A.O. Smith BTH 120 Service And Parts Manual
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A.O. Smith BTH 120 Service And Parts Manual

For series 960 through 967
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See also: Service Handbook
BTH 120, 150, 199, 250
Service Handbook
Includes Parts List For
Series 960 through 967
This Service Handbook was prepared by:
The Training Department
Irving, Texas
$15.00 Printed in the U.S.A. 3 00
Part No. TC-044R2

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Summary of Contents for A.O. Smith BTH 120

  • Page 1 BTH 120, 150, 199, 250 Service Handbook Includes Parts List For Series 960 through 967 This Service Handbook was prepared by: The Training Department Irving, Texas $15.00 Printed in the U.S.A. 3 00 Part No. TC-044R2...

  • Page 2: Table Of Contents

    BTH HANDBOOK TABLE OF CONTENTS PAGE PAGE Introduction........2 Troubleshooting - continued Pressure Switch Continuity ..27-28 Installation Voltage Test - Igniter ....29 Clearances........3-4 250 Blower Test ......29 Air Requirements ......5-9 Gas Pressure Test ....... 30 Contaminated Air ......

  • Page 3: Introduction

    BTH HANDBOOK INTRODUCTION This service handbook is designed to aid in servicing and troubleshooting A. O. Smith BTH water heaters in the field. No duplication or reproduction of this book may be made without the express written authorization of the A. O. Smith Water Products Company. The following text and illustrations will provide you with a step by step procedure to verify proper installation, operation and troubleshooting procedures.

  • Page 4: Clearances

    Installation: This portion of the handbook will review often overlooked installation considerations, taking note of necessary instruction requirements for the BTH 120 - 250 / 966 and 967 Series. The instal- lation manual covers most of these items in de- tail.

  • Page 5: Clearances

    EXTERIOR CLEARANCES Horizontal Vent (using room air for combustion) Warning- Vent Hood(s) May Be Vent Hood Must Be Extremely Hot During Mounted 4' Minimum Operation Below Doors and Windows 4' Minimum Exhaust 4' Minimum Regulator Exhaust 3' Min. Vent Hood Must Be Exhaust Mounted Minimum...

  • Page 6: Direct Vent Installation

    MINIMUM AIR FOR COMBUSTION 10 CUBIC FEET OF AIR PER 1,000 BTU 10 CU. COMB. 1,000 2.5 CU. FT. EXCESS Stoichiometric or theoretical complete combustion requires 10 cubic feet of air per 1000 BTUH input of the gas input. The National Fuel Gas Code also recommends an additional 2.5 cu.ft. of "excess air". This 12.5 cu.ft.
  • Page 7 MAKE-UP AIR DIRECT COMMUNICATION A fresh supply of make-up air for combustion can be supplied to the heater through make-up air ducts, which directly communicate with the out of doors. Two openings are required - one within 12 inches of the top of the enclosure and one within 12 inches of the bottom of the enclosure.
  • Page 8 MAKE-UP AIR VERTICAL DUCTS Often it is more practical to install vertical make-up air ducts to the out doors. Again, two openings are required - within 12 inches (30 cm.) of the top of the enclosure and one within 12 inches (30 cm.) of the bottom of the enclosure.
  • Page 9 MAKE-UP AIR HORIZONTAL DUCTS When the heater is installed in an interior room with no roof access for vertical ducts, horizontal make-up ducts should be installed. When using horizontal ducts, two openings are required - within 12 inches (30 cm.) of the top of the enclosure and one within 12 inches (30 cm.) of the bottom of the enclo- sure.

  • Page 10: Air Requirements

    INSUFFICIENT MAKE-UP AIR BACKDRAFT Insufficient make-up air is a major cause of combustion problems. One common example is in a restaurant installation where exhaust vent equipment was not considered in sizing make-up air requirements. This may result in air being backdrafted by the restaurant exhaust equipment through the heater causing flue gas spill- age, flame roll out, improper combustion, inconsistent pilot operation, and/or erratic heater shutdown.

  • Page 11: Flammable

    CONTAMINATED AIR = RUST CHIPS Along with adequate make-up air, the quality of the air is important. Contaminants in combustion air can lead to premature heater failure. Vapors from bleaches, soaps, salts, etc. are drawn into the combustion chamber with the make up air and, once fired, mix with water vapor in the gasses to form extremely corrosive hydrochlo- ric or hydrofluoric acid an other corrosive byproducts.

