A.O. Smith CYCLONE XHE BTH 300A Installation & Operating Instructions Manual

Commercial gas water heater gas-fired power burner for domestic hot water

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Page 1 CYCLONE XHE ® Model BTH 300A AND 400A COMMERCIAL GAS WATER HEATER GAS-FIRED POWER BURNER FOR DOMESTIC HOT WATER • 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.
Page 2: Rough-In Dimensions
ROUGH-IN-DIMENSIONS GAS VALVE PIPING BTH-300 3/4" NPT BTH-400 3/4" NPT TABLE 1, RECOVERY CAPACITIES U.S. Gallons/Hr and Litres/Hr at TEMPERATURE RISE INDICATED TYPE OF INPUT Approx. F° 20F° 30F° 40F° 50F° 60F° 70F° 80F° 90F° 100F° 110° 120F° 130F° 140F° MODEL BTUH Capacity...
Page 3: Table Of Contents
TABLE OF CONTENTS PAGE PAGE ROUGH-IN DIMENSIONS ..............Closed System ................13 FOREWORD ..................Water (Potable) Heating & Space Heating ........13 FEATURES ..................Heater Wiring .................. 14-15 Water Temperature Control ............OPERATION ..................15 High Limit Switch (E.C.O.) ............Sequence of Operation ..............
Page 4: High Limit Switch (E.c.o.)
The temperature may be adjusted from 80°F/27°C to 180°F/82°C. the display board. The water temperature must drop below 160°F/ The thermostat was adjusted to 120°F/49°C before the heater was 71°C before the controller can be reset. shipped from the factory. It is recommended that lower water Continued manual resetting of high limit control, preceded by higher temperatures be used to avoid the risk of scalding.
Page 5: Locating The Heater
WARNING WARNING THIS WATER HEATER IS A CONDENSING UNIT AND REQUIRES Should you choose to apply an insulation blanket to this heater, A DRAIN TO BE LOCATED IN CLOSE PROXIMITY TO ALLOW you should follow these instructions. Failure to follow these THE CONDENSATE TO DRAIN SAFELY.
Page 6: Air Requirements
See MAINTENANCE section for details of tank cleanout procedure. CHEMICAL VAPOR CORROSION AIR REQUIREMENTS WARNING CORROSION OF THE FLUE WAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE CHEMICAL VAPORS. SUCH CORROSION MAY RESULT IN MATERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS FAILURE AND RISK OF ASPHYXIATION.
Page 7 DIRECT VENT ON DIRECT VENT INSTALLATIONS, INLET VENT FIGURE 5 HOOD MUST BE LOCATED 1' (30.5cm) MINIMUM DO NOT TERMINATE EXHAUST FROM ANY OPENING IN BUILDING. OVER PUBLIC AREA WHERE CONDENSATE OR VAPOR CAN HORIZONTAL VENT CAUSE NUISANCE OR HAZARD. ON DIRECT VENT INSTALLATIONS, EXHAUST VENT HOOD MUST BE LOCATED 4' (122cm) MINIMUM FROM ANY OPENING IN BUILDING.
Page 8: Direct Venting
4. The manufacturer also recommends the vent system DIRECT VENT TERMINAL INSTALLATION terminations not be installed closer than 3' (91cm) from an inside IMPORTANT corner of an L shaped structure. And not less than 1' (30.5 cm) above grade or anticipated snow level. THIS UNIT CONSISTS OF TWO VENT TERMINALS - AN INTAKE VENT TERMINAL AND AN EXHAUST VENT TERMINAL.
Page 9: Vertical Vent Terminal Installation
wall. Align the holes by drilling a hole through the center of the VERTICAL VENT TERMINAL INSTALLATION template from the inside through to the outside. The template IMPORTANT can now be positioned on the outside wall using the drilled holes as a centering point for the template.
Page 10: Installation Of Vent System
INSTALLATION OF VENT SYSTEM NOTE: for Water Heaters in locations with high ambient temperatures (above 100°F or 38°C) and/or insufficient dilution air, it is recommended that CPVC or ABS pipe and fittings (MUST USE WARNING SUPPLIED VENT TERMINAL) be used. THE OPTIONAL INTAKE VENTING ARRANGEMENT AND THE EXHAUST VENTING ARRANGEMENT MUST BE INSTALLED TO 5.
Page 11: Controls And Switches
F. Contact the manufacturer, supplier, or competent consulting BLOCKED INLET PROVER SWITCH agency if you have any questions about the application or (SEE FIGURE 13) installation of PVC, PVC cellular core, ABS or CPVC pipe. The Blocked Inlet Prover Switch is set up to shut the unit off when G.
Page 12: Gas Piping
GAS PIPING IