State Water Heaters 400 Series Instruction Manual

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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.

KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS

PRINTED 0625

LOW LEAD

CONTENT

LISTED

and

service

must

qualified

installer,

HIGH-EFFICIENCY COMMERCIAL GAS WATER HEATERS

INSTALLATION - OPERATION - SERVICE - MAINTENANCE

AN ODORANT IS ADDED TO THE GAS USED

REQUIRED.

Instruction Manual

MODELS FLEX 60G/100G/119G

SERIES 400-401-450-451

⚠

WARNING

Safety Hazard

Failure to follow these instructions and safety

messages could result in death or serious injury.

Read and understand this instruction manual and the

safety messages herein before installing, operating or

servicing this water heater.

This manual must remain with the water heater.

For Your Safety

BY THIS WATER HEATER.

100350709_2000594666A

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Summary of Contents for State Water Heaters 400 Series

Page 1 Instruction Manual HIGH-EFFICIENCY COMMERCIAL GAS WATER HEATERS MODELS FLEX 60G/100G/119G SERIES 400-401-450-451 INSTALLATION - OPERATION - SERVICE - MAINTENANCE LOW LEAD CONTENT LISTED 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 CONTENTS APPROVALS ..................... 3 Concentric Termination Installation ..........37 Low Profile Vent Installation ............41 GENERAL SAFETY INFORMATION ..............3 Venting Arrangements ..............43 Do Not Operate if damaged .............3 Sidewall Termination Clearances ........... 45 Limiting the Risk of Scalding ............3 INSTALLING THE WATER HEATER ..............
Page 3 APPROVALS LISTED LOW LEAD CONTENT Note: ASME construction is optional on the 60G and 100G water heaters covered in this manual. GENERAL SAFETY INFORMATION DO NOT OPERATE IF DAMAGED increasing risk of scalds. A higher temperature setting allows the tank to provide much more hot water and can help provide proper DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN EXPOSED TO water temperatures for appliances such as dishwashers and washing FLOODING OR WATER DAMAGE.
Page 4 IMPORTANT DEFINITIONS of the National Fuel Gas Code”, ANSI Z223.1/NFPA 54 as it relates to the Qualified Installer: A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing, air supply, venting and installation of gas fired water heaters. The service agency must also gas supply, including a thorough understanding of the requirements have a thorough understanding of this Installation and Operating of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 as it relates to the...
Page 5 General Safety Information ⚠ ⚠ WARNING CAUTION Fire or Explosion Hazard Property Damage Hazard While the water heater is in rou�ne opera�on, it can • Do not store or use gasoline or other flammable release hot water from the temperature-pressure relief vapors and liquids in the vicinity of this or any other valve discharge pipe in quan��es that could cause appliance.
Page 6 General Safety Information ⚠ ⚠ WARNING WARNING Electrical Shock Hazard Fire and Explosion Hazard • Use joint compound or thread sealer tape compatible Servicing this water heater exposes you to with propane gas. electrified components that can cause severe • Leak test gas connections injury or death if you touch them.
Page 7 INTRODUCTION BUILDING MANAGEMENT SYSTEM Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service. This water heater is connectible to BACnet or Modbus compliant Supervisory controls via the optional ICC BMS Gateway. This allows ABBREVIATIONS USED connection of the water heater to local Building Management Systems using Serial RS-485 (MS/TP) or IP connections.
Page 8 Introduction The installation must conform to all instructions contained in this manual and the local code authority having jurisdiction. These shall be carefully followed in all cases. Authorities having jurisdiction should be consulted before installation begins if there are any questions regarding compliance with local, state or national codes.
Page 9 FEATURES AND COMPONENTS BASIC OPERATION GAS VALVE The water heaters covered in this manual have a helical coil shaped This heater is equipped with a gas adaptive system and motor driven heat exchanger that is submerged in the storage tank. The water throttle.
Page 10 Features and Components Spark Igniter Flame Sensor The control system energizes the spark ignition control with 120 VAC The control system also monitors the flame sensor to confirm a flame is during the ignition period. The spark ignition control then sends a present at the Main Burner.