  • Page 12: Condensation

    CONDENSATION The average dewpoint of natural gas flue products is 127 °F. Propane flue products is 119° F. With 70° F ambient air temperature and 180° F stored water temperature, exhaust gas will be approximately 140° F. Recommended safe water storage temperature is 120° F. NOTE: This unit can be vented using only PVC (Class 160, ASTM D- 2241;...

  • Page 13: Venting

    VENTING Equivalent Feet of Pipe Intake or Exhaust VENT LENGTH TABLE 4" 3" Maximum Number of 3" Minimum Maximum Pipe 90° Elbows Pipe (Feet) Pipe (Feet) (Feet) One (1) Two (2) Three (3) Four (4) Five (5) Six (6) 4-inch PVC may be used for a MAXIMUM intake of ONE HUNDRED TWENTY (120) EQUIVALENT FEET and a MAXIMUM exhaust of ONE HUNDRED TWENTY (120) EQUIVALENT FEET.
  • Page 14 HSI is Energized Weighted Average tank temp. setting. Blocked Outlet-NC Blower speed Tank Termpature Push once and hold Opens at 2.5" BTH 120 and 250 reduces BTH 250 Bottom vs Top to increase setting. Positive Press Only only Push twice and hold...
  • Page 15 MULTIPLE UNIT - WATER PIPING PARALLEL PIPING HOT TO FIXTURES REVERSE RETURN PIPING 2" 1 1/2" RETURN COLD EXHAUST VENT TO OUTDOORS 2" PUMP NOTES APPLY TO ALL SYSTEMS: *ADD GATE VALVES TO INLET AND OUTLET OF EACH UNIT FOR ISOLATION FLEXIBILITY. LOCATE AT THE SAME POINT FROM TEE.

  • Page 16: Controls

    CYCLONE BTH NORMAL INDICATIONS / READINGS DURING CALL FOR HEAT Tank temperature below control setting (to check control setting, press reset button) • On/off switch “on” Note: Power must be on at least 4 seconds before reset can be pressed to indicate control set- ting.
  • Page 17 CYCLONE BTH NORMAL INDICATIONS / READINGS 120 VAC present to ground and: • Each black terminal of on/off switch • CN1 black term 1 • CN 2 black term 1 • CN 4 black term 1 • CN 5 white term 1 (only while ignitor is heating) Note: CN 6 black term 2 will give reading of 90-100 volts –...

  • Page 18: Controls

    • On/off switch light • 120 VAC • 24 VAC • High limit • Control status • Current (average) tank temperature will be displayed (BTH 120, 250 Only) A. O. Smith Water Products Company Service Handbook © Irving, Texas 2000 Training Department...

  • Page 19: Pre-Service

    TROUBLESHOOTING PRE-SERVICE TIPS CHECK THAT: • Tank is full of water • Exhaust and intake vent do not exceed allowable limits • All plugs into boards are secure • Condensate hose is drained and open • 115-120 VAC is supplied to the heater (including polarity check a neutral to ground check results in "0"...

  • Page 20: Troubleshooting

    TROUBLESHOOTING STEP 2 - CHECK CONTINUITY THROUGH THE VALVE COIL STEP 2. Check Continuity Through The Valve OHMS RESISTANCE TABLE Coil BTH Model OHMS Resistance • Power off 150, 199 • Gas valve - coil continuity check 150, 199 • Disconnect wires from gas valve •...

  • Page 21: Control Board Check

    TROUBLESHOOTING STEP 3 - CONTROL BOARD CHECK STEP 3. 120 VAC SUPPLIED TO CONTROL BOARD - CN1 CONNECTION • Disconnect plug from CN1 terminal • Power switch "On" - 120 VAC indicator light should be "On" Check for 120 VAC black wire terminal to white wire terminal on plug.

  • Page 22: Transformer

    TROUBLESHOOTING STEP 4 - TRANSFORMER TEST STEP 4. 120 VAC SUPPLIED TO 24 VAC TRANSFORMER CN4. • Disconnect CN 4 plug from board Check for 120 VAC between the black terminal connect and white terminal connect on the control board. IF…...

