A.O. Smith SERIES 100 Installation & Operating Instructions Manual

Series 100 and 101 commercial gas water heater gas-fired power burner for domestic hot water

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Instruction manual (120 pages)

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CYCLONE Xi Model BTH 120-250(A)

COMMERCIAL GAS WATER HEATER

• INSTALLATION • OPERATION • SERVICE • MAINTENANCE • LIMITED WARRANTY

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 and service must be

performed by a qualified installer,

service agency or the gas supplier.

Thank you for buying this energy efficient water heater from

A.O. Smith Water Products Company. We appreciate your

confidence in our products.

TEXT PRINTED OR UNDERLINED IN RED CONTAINS

INFORMATION RELATIVE TO YOUR SAFETY. PLEASE

READ THOROUGHLY BEFORE INSTALLING AND USING

THIS APPLIANCE.

PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND

NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.

PRINTED IN U.S.A. 0307

SERIES 100 AND 101

GAS-FIRED POWER BURNER

FOR DOMESTIC HOT WATER

CAUTION

A DIVISION OF A.O. SMITH CORPORATION

Mc BEE, SOUTH CAROLINA

PART NO. 197727-000

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Page 1 Thank you for buying this energy efficient water heater from A.O. Smith Water Products Company. We appreciate your confidence in our products. CAUTION TEXT PRINTED OR UNDERLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY.
Page 2: Rough-In Dimensions
CYCLONE Xi BTH 120 - 250A ROUGH-IN-DIMENSIONS GAS VALVE PIPING BTH-120, 199 & 250 1/2" NPT BTH-150 3/4" NPT Table 1. RECOVERY CAPACITIES - NATURAL GAS / L.P. Approx. Input Gallon Model BTU/Hr. Usage Capacity BTH 120 120,000 nat/lp BTH 150 150,000 nat/lp BTH 199 199,900 nat/lp...
Page 3: Table Of Contents
ROUGH-IN DIMENSIONS ... FOREWORD ... FEATURES ... Water Temperature Control ... High Limit Switch (E.C.O.) ... Dishwashing Machine Requirement ... Circulating Pump ... INSTALLATION INSTRUCTIONS ... 4-12 Required Ability ... Insulation Blankets ... Locating The Heater ... Clearances ... Hard Water ... Air Requirements ...
Page 4: High Limit Switch (E.c.o.)
INSULATION BLANKETS Insulation blankets available to the general public for external use on gas water heaters are not approved for use on your A.O. Smith water heater. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank water heaters.
Page 5: Locating The Heater
LOCATING THE HEATER WARNING THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH AS GAS WATER HEATERS IN ROOMS, GARAGES OR OTHER AREAS WHERE GASOLINE, OTHER FLAMMABLE LIQUIDS OR ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED, OPERATED OR REPAIRED. FLAMMABLE VAPORS ARE HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE IGNITED BY THE HEATER’S IGNITER OR MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION.
Page 6: Hard Water
HARD WATER Where hard water conditions exist, water softening or the threshold type of water treatment is recommended. This will protect the dishwashers, coffee urns, water heaters, water piping and other equipment. See MAINTENANCE section for details of tank cleanout procedure. AIR REQUIREMENTS KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS.
Page 7: Installation Requirements For The Commonwealth Of Massachusetts
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied: INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled...
Page 8: U.s. Power Vent
U.S. POWER VENT FIGURE 5a. CAUTION TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN THESE TWO TERMINALS IS RECOMMENDED. CANADIAN POWER VENT FIGURE 5b.
Page 9 U.S. DIRECT VENT FIGURE 6a. CAUTION TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN THESE TWO TERMINALS IS RECOMMENDED. CANADIAN DIRECT VENT FIGURE 6b.
Page 10: Direct Venting
IMPORTANT The vent system must terminate so that proper clearances are maintained as cited in local codes or the current editions of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the Natural Gas and Propane Installation Code, CAN/CSA-B149.1. Do not terminate the exhaust vent terminal over public area where condensate or vapor can cause nuisance or hazard.
Page 11: Vertical Vent Terminal Installation
