and satisfactory service when properly operated and floor drain to insure against personal contact with hot water and maintained. - Page 37 2. PILOT BURNER - ELECTRONIC IGNITION deliver a sufficient flame at the pilot burner to cover 3/8" to 1/2" (10- 12 mm) of the sensing probe tip. See Figure 22. Servicing of the pilot burner (every six months) includes keeping pilot shield (not shown) free of lint, cleaning the burner head, the If the pilot does not light, perform the following checks: primary air opening and the orifice of the pilot burner, Figure 22.
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Page 38: Thermal Balancer (Hwh-200, Hwh-225)
THERMAL BALANCER (HWH-200, HWH-225) Figure 24 shows the internal wiring of the thermal balancer. The device may be tested after disconnecting the four leads from their respective terminals on the unit. Apply a test light to the yellow and red leads. •... -
Page 39: Wiring
WIRING may the controlling system allow the burner to fire when there is WIRING CONNECTIONS no water flow through the water heaters. Refer to the connection and schematic diagrams on the following pages for proper wiring sequence with conventional water heater installations. - Page 40 FIGURE 25. WIRING DIAGRAMS...
- Page 41 FIGURE 26. CER - TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION FIGURE 27. SCHEMATIC: CER - TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION...
- Page 42 FIGURE 28. CER - TEMP 80 - 2 OR 3 UNIT INSTALLATION CONNECTION DIAGRAM - FOR HOT WATER SUPPLY APPLICATION...
- Page 43 FIGURE 29. CER - TEMP 80 - 2 OR 3 UNIT INSTALLATION SCHEMATIC DIAGRAM - FOR HOT WATER SUPPLY APPLICATION...
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Page 44: Piping Diagrams
PIPING DIAGRAMS STORAGE TANK... -
Page 46: Notes
NOTES... -
Page 47: Limited Warranty
LIMITED WARRANTY COMMERCIAL CIRCULATING WATER HEATER LIMITED WARRANTY EFFECTIVE WHAT'S NOT COVERED If within FIVE years • Problems caused by improper: gas supply line sizing, gas type, after initial installation of the water venting, connections, combustion air, voltage, wiring, or fusing heater, a heat exchanger or gas burner shall prove upon examination by the warrantor to be defective in material or •... - Page 48 25589 Highway 1, McBee, SC 29101 Technical Support: 800-527-1953 • Parts: 800-433-2545 • Fax: 800-644-9306 www.hotwater.com...
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