Page 11 Features and Components 100 Gallon Top View The Enable/Disable switch listed in this manual is NOT an “on/off” switch and does not disconnect 120 volt power to the control boards and other heater components. Water Heater’s Dual Voltage Enable/Disable Switch. When in the “Disabled” position the switch removes electrical power from the gas valve so that water heating is disabled.
Page 12 Features and Components The Enable/Disable switch listed in this manual is NOT an “on/off” switch and does not disconnect 120 volt power to the control boards and other heater components. Water Heater’s Dual Voltage Enable/Disable Switch. When in the “Disabled” position the switch removes electrical power from the gas valve so that water heating is disabled.
Page 13 Features and Components SIDE VIEW COMPONENTS 60 and 100 Gallon Models Temperature-Pressure Relief Valve. See Temperature-Pressure Relief Valve (page 22). User Interface Module (UIM). The UIM includes the display circuit board and the control system’s LCD Touch Display. Used to adjust various user settings and view operational information.
Page 14 Features and Components 119 Gallon Models Control boards enclosure. See Figure 5, Figure 6, and Figure 7 (page 10) for description. Water outlet - 1 1/2” NPT connection. User Interface Module (UIM). The UIM includes the display circuit board and the control system’s LCD Touch Display.
Page 15 Features and Components RECOVERY AND STORAGE CAPACITIES Table 1. Storage Capacities Model U.S. Gallons Liters 60 gallon 100 gallon 119 gallon Table 2. Recovery Capacities U.S. Gallons/hr & liters/hr at temperature rise indicated Input °F 30°F 40°F 50°F 60°F 70°F 80°F 90°F 100°F...
Page 16 INSTALLATION CONSIDERATIONS ROUGH IN DIMENSIONS SUPPLY GAS 60 Gallon CONNECTION INTAKE AIR CONNECTION 3 INCH PVC 22° 65° TOP VIEW WATER OUTLET HEIGHT T & P VALVE FRONT 3/4” NPT VENT RECIRCULATION LOWER CONNECTION TEMPERATURE RETURN 1 1/2" NPT 3 INCH PROBE WATER (exhaust elbow)
Page 17 Installation Considerations Table 3. Dimensions by Model APPROX. SHIP APPROX. SHIP Model WEIGHT STD WEIGHT ASME (Gallon) in (cm) in (cm) in (cm) in (cm) in (cm) in (cm) in (cm) in (cm) in (cm) in (cm) LBS (KG) LBS (KG) 55-1/2 27-3/4 6-5/16...
Page 18 Installation Considerations ⚠ Service Clearance WARNING A service clearance of 24 inches (61 cm) should be maintained from Fire or Explosion Hazard serviceable parts such as the T&P valve, control system components, • Do not store or use gasoline or other flammable gas valve, clean out opening, drain valve, the vent connection (exhaust/ vapors and liquids in the vicinity of this or any other condensate elbow) and the condensate drain.
Page 19 Installation Considerations purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. The water heaters covered by this manual meet or exceed the Energy Policy Act standards with respect to insulation and standby heat loss requirements, making an insulation blanket unnecessary.
Page 20 INSTALLATION REQUIREMENTS GAS SUPPLY SYSTEMS Positive lock-up gas pressure regulators must be rated at or above the input Btu/hr rating of the water heater they supply. Low pressure building gas supply systems are defined as those systems Supply gas regulators shall have inlet and outlet connections not that cannot under any circumstances exceed 14”...
Page 21 Installation Requirements MIXING VALVES HOT WATER ⚠ OUTLET DANGER 12” TO 15” Burn Hazard (30-38 cm) Because of the increased risk from scalding, if you TEMPERED WATER set the water heater’s gas control knob higher than OUTLET 120°F (49°C), install thermosta�c point-of-use mixing valves at each point of use.
Page 22 Installation Requirements A properly sized and pressurized thermal expansion tank must be No valve or other obstruction is to be placed between the Temperature- installed on all closed systems to control the harmful effects of thermal Pressure Relief Valve and the tank. Do not connect discharge piping expansion.
Page 23 Installation Requirements Note: The purpose of a Temperature-Pressure Relief Valve is to THIS SIDE VIEW EXHAUST (VENT) prevent excessive temperatures and pressures in the storage OF EXHAUST ELBOW ELBOW AND tank. The T&P valve is not intended for the constant relief of ARROW INDICATE thermal expansion.
Page 24 Installation Requirements CONTAMINATED AIR An insufficient supply of air can cause recirculation of combustion ⚠ products resulting in contamination that may be hazardous to life. WARNING Such a condition often will result in a yellow, luminous burner flame, causing sooting of the combustion chamber, burners and flue tubes Breathing Hazard - Carbon Monoxide Gas and creates a risk of asphyxiation.
Page 25 Installation Requirements cause air to be drawn into the room through the water heater’s vent Outdoor Air Through One Opening system causing poor combustion. Sooting, serious damage to the water heater and the risk of fire or explosion may result. It can also create a risk of asphyxiation.
Page 26 Installation Requirements The horizontal ducts shall communicate directly with the outdoors. Each duct opening shall have a minimum free area of 1 square inch See Figure 18. per 4,000 Btu/hr (550 mm per kW) of the aggregate input rating of all appliances installed in the enclosure.
Page 27 Installation Requirements MASSACHUSETTS INSTALLATION REQUIREMENTS Commonwealth Of Massachusetts Inspection For all side wall terminated, horizontally vented power vent, direct The state or local gas inspector of the side-wall horizontally-vented vent, and power direct vent gas fueled water heaters installed in every gas-fueled equipment shall not approve the installation unless, upon dwelling, building or structure used in whole or in part for residential inspection, the inspector observes carbon-monoxide detectors and...
Page 28 VENTING INSTALLATION ⚠ Approved vent pipe materials that must be used in Canada: WARNING • ULC S636 PVC / CPVC Breathing Hazard - Carbon Monoxide Gas • ULC S636 Polypropylene • AL29-4C Stainless Steel • Install vent system In accordance with codes. •...
Page 29 Venting Installation GENERAL VENTING INSTRUCTIONS 17. Ensure that the screens in the factory supplied terminations are securely installed to prevent blockage in the vent system. These instructions must be followed on all installations. 18. Stress levels in pipe/fittings can be significantly increased by improper installation.
Page 30 Venting Installation Factory Supplied Fittings Tee is a 3” x 3” x 1/2” fitting. The intake-air connection Tee fitting has a hose barb installed in the 1/2 inch branch to connect the Blocked The 119 gallon water heater ships with two (2) factory supplied 4 inch Intake Air switch sensing tube.
Page 31 Venting Installation Blocked Intake Sensing Tube 90° TO 130° END VIEW Figure 24. Intake Air Connection Hose Barb Angle Range for Proper Operation The intake-air Tee fitting is factory-installed with the 1/2 inch branch and hose barb angled to the right at approximately 130° when viewed from the end.
Page 32 Venting Installation If the vent piping will terminate horizontally through a sidewall, Plan the layout of the vent and intake-air piping backwards from see Horizontal Termination Installation (page 35). the termination point outdoors to the water heater. Layout the vent and intake-air piping to use a minimum of pipe and elbows. PIPE FIELD Install the terminations first.
Page 33 Venting Installation On 60/100 gallon models, if installing three-inch intake-air pipe, FACTORY INSTALL TEE FITTING AS CLOSE INSTALLED TO WATER HEATER INTAKE AIR connect the intake-air pipe to the intake-air connection on the INTAKE AIR CONNECTION AS POSSIBLE CONNECTION water heater. (REDUCER) 14.
Page 34 Venting Installation wall, or structure within 10 ft (3 m) horizontally. See 2” (5 cm) Figure 32. MAXIMUM FACTORY SUPPLIED If installing both intake-air and vent piping in a direct-vent STANDARD TERMINATION FIELD configuration vertically through the roof, ensure that all exterior POINTED DOWN TOWARDS SUPPLIED vertical clearance requirements shown in Figure 31, Figure 32 (page...
Page 35 Venting Installation in Figure 31. The short section of pipe that connects between the are being maintained. These clearances, and those cited by local field-supplied 90° elbow and the factory-supplied termination must and national codes, must be maintained. not be excessive in length. The exposed portion of this pipe shall If installing both intake-air and vent piping in a direct-vent be no more than 2 in (5 cm).
Page 36 Venting Installation discoloration are not a concern. Extending the exposed vent piping comply could result in severe personal injury, death, or substantial up to a maximum of 6 in (15.2 cm) from the wall helps vapor from property damage. being trapped along a building’s face. To avoid this problem, the Installations must comply with applicable national, state, and local vent can also be terminated vertically through the roof, see Vertical codes.
Page 37 Venting Installation CONCENTRIC TERMINATION INSTALLATION The water heaters covered by this manual are approved to be installed with AL29-4C ® stainless steel vent material using parts from Concentric terminations must be ordered separately. the manufacturers listed in Table 13 and Table 14 below. These listed systems must be installed using the vent manufacturer’s instructions •...
Page 38 Venting Installation When installing multiple concentric terminations vertically through INTAKE AIR CONNECTION a roof or horizontally through a sidewall, ensure that the required 6” x 4” BUSHING INTAKE AIR PIPE (FACTORY 6” x 6” x 6” clearances between terminations and groupings of multiple VENT PIPE INSTALLED) Y FITTING...
Page 39 Venting Installation Do not exceed the maximum equivalent vent length specified are measured between the edges of the concentric termination Table 7, Table 8, and Table 9 (page 30). caps. 18. Return to Direct Vent Installation (page 32) to complete the When installing multiple concentric terminations through a roof or through a sidewall, the clearances shown in Figure 41 (page 39) installation of the intake-air and vent piping between the concentric...
Page 40 Venting Installation Multiple Concentric Termination Arrangements The illustrations on this page show some of the installation arrangements for multiple concentric terminations that are allowed. CONCENTRIC See Multiple Concentric Termination Clearances (page 39) for detailed TERMINATION information on clearances and additional arrangement options. CAPS END VIEW Note: When multiple concentric terminations are installed through a roof in the same location, all termination caps must be at the...
Page 41 Venting Installation SIDEWALL SIDEWALL ROOF ROOF Figure 48. Eight Concentric Terminations - Sidewall and Roof Figure 47. Four Concentric Terminations - Sidewall and Roof LOW PROFILE VENT INSTALLATION Eight Concentric Terminations Eight concentric terminations can be installed in two stacked groups This water heater is certified for sidewall direct venting with IPEX of four, in close proximity, as shown in Figure 39 .
Page 42 Venting Installation 12” Min between Edge of Air Inlet Vent (Exhaust) and Adjacent Vent (Exhaust) Outlet Air Inlet Piping Air Inlet Vent Base Vent Cap Vent (Exhaust) Piping Vent/Air Figure 49. Inlet and Vent Flow in Low Profile Installation Termination Figure 51.
Page 43 Venting Installation VENTING ARRANGEMENTS Enlarged View of Direct Vent Air Intake Moisture Protection* To drain Figure 52. Power Vent Vertical Figure 53. Power Vent Horizontal Figure 54. Direct Vent Vertical Enlarged View of Enlarged View of Direct Vent Air Enlarged View of Direct Vent Air Intake Moisture Direct Vent Air...
Page 44 Venting Installation Enlarged View of Enlarged View of Enlarged View of Direct Vent Air Direct Vent Air Direct Vent Air Intake Moisture Intake Moisture Intake Moisture Protection* Protection* Protection* To drain To drain To drain Figure 60. Direct Vent Horizontal Low-Profile Figure 58.
Page 45 Venting Installation SIDEWALL TERMINATION CLEARANCES Inside corner detail 15 ft Fixed closed Operable Fixed Closed Operable Regulator vent outlet In the event no regulator is present, Legend: H and I can be = Area where terminal is not permitted = Vent terminal = Air supply inlet disregarded Figure 61.
Page 46 Venting Installation Inside corner detail 15 ft Fixed closed Operable Fixed Closed Operable Regulator vent outlet In the event no regulator is present, Legend: H and I can be = Area where terminal is not permitted = Vent terminal = Air supply inlet disregarded Figure 62.
Page 47 INSTALLING THE WATER HEATER CONDENSATE DRAIN INSTALLATION CONDENSATE DRAIN LINE - FIELD INSTALLED EXHAUST/CONDENSATE (VENT) ELBOW Installation must conform with these instructions and local building codes. PRESSURE PORT 1/2” NPT CONDENSATE DRAIN CONNECTION Condensate neutralizer kits are available. Contact your distributor or Service Agency.
Page 48 Installing the Water Heater SUPPLY GAS LINE INSTALLATION Ensure that all gas pipe is clean on the inside before installation. To trap any dirt or foreign material in the gas supply line a sediment trap must Contact your local gas utility company to ensure that adequate gas be installed as shown in Figure 65.
Page 49 Note: If overheating occurs or the gas supply fails to shut off, Table 18. Supply Gas Line Sizing Metric Units turn off the Main Gas Shutoff valve to the water heater. Normal Iron Pipe Sizes (inches) Input in kW Supply Gas Pressure Test Port Length In Meters 1/2”...
Page 50 Installing the Water Heater Gas Line Leak Testing Note: This water heater should not be connected to an electrical ⚠ supply with a Ground Fault Circuit Interrupter (GFCI) or Arc WARNING Fault Circuit Interrupter (AFCI) with Integral GFCI protection as defined in NFPA 70, CSA C22.1 and UL 943.
Page 51 Installing the Water Heater Note: Do not apply power to the water heater before pump is used, it is important to note that the flow rate should be slow installation is complete and the water heater is filled with so that there will be a minimum of turbulence inside the water heater water.
Page 52 Installing the Water Heater ⚠ CAUTION Property Damage Hazard While the water heater is in rou�ne opera�on, it can release hot water from the temperature-pressure relief valve discharge pipe in quan��es that could cause damage to the surroundings. Locate the water heater near an adequate drain and in an area where water from the temperature-pres- sure relief valve discharge pipe will not result in damage to the area or the lower ﬂoors of the...