  • Page 23: Transformer

    TROUBLESHOOTING STEP 5 - 24 VAC FROM TRANSFORMER STEP 5. 24 VAC FROM TRANSFORMER 24 VAC transformer indicator light should be "on". Insert probe into back of connect. Check for 24 VAC blue wire connect to ground and yellow wire connect to ground.
  • Page 24 TROUBLESHOOTING STEP 6. (continued) IF… THEN 24 VAC is not present replace 24 VAC is present go to St STEP 7 - TEST FOR 24 VAC THRU ECO STEP 7. 24 VAC THRU ECO (ECO IS NOT A THERMISTOR). Reinstalled plug. Check for 24 VAC from back of red 1 plug to ground.

  • Page 25: Temperature

    TROUBLESHOOTING STEP 8 - TEMPERATURE THERMISTOR CHECK STEP 8. TEMPERATURE THERMISTOR CHECK. The ohm’s resistance thru a thermistor is interpreted by the control board as a water temperature reading. • Note tank water temperature on display board or tank a thermometer reading from the T&P valve and drain valve •...

  • Page 26: Blower

    2 (white) to ground. He a te r m ode ls - Ohm s re sista nce 966 or 967 de sire d +/- 7.5% BTH 120 11.5 BTH 150 AND 199 11.2 BTH 250 Note: A shorted blower motor may damage the control board or, on BTH 250 models, the blower speed reduction board.

  • Page 27: Blower

    TROUBLESHOOTING STEP 9A - BLOWER SPEED REDUCTION TEST BTH 250 ONLY HAS BLOWER SPEED REDUCTION BOARD Blower wires (CN 2), igniter wires (CN 5), gas valve pressure switches and flame sense (CN6) plug directly into blower speed reduction board. The cables from the blower speed reduction board plug into the control board recepticles CN 2, CN 5, and CN 6.
  • Page 28 Blower proving switch does not show continuity continue Blower proving switch does show continuity replace Low gas pressure switch (BTH 120 and 250 only) does  check not show continuity  replac Low gas pressure switch does show continuity...
  • Page 29 • replace switc blower prover (T) to gnd does have 24 VAC continue. (BTH 120 and 250 only) low gas press (B) to gnd does not have 24 VAC check wire con low gas press. (B) to gnd does have 24 VAC continue.
  • Page 30 TROUBLESHOOTING STEP 13 - VOLTAGE TEST ON 250 MODELS ONLY STEP 13. VOLTAGE TEST TO IGNITER. HSI PLUG MAY BE REMOVED. Check for 120 VAC on the control circuit board - plug CN 5, term 1 to ground. IF… THEN 120 VAC is not present replace control b 120 VAC is present...

  • Page 31: Gas Pressure Test

    BTH 155, 199 •pressure is not 4.0" w.c. ± 0.2" natural gas or 10.0" propane on BTH 120 or 250 •pressure is 3.5" w.c. ± 0.2" natural gas or 10.0" w.c. ± 0.2" propane on BTH 155 or 199 •pressure is 4.0"...

  • Page 32: Component Part

    COMPONENT PART INFORMATION GAS VALVES Model AOS PT# Voltage W.R. 36E36-319 192966-0 Nat. 24 VAC Hnwl VR8305M-4009 192797-Nat. 24 VAC W.R. 36C68-814 192454-1 Prop 24 VAC W.R. 36C68-809 1922454-0 Nat. 24 VAC Flame Rod AOS PT# Flame S (µ) 192478 .7 Micro Hot Surface Igniter (HSI) AOS PT#...

  • Page 33: Pressure Switches

    PRESSURE SWITCHES Inches Blocked Inlet Blow Model Series N.C. Opens Prover Closes BTH 120 -1.0 0.45 BTH 120 -2.0 0.45 BTH 150 0.42 BTH 150 -0.75 0.45 BTH 150 -1.6 0.45 BTH 150 967 (Prop.) -1.6 0.45 BTH 199 0.42 BTH 199 -0.76...