5. Glue the intake vent terminal to the section of the pipe. 6. Slide the wall plate over the pipe to stop against intake vent terminal. 7. Place a bead of caulking (not supplied) around the gap between the pipe and the wall. Place some of the caulking on the back of the plate to hold it against the wall after installation.
Page 12: Installation Of Vent System
INSTALLATION OF VENT SYSTEM WARNING THE OPTIONAL INTAKE VENTING ARRANGEMENT AND THE EXHAUST VENTING ARRANGEMENT MUST BE INSTALLED TO RUN DIRECTLY TO THE OUTDOORS AND NOT IN ANY WAY BE CONNECTED TO ANOTHER VENTING SYSTEM (I.E. FURNACE, DRYERS OR SPACE HEATERS). IT IS CRUCIAL THAT THE VENTING ARRANGEMENT BE KEPT SEPARATE FROM OTHER VENTING SYSTEMS.
Page 13: Control And Switches
CONTROLS AND SWITCHES All BTH models are provided with four pressure switches. These switches are essential to the safe and proper operation of the unit. All switches are wired in series. The controller is set up to shut the unit down whenever there is a failure of any of the switches.
Page 14: Connection Of Gas Pipe
WARNING THE HEATER IS NOT INTENDED FOR OPERATION AT HIGHER THAN 10.5" (2.59 KPa) WATER COLUMN SUPPLY GAS PRESSURE. HIGHER GAS SUPPLY PRESSURES REQUIRE SUPPLEMENTAL REDUCING SERVICE REGULATION. EXPOSURE TO HIGHER GAS SUPPLY PRESSURE MAY CAUSE DAMAGE TO THE GAS CONTROLS WHICH COULD RESULT IN FIRE OR EXPLOSION.
Page 15: Purging
DISCONNECT THE APPLIANCE AND ITS MANUAL GAS SHUTOFF VALVE FROM THE GAS SUPPLY PIPING SYSTEM DURING ANY SUPPLY PRESSURE TESTING EXCEEDING 1/2 PSIG (3.45Kpa). GAS SUPPLY LINE MUST BE CAPPED WHEN DISCONNECTED FROM THE HEATER. FOR TEST PRESSURES OF 1/2 PSIG (3.45Kpa) OR LESS, THE APPLIANCE NEED NOT BE DISCONNECTED, BUT MUST BE ISOLATED FROM THE SUPPLY PRESSURE TEST BY CLOSING THE MANUAL GAS SHUTOFF VALVE.
Page 16: Heater Wiring
3. This unit may never be connected to any existing heating system or component(s) previously used with non-potable water heating appliance. 4. When the system requires water for space heating at temperatures higher than required for domestic water purposes, a tempering valve must be installed.
Page 17: Using The Electronic Controller
USING THE ELECTRONIC CONTROLLER 1.Overview Interaction with the water heater controller is done through an up, a down, and three operation buttons. These buttons are illustrated to the right. Operation of the three lower buttons is defined immediately above them on the screen. The [UP] and [DN] buttons are used to navigate through the menus and make adjustments to the water heater.
Page 18: Operating States
2. Operating States In the main desktop screen, there are some specific Operating States that are indicated on the status line. These are summarized below: 3. Adjusting the Operating Set Point The Operating Set Point of this water heater determines the regulated temperature for the water in the tank.
Page 19: Changing The Display Units
4. Changing the Display Units The display interface to the heater has the option of selecting between degrees Fahrenheit and degrees Celsius for temperature displays. This can be found in the “Display Settings” menu. Also in this menu, you may adjust how the backlight operates and the contrast of the LCD screen.
Page 20: Viewing The Fault History
ACTION: To get to the current fault information screen, press Menu. DISPLAY: ACTION: Press the DOWN button to highlight "current Fault" and press Select. DISPLAY: ACTION: Press the DOWN button for more information. DISPLAY: INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE FIELD INVOLVED.
Page 21: Operatiing Instructions
OPERATING INSTRUCTIONS IMPORTANT IT IS RECOMMENDED THAT A QUALIFIED SERVICE TECHNICIAN PERFORM THE INITIAL FIRING OF THE HEATER. AT THIS TIME THE USER SHOULD ASK THE TECHNICIAN ANY QUESTIONS IN REGARD TO THE OPERATION AND MAINTENANCE OF THE UNIT. CAUTION BEFORE PROCEEDING WITH THE OPERATION OF THE UNIT, MAKE SURE HEATER AND SYSTEM ARE FILLED WITH WATER AND ALL AIR IS EXPELLED FROM HEATER AND PIPING.
Page 22: Cathodic Protection
WARNING UNDER NO CIRCUMSTANCES SHOULD THE INPUT EXCEED THE RATE SHOWN ON THE HEATER RATING PLATE. OVER FIRING COULD RESULT IN DAMAGE OR SOOTING OF THE HEATER. CATHODIC PROTECTION CAUTION HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER SYSTEM SERVED BY THIS HEATER THAT HAS NOT BEEN USED FOR A LONG PERIOD OF TIME (GENERALLY TWO WEEKS OR MORE).
Page 23: For Your Safety Read Before Operating