Page 53 START UP PRIOR TO START UP FILLING THE WATER HEATER Installation and start up of this water heater requires abilities and skills Follow these steps to fill the water heater prior to start up. equivalent to that of a licensed tradesman in the field involved. See Close the heater drain valve.
Page 54 Start Up GAS CALIBRATION At the initial start up of the heater, an initial calibration routine runs After calibration, the continuous monitoring function becomes automatically. This initial calibration may take up to 15 minutes. active. This function can trigger a new calibration in case a gas quality change is detected.
Page 55 Start Up START UP CONDITIONS HYDROGEN GAS: Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally two weeks Smoke/Odor or more). Hydrogen gas is extremely flammable and explosive. To prevent the possibility of injury under these conditions, we recommend It is not uncommon to experience a small amount of smoke and odor the hot water faucet, located farthest away, be opened for several...
Page 56 Start Up Gas Connection Supply Gas Pressure Combustion Air Inlet Test Port Venturi Valve Supply Gas Test Port Connection Manifold Gas Pressure Test Port (Non Adjustable) Manifold Gas Pressure Test Port (Non Adjustable) Figure 71. 100 Gallon VK - Gas Valve Assembly Figure 72.
Page 57 Start Up FOR YOUR SAFETY READ BEFOR LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES •...
Page 58 Start Up SUPPLY GAS PRESSURE ADJUSTMENT CHECKING THE FIRING RATE ⚠ WARNING Follow these instructions to determine the actual firing rate of the water heater: Fire and Explosion Hazard Ensure that there are no other gas fired appliances connected to •...
Page 59 Start Up HIGH ALTITUDE INSTALLATIONS The water heaters covered by this manual are certified for use without modification for altitudes up to 10,100 feet. ⚠ WARNING Fire and Explosion Hazard Modifying the water heater to exceed the ﬁring rate on the ra�ng label can result in property damage, personal injury or death.
Page 60 TEMPERATURE REGULATION ⚠ HIGH TEMPERATURE LIMIT CONTROL WARNING Burn Hazard This water heater is equipped with a non adjustable high temperature limit control. The temperature of the water in the water heater can exceed the thermostat se�ng and The high temperature limit control sensors are located inside the Main be hot enough to cause burns.
Page 61 Temperature Regulation The Operating Setpoint is adjusted to regulate water temperature inside the storage tank. This is an adjustable user setting in the control system’s “Temperatures Menu.” This and all control system menus are accessed through the user interface module (UIM) located on the front of the water heater.
Page 62 CONTROL SYSTEM OPERATION LIMITING THE RISK OF SCALDING 11. If the local network is password protected, a new screen will appear asking for the password. Enter the password for the local network For a variety of reasons, water heaters can produce water that is much and click Connect.
Page 63 Control System Operation or alert conditions or when there has been no user input for several Table 20. Status Icons minutes. Icon Description • Manufacturer and water heater model information displays in The Combustion Blower is energized. the Title Bar at the top of the Home screen. •...
Page 64 Control System Operation Table 21. Operating States Table 22. Control System Menus State Description Menu Description Uncalibrated The unit is currently uncalibrated and must go through Setpoint Manager Most commonly accessed menu. Contains the Operat- calibration before use. ing Setpoint and Differential user settings. Calibration The unit is currently going through calibration procedure.
Page 65 Control System Operation Setpoint Manager From the Setpoint Manager, you can adjust the Differential Mode, the BTH250-NAT Differential, and see the current Tank Temperature. HEATING To change the Operating Set-Point and Differential, do the following: °F From the Home screen, press MENU icon. The “Main Menu” screen °...
Page 66 Control System Operation To change the differential setting: change the mode from automatic to manual, then use the up and down arrows on the differential to SETPOINT MANAGER change setting. Confirm to keep changes or Press the Cancel button to return to the previously saved settings. CANCEL MODE: •...
Page 67 Control System Operation Bottom of Menu iCOMM AC000W006323619 Wi-Fi Strength 0Bars Wi-Fi Strength -128dBm Wi-Fi Enabled Heater Information Menu From the Home screen, press MENU icon. The “Main Menu” screen will be displayed. MAIN MENU From the Main Menu, press the Heater icon to access the Heater menu.