  • Page 34: Wiring Connections

    WIRING CONNECTIONS BTH 150, 199 DIAGRAM BTH 120 and 250 DIAGRAM BTH 250 DIAGRAM A. O. Smith Water Products Company Service Handbook © Irving, Texas 2000 Training Department...
  • Page 35 SERVICING AIDS This type product is polarity sensitive. Be certain that your electrical supply wire neutral has no voltage. This unit will produce condensation--quite heavily at times. The outlet drain hose must be allowed to drain. Exhaust Vent piping must also drain condensate. Code 11 error would imply that these must be checked.

  • Page 36: Questions And Answers

    QUESTIONS AND ANSWERS How much electrical power is required for a BTH water heater? A. The BTH models draw approximatley 5.0 Amps Max. When should BTHs be delimed? A. Many variables affect the lime build up process including: • Water temperature - the amount of lime accumulation during the same period of time will be nearly 2 times greater if water is stored at 140 degress F than at 120 degrees F.

  • Page 37: Bth Error Codes

    BTH ERROR CODES BTH COMMON ERROR CODES - Code 04 - ECO Open The hi-limit has been tripped or is malfunctioning -- Try to reset the ECO. Test to see if ECO is malfunctioning. Also make sure to test the lower temp probe for continuity.

  • Page 38: Service Checklist

    SERVICE CHECKLIST This is not intended to be an all-inclusive list of the problems that the Service Agent may encounter. Any item checked "no" on this list should be thoroughly investigated and corrective action taken, if required. SERVICE AGENT: __________________________ INSTALLATION DATE: __________________________ MODEL NUMBER: _________________________ SERVICE DATE: ______________________________...

  • Page 39: Series

    COMMERCIAL WATER HEATER PARTS LIST CYCLONE XHE ® MODEL BTH-120 SERIES 966 (PARTIAL PARTS LISTING) EXHAUST TERMINAL DIRECT VENT INTAKE TEE CLEAN OUT ASSEMBLY A.O. SMITH WATER PRODUCTS CO., INC. PARTS INFORMATION PHONE: 1-800-433-2545 FAX: 1-800-433-2515 • WWW.HOTWATER.COM A. O. Smith Water Products Company Service Handbook Irving, Texas 2000©...
  • Page 40 ® CYCLONE XHE MODEL BTH-120 WATER HEATER PARTS LIST (PARTIAL) SERIES 966 ITEM DESCRIPTION BTH-120 1 ..... Anode ......... 043817-029 2 ..... Panel, Front ....... 192935-000 5 ..... Panel, Left Side......193237-000 6 ..... Panel, Right Side ....... 193238-000 20 ....Condensate Hose ..... 181864-072 22 ....
  • Page 41 ® CYCLONE XHE MODEL BTH-120 CONTROLS PARTS LIST - SERIES 966 ITEM DESCRIPTION BTH-120 1 ..... Transformer ....... 192608-001 2 ..... Control Board ......193822-000 3 ..... E.C.O./Temperture Probe ..192606-000 4 ..... Blower Proving Air Switch ..193295-000 7 ..... Blower Assembly ...... 193341-000 8 .....
  • Page 42 ® CYCLONE XHE MODEL BTH-120 BURNER & BLOWER PARTS LIST - SERIES 966 ITEM DESCRIPTION BTH-120 1 ..... Burner ........194114-003 2 ..... Igniter Assembly......192638-000 6 ..... Barb, Hose, 3/16" ...... 181863-000 7 ..... Flame Rod Assembly ....192478-000 9 .....
  • Page 43 COMMERCIAL WATER HEATER PARTS LIST ® CYCLONE XHE MODEL BTH-150, BTH-199 SERIES 966 & 967 (PARTIAL PARTS LISTING) EXHAUST TERMINAL DIRECT VENT INTAKE TEE CLEAN OUT ASSEMBLY A.O. SMITH WATER PRODUCTS CO., INC. PARTS INFORMATION PHONE: 1-800-433-2545 FAX: 1-800-433-2515 • WWW.HOTWATER.COM A.
  • Page 44 ® CYCLONE XHE MODELS BTH-150& BTH-199 SERIES 966 & 967 CONTROLS PARTS LIST (PARTIAL) BTH-150 BTH-199 ITEM DESCRIPTION NATURAL PROPANE NATURAL PROPANE 1 ..Anode ......043817-053 ..043817-053 ..043817-053 ..043817-053 2 ..Panel, Front ....192935-000 ..192935-000 ..192935-000 ..192935-000 3 ..
  • Page 45 ® CYCLONE XHE MODELS BTH-150 & BTH-199 SERIES 966 & 967 CONTROLS PARTS LIST BTH-150 BTH-199 ITEM DESCRIPTION NATURAL PROPANE NATURAL PROPANE 1..Transformer ....192608-001 ..192608-001 ..192608-001 ..192608-001 2..Control Board ....193822-000 ..193822-000 ..193822-000 ..193822-000 3..
  • Page 46 ® CYCLONE XHE MODELS BTH-150 & BTH-199 SERIES 966 & 967 BURNER & BLOWER PARTS LIST BTH-150 BTH-199 ITEM DESCRIPTION NATURAL PROPANE NATURAL PROPANE 1 ..Burner......194114-001 ..194114-005 ..194114-000 ..194114-004 2 ..Igniter Assembly ..192638-000 ..192638-000 ..192638-000 ..192638-000 7 ..
  • Page 47 COMMERCIAL WATER HEATER PARTS LIST ® CYCLONE XHE MODEL BTH-250 SERIES 966 (PARTIAL PARTS LISTING) EXHAUST TERMINAL DIRECT VENT INTAKE TEE CLEAN OUT ASSEMBLY A.O. SMITH WATER PRODUCTS CO., INC. PARTS INFORMATION PHONE: 1-800-433-2545 FAX: 1-800-433-2515 • WWW.HOTWATER.COM A. O. Smith Water Products Company Service Handbook Irving, Texas 2000©...
  • Page 48 CYCLONE XHE ® MODEL BTH-250 WATER HEATER PARTS LIST (PARTIAL) SERIES 966 ITEM DESCRIPTION BTH-250 1 ..... Anode ......... 043817-053 2 ..... Panel, Front ....... 192935-000 3 ..... Burner Assembly ...... 194114-002 4 ..... Blower ........193203-000 5 ..... Panel, Left Side ......193237-000 6 .....
  • Page 49 ® CYCLONE XHE MODELS BTH-250 CONTROLS PARTS LIST - SERIES 966 ITEM DESCRIPTION BTH-250 1 ..... Transformer ....... 192608-001 2 ..... Control Board ......193822-000 3 ..... E.C.O./Temperture Probe ..192606-000 4 ..... Blower Proving Air Switch ..193295-000 7 ..... Blower Assembly ...... 193203-000 8 .....