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. BTH 120 MODELS ONLY.
Page 24 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. OPERATING INSTRUCTIONS TURN OFF GAS TO APPLIANCE BTH 150 MODELS ONLY.
Page 25 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. OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS TURN OFF GAS TO APPLIANCE TURN OFF GAS TO APPLIANCE BTH 199/250 MODELS ONLY.
Page 26: Flushing
(part no. 4763) and 5 gallon (19L) (part no. 4813) sizes. Hydrochloric base acids are not recommended for use on glass-lined tanks. A.O. Smith Form No. 4800, entitled “Why, When and How”, describes tank cleaning methods and materials. UN•LIME and the booklet may be obtained through your A.O.
Page 27: Drain Valve And Access Panels
DRAIN VALVE AND ACCESS PANELS The heaters are equipped with a 3/4" drain valve. An access panel covers the cleanout opening in the tank which is sealed by a gasket and cover, figure 25. RELIEF VALVE At least twice a year, the temperature and pressure relief valve should be checked to ensure that it is in operating condition.
Page 28: Installation Diagrams
ONE TEMPERATURE - ONE HEATER VERTICAL STORAGE TANK FORCED CIRCULATION CAUTION: IF THE PLUMBING REQUIRES THE USE OF PIPES WITH DISSIMILAR MATERIAL (FOR EXAMPLE, STEEL AND COPPER), USE DIELECTRIC UNIONS TO PREVENT AN ELECTRO-GALVANIC ACTION BETWEEN THE PIPING COMPONENTS WITH DISSIMILAR MATERIALS.
Page 29 TWO TEMPERATURE - ONE HEATER HIGH TEMPERATURE DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE FIXTURES. TEMPERATURE CONTROL WARNING ON PAGE 4. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
Page 30 TWO TEMPERATURE - TWO HEATERS HIGH TEMPERATURE CAUTION: IF THE PLUMBING REQUIRES THE USE OF PIPES WITH DISSIMILAR MATERIAL (FOR EXAMPLE, STEEL AND COPPER), USE DIELECTRIC UNIONS TO PREVENT AN ELECTRO-GALVANIC ACTION BETWEEN THE PIPING COMPONENTS WITH DISSIMILAR MATERIALS. TWO TEMPERATURE - THREE HEATERS (TWO PRE-HEATERS/ONE BOOSTER HEATER) MUST BE IDENTICAL HEATERS FOR MULTIPLE HEATER INSTALLATION SEE MANIFOLD KIT SPECIFICATIONS, PAGE 33.
Page 31 TWO TEMPERATURE - TWO HEATERS (ONE PRE-HEATER/ONE BOOSTER HEATER) DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 4. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
Page 32 TWO TEMPERATURE - ONE HEATER HIGH TEMPERATURE DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 5. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
Page 33: Manifold Kits
Precision cut type “L” all copper A.O. Smith manifold kits assure water flow balance of all units. Without this balance, the full water heating and storage potential of the system cannot be achieved. Plus, the units with the higher water flow may have a shortened life.
Page 34: Checklist And Service Information
OPERATING SEQUENCE AND IGNITION SAFETY. IF YOU DO NOT HAVE THE PROPER TEST EQUIPMENT, I.E. A VOLT-OHM METER AND A MICROAMMETER, DO NOT ATTEMPT TO TROUBLESHOOT OR REPAIR A.O. SMITH EQUIPMENT. ALTERING THE CONTROLLER AND/OR CONTROLLER WIRING IN ANY WAY...
Page 35 Check for defective gas valve or thermostat. If operation is incorrect, replace. REPLACEMENT PARTS Replacement parts may be ordered through A.O. Smith dealers, authorized servicers or distributors. Refer to the Yellow Pages for where to call or contact the A.O. Smith Water Products Company, 500 Tennessee Waltz Parkway, Ashland City, TN 37015, 1-800-433-2515.
Page 36: Limited Warranty
A.O. Smith water heater of equivalent size and current model at the warrantor's option. Some government agencies are requiring energy efficient standards for water heaters. In the event regulations prohibit sale of a model of equivalent size and construction, A.O. Smith will provide a model which complies with the regulations of your area, in which case the consumer will be charged the difference in price between the like replacement and the energy efficient model required.
Page 37 NOTES:...
Page 38 NOTES:...
Page 39 NOTES:...
Page 40 A.O. SMITH WATER PRODUCTS COMPANY 500 TENNESSEE WALTZ PARKWAY ASHLAND CITY, TN 37015 PHONE: 1-800-433-2545 FAX: 1-800-433-2515 www.aosmithwaterheaters.com / email: parts@hotwater.com...

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A.O. Smith SERIES 100 Installation & Operating Instructions Manual

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