Page 68 Control System Operation This screen contains non adjustable operational information. Historical data is stored in the Flex Memory Module (FMM). If the FMM is removed or damaged during servicing, the historical data • Elapsed Time - Total accumulated time the control system will be lost and heater may no longer operate.
Page 69 Control System Operation The Heater Status menu displays the following information: Top of Menu • Status - Indicates whether the heater is Enabled or Disabled. HEATER STATUS • Blocked Inlet PS - Indicates if the Inlet is blocked. • Blocked Outlet PS - Indicates if the Outlet is blocked. •...
Page 70 Control System Operation The Settings screen contains adjustable display options for viewing information on the LCD screen. • Temperature Units - Adjustable user setting that changes SETTINGS temperature units display to Celsius °C or Fahrenheit °F. • Back-light Delay - Adjustable user setting that determines Temp Units °F how long the LCD back light remains illuminated after a key...
Page 71 Control System Operation The Current Fault screen contains the current Fault or Alert error message. The time the Fault or Alert message occurred appears directly CURRENT FAULT below. A brief description of what causes the particular Fault or Alert condition appears below that. CURRENT FAULT NAME Press the MORE button for more detailed service information and a Occurred:...
Page 72 Control System Operation Fault Occurrence Menu From the Home screen, press MENU icon. MAIN MENU The “Main Menu” screen will be displayed. From the Main Menu, press the Faults icon to access the Fault Menu. HEATER FAULTS SETTINGS From the Faults Menu, press the Fault Occurrence icon to access the Fault Occurrence screen.
Page 73 Control System Operation Lockout Function From the Home screen, press MENU icon. BTH250-NAT The “Main Menu” screen will be displayed. From the Main Menu, press the Settings icon to access the Settings HEATING screen. Use the arrow buttons to scroll through the list to the Lock item. °...
Page 74 Control System Operation Restore Factory Defaults Function Press and hold on the A. O. Smith logo on the Home screen. BTH250-NAT The Service Information screen displays HEATING ° °F GAS O SETPOINT Select Restore User Defaults on the Service Information screen. SERVICE INFORMATION Access Code Restore User Defaults...
Page 75 Control System Operation Service Contact Information The control system has a menu that Installing contractors and/ or service agents can access to enter their contact information for customers. This contact information will be displayed with all Fault BTH250-NAT and Alert messages. HEATING From the Home screen, press the Main Menu icon.
Page 76 MAINTENANCE Water heater maintenance includes periodic tank flushing and cleaning, If overheating occurs or the gas supply fails to shut off, turn off the Main Gas Shutoff valve. See Figure 65 (page 48). and removal of lime scale. The water heater should be inspected and adjusted to maintain proper combustion.
Page 77 Maintenance Ensure that the drain hose is secured before and during the entire CLEANOUT flushing procedure. Flushing is performed with system water ACCESS PANEL pressure applied to the water heater. Open the water heater drain valve to flush the storage tank. Flush the water heater storage tank to remove sediment and allow the water to flow until it runs clean.
Page 78 Maintenance BURNER FLAME INSPECTION If the air intake fitting and air intake terminal are clear and the burner continues to exhibit abnormal flames, contact a qualified service Check main burner every three months for proper flame characteristics. agency or have a qualified service professional inspect and clean the You can see the burner flame through the sight glass on top of the burner.
Page 79 Maintenance ⚠ TEMPERATURE-PRESSURE RELIEF VALVE TEST WARNING ⚠ DANGER Explosion Hazard Burn Hazard Normal opera�on of the water heater can cause it to become suﬃciently over-heated and/or The discharge water from the temperature-pressure over-pressurized that it can explode, resul�ng in relief valve is hot enough to cause burns.
Page 80 TROUBLESHOOTING INSTALLATION CHECKLIST Electrical Connections 11. Ensure that the power supply is on a dedicated circuit and The list below represents some of the most critical installation connections to the water heater are polarity correct. See the requirements that, when overlooked, often result in operational requirements for the Power Supply (page 20) and Electrical Wiring problems, down time and needless parts replacement.