  • Page 50: Series

    ® CYCLONE XHE MODELS BTH-250 BURNER & BLOWER PARTS LIST - SERIES 966 ITEM DESCRIPTION BTH-250 1 ..... Burner ........194114-002 2 ..... Igniter Assembly......192638-000 7 ..... Flame Rod Assembly ....192478-000 9 ..... Orifice ......... 192477-002 13 ....Valve, Gas ........192454-000 14 ....

  • Page 51: Series

    COMMERCIAL WATER HEATER PARTS LIST CYCLONE XHE ® MODEL BTH-150, BTH-199 SERIES 960 EXHAUST TERMINAL DIRECT VENTTERMINAL CLEAN OUT ASSEMBLY A.O. SMITH WATER PRODUCTS CO., INC. PARTS INFORMATION PHONE: 1-800-433-2545 FAX: 1-800-433-2515 • WWW.HOTWATER.COM A. O. Smith Water Products Company Service Handbook Irving, Texas 2000©...
  • Page 52 ® CYCLONE XHE MODEL BTH-150 & BTH-199 WATER HEATER PARTS LIST SERIES 960 ITEM DESCRIPTION BTH-150 BTH-199 1 ..... Anode ..........043817-053 ..043817-053 2 ..... Cover, Jacket ........192664-000 ..192664-000 3 ..... Burner Assembly ......192417-001 ..192417-001 4 .....
  • Page 53 CYCLONE XHE ® MODEL BTH-150 & BTH-199 WATER HEATER PARTS LIST SERIES 960 ITEM DESCRIPTION BTH-150 BTH-199 1 ..... Transformer ........192608-000 ..192608-000 2 ..... Control Board ........192624-000 ..192624-000 3 ..... E.C.O./Temperture Probe ....192606-000 ..192606-000 4 .....

  • Page 54: Series

    CYCLONE XHE ® MODEL BTH-150 & BTH-199 BURNER & BLOWER PARTS LIST SERIES 960 ITEM DESCRIPTION BTH-150 BTH-199 1 ..... Burner ........192416-000 ..192416-000 2 ..... Igniter Assembly ......192638-000 ..192638-000 4 ..... Air Deflector ....... 192414-000 ..192414-000 5 .....

  • Page 55: Series

    COMMERCIAL WATER HEATER PARTS LIST ® CYCLONE XHE MODEL BTH-250 SERIES 962 (PARTIAL PARTS LISTING) EXHAUST TERMINAL DIRECT VENT INTAKE TEE CLEAN OUT ASSEMBLY A.O. SMITH WATER PRODUCTS CO., INC. PARTS INFORMATION PHONE: 1-800-433-2545 FAX: 1-800-433-2515 • WWW.HOTWATER.COM A. O. Smith Water Products Company Service Handbook Irving, Texas 2000©...
  • Page 56 ® CYCLONE XHE MODEL BTH-250 WATER HEATER PARTS LIST (PARTIAL) SERIES 962 ITEM DESCRIPTION BTH-250 1 ..... Anode ..........043817-004 2 ..... Cover, Jacket ........192664-000 3 ..... Burner Assembly ......192417-003 4 ..... Motor, Blower ........193203-000 5 ..... Cage, Housing ........192420-000 6 .....
  • Page 57 ® CYCLONE XHE MODELS BTH-250 CONTROLS PARTS LIST - SERIES 962 ITEM DESCRIPTION BTH-250 1 ..... Transformer ........192608-001 2 ..... Control Board ........192624-000 3 ..... E.C.O./Temperture Probe ....192606-000 4 ..... Blower Proving Air Switch ....193221-000 5 ..... Low Voltage Cable Assembly... 192605-000 6 .....
  • Page 58 ® CYCLONE XHE MODELS BTH-250 BURNER & BLOWER PARTS LIST - SERIES 962 ITEM DESCRIPTION BTH-250 1 ..... Burner ........192416-000 2 ..... Igniter Assembly......192638-000 3 ..... Rivet, Blind, 1/8" Dia 316 SS ..192730-000 4 ..... Air Deflector ....... 192414-000 5 .....
  • Page 59 COMMERCIAL WATER HEATER PARTS LIST ® CYCLONE XHE MODEL BTH-150 & BTH-199 SERIES 962 (PARTIAL PARTS LISTING) EXHAUST TERMINAL DIRECT VENT TERMINAL CLEAN OUT ASSEMBLY A.O. SMITH WATER PRODUCTS CO., INC. PARTS INFORMATION PHONE: 1-800-433-2545 FAX: 1-800-433-2515 • WWW.HOTWATER.COM A. O. Smith Water Products Company Service Handbook Irving, Texas 2000©...
  • Page 60 ® CYCLONE XHE MODEL BTH-150 & BTH-199 WATER HEATER PARTS LIST - SERIES 962 ITEM DESCRIPTION BTH-150 BTH-199 1 ..... Anode ..........043817-053 ..043817-053 2 ..... Cover, Jacket ........192664-000 ..192664-000 3 ..... Burner Assembly ......192417-001 ..192417-001 4 .....
  • Page 61 ® CYCLONE XHE MODELS BTH-150 & BTH-199 CONTROLS PARTS LIST - SERIES 962 ITEM DESCRIPTION BTH-150 BTH-199 1 ....Transformer ........192608-000 ..192608-000 2 ....Control Board ........192624-000 ..192624-000 3 ....E.C.O./Temperture Probe ....192606-000 ..192606-000 4 ....

  • Page 62: Series

    ® CYCLONE XHE MODELS BTH-150 & BTH-199 BURNER & BLOWER PARTS LIST SERIES 962 ITEM DESCRIPTION BTH-150 BTH-199 1 ...... Burner ........192416-000 ..192416-000 2 ...... Igniter Assembly ......192638-000 ..192638-000 4 ...... Air Deflector ....... 192414-000 ..192414-000 5 ......
  • Page 63 Notes A. O. Smith Water Products Company Service Handbook Irving, Texas 2000© Training Department...
  • Page 64 Notes A. O. Smith Water Products Company Service Handbook © Irving, Texas 2000 Training Department...

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