Page 81 Troubleshooting the Operating Setpoint minus the Differential setting, the control will automatically return to Step 2 and repeat the operating cycle. Sequence is shown with Enable/Disable Switch in the Enable position If tank temperature drops below Operating Set Point minus Differential setting a heating cycle is activated Control System performs diagnostic checks •...
Page 82 Troubleshooting OPERATIONAL PROBLEMS • Supply gas regulator is not installed per installation requirements ⚠ (erratic gas supply volume/pressures). See Supply Gas Regulator WARNING (page 20). Safety Hazard • Excessive supply gas pressure. See Table 5 (page 17) and Supply Gas Regulator (page 20). Failure to follow these instructions and safety messages could result in death or serious injury.
Page 83 Troubleshooting Not Enough Or No Hot Water • Check the Temperature-Pressure Relief Valve. • Excessive water temperature. • No power to the water heater, check breaker or fuses. • Excessive water pressure. • Enable/Disable switch in “Disabled” position. Set to “Enable” to •...
Page 84 Troubleshooting FAULT AND ALERT CONDITIONS Note: If you are not qualified and licensed or certified as required by the authority having jurisdiction to perform a given task do not Fault Conditions attempt to perform any of the diagnostic or service procedures described in the following section.
Page 85 Troubleshooting Fault and Alert Messages FAULT CODE Possible Causes - Check/Repair Displayed Fault/Alert Message Lower Temperature Probe Failure CURRENT FAULT CURRENT FAULT Data Error Code: The indicated temperature probe might be shorted or open. (4,1006) NTC open Lower Temperature Probe Failure (4,1007) NTC short The control system has detected an issue with the lower Occurred:...
Page 86 Troubleshooting Fault and Alert Messages FAULT CODE Possible Causes - Check/Repair Displayed Fault/Alert Message Communication Failure CURRENT FAULT Data Error Code: Communications between the display and the TRC is lost. (20,0) Communication Failure The control system has lost communications with UIM. Occurred: Cycle the main power supply to the heater by turning 04/28/2025 12:34 AM...
Page 87 Troubleshooting Fault and Alert Messages FAULT CODE Possible Causes - Check/Repair Displayed Fault/Alert Message Water Leak Detected CURRENT FAULT Data Error Code: A water leak or other water-present condition is being (31,7002) or detected. Check for a leak or other water problem at the (31, 7003) or Water Leak Detected water sensor.
Page 88 Troubleshooting Fault and Alert Messages FAULT CODE Possible Causes - Check/Repair Displayed Fault/Alert Message No Water CURRENT FAULT Data Error Code: No water is detected by the powered anode. (34, 60x4) where x = 0 is on TRC-1000 No Water The Control System is not detecting water in the tank.
Page 89 Troubleshooting Fault and Alert Messages FAULT CODE Possible Causes - Check/Repair Displayed Fault/Alert Message Ignition Failure CURRENT FAULT CURRENT FAULT CURRENT FAULT (Resideo 129, 147, The control system failed to sense a flame signal during the 241) ignition sequence. or 38 Ignition Failure Occurred: The control system failed to sense a flame signal during the...
Page 90 Troubleshooting Fault and Alert Messages FAULT CODE Possible Causes - Check/Repair Displayed Fault/Alert Message Blocked Air Intake CURRENT FAULT CURRENT FAULT CURRENT FAULT Data Error Code: 71 There is a restriction in the air intake. Check the intake pipe (201, 71) and termination for blockage.
Page 91 Troubleshooting Fault and Alert Messages FAULT CODE Possible Causes - Check/Repair Displayed Fault/Alert Message Software and FMM Incompatible CURRENT FAULT Data Error Code: The TRC version is older than the TRC version stored in key. (205,200x) Software and FMM Key Incompatible Where: The control system has detected a device that is incompatible x =2 if the key is...
Page 92 Troubleshooting Fault and Alert Messages FAULT CODE Possible Causes - Check/Repair Displayed Fault/Alert Message Auto Test Complete CURRENT FAULT Data Error Code: Cycle Main Power to water heater. If problem continues, (210, 35) contact technical support for further instructions. Auto Test Complete/Passed Occurred: 04/28/2025 12:34 AM No action required.
Page 93 Troubleshooting Fault and Alert Messages FAULT CODE Possible Causes - Check/Repair Displayed Fault/Alert Message Software Failure CURRENT FAULT Data Error Code: The CSC has detected a software issue. (214, xxx) where xxx Software Failure =149, 153, 155 or 157 Cycle the main power supply to the water heater Occurred: by turning off the breaker/disconnect, then wait approximately 30 seconds and turn main power supply...
Page 94 Troubleshooting Fault and Alert Messages FAULT CODE Possible Causes - Check/Repair Displayed Fault/Alert Message Anode Shorted The central control board (TRC) is detecting low-resistance CURRENT FAULT or a short to earth ground or the tank. Anode Shorted Possible Causes: Occurred: Water at anode area.
Page 95 Troubleshooting Fault and Alert Messages FAULT CODE Possible Causes - Check/Repair Displayed Fault/Alert Message Missing Display Data Error Code: The display was found to be missing. (223, 2006) CURRENT FAULT The control system has detected that the User Interface Module (UIM) is either missing or disconnected. Missing Display Ensure the wire connections are secure and free of Occurred:...
Page 96 Troubleshooting Fault and Alert Messages FAULT CODE Possible Causes - Check/Repair Displayed Fault/Alert Message FMM Incompatible CURRENT FAULT (227, 4001) The control system has detected that the Software Version on the Flex Memory Module (FMM) is outdated. FMM Incompatible Occurred: The control system has detected that the Software Version 04/28/2025 12:34 AM on the Flex Memory Module (FMM) is outdated...
Page 97 Troubleshooting CHECKING FOR LEAKS ⚠ WARNING Safety Hazard Failure to follow these instructions and safety messages could result in death or serious injury. Read and understand this instruction manual and the safety messages herein before installing, operating or servicing this water heater. This manual must remain with the water heater.
Page 98 DIAGRAMS WIRING DIAGRAMS Circulation Pump Wiring Diagrams 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 99 Diagrams Control Circuit Diagrams Figure 84. 60 Gallon Models Temperature Regulation and Combustion and Safety Control Wiring Diagram High-Efficiency Commercial Gas Water Heaters • 99...
Page 100 Diagrams Figure 85. 100 Gallon Models - Temperature Regulation and Combustion and Safety Control Wiring Diagram 100 • High-Efficiency Commercial Gas Water Heaters...
Page 101 Diagrams Figure 86. 119 Gallon Models Temperature Regulation and Combustion and Safety Control Circuit Diagram High-Efficiency Commercial Gas Water Heaters • 101...
Page 102 Diagrams WATER PIPING DIAGRAMS One Water Heater, Single Temperature with Building Recirculation See Water Line Connections (page 51). Before installation of water piping review the following: If a pump is being installed between a water heater and storage See Mixing Valves (page 21). tank or on a building recirculation loop wire according to Figure 82 See Dish-washing Machines (page 21).
Page 103 Diagrams One Water Heater, Two Temperatures with High-Temperature Loop Recirculation - With Building Recirculation See Water Line Connections (page 51). Before installation of water piping review the following: If a pump is being installed between a water heater and storage See Mixing Valves (page 21).
Page 104 Diagrams One Water Heater, Single Temperature with Vertical Storage Tank Forced Recirculation with Building Recirculation See Water Line Connections (page 51). Before installation of water piping review the following: If a pump is being installed between a water heater and storage See Mixing Valves (page 21).
Page 105 Diagrams One Water Heater, Single Temperature with Horizontal Storage Tank, Forced Recirculation with Building Recirculation See Water Line Connections (page 51). Before installation of water piping review the following: If a pump is being installed between a water heater and storage See Mixing Valves (page 21).
Page 106 Diagrams Two Water Heaters, Single Temperature with Building Recirculation See Water Line Connections (page 51). Before installation of water piping review the following: If a pump is being installed between a water heater and storage See Mixing Valves (page 21). tank or on a building recirculation loop wire according to Figure 82 See Dish-washing Machines (page 21).
Page 107 Diagrams Three Water Heaters, Single Temperature with Building Recirculation See Water Line Connections (page 51). Before installation of water piping review the following: If a pump is being installed between a water heater and storage See Mixing Valves (page 21). tank or on a building recirculation loop wire according to Figure 82 See Dish-washing Machines (page 21).
Page 108 Diagrams Four Water Heaters, Single Temperature with Building Recirculation See Water Line Connections (page 51). Before installation of water piping review the following: If a pump is being installed between a water heater and storage See Mixing Valves (page 21). tank or on a building recirculation loop wire according to Figure 82 See Dish-washing Machines (page 21).
Page 109 Diagrams NOTES High-Efficiency Commercial Gas Water Heaters • 109...
Page 110 Diagrams NOTES 110 • High-Efficiency Commercial Gas Water Heaters...
Page 111 Diagrams NOTES High-Efficiency Commercial Gas Water Heaters • 111...

This manual is also suitable for:

401 series 450 series 451 series Flex 60g Flex 100g Flex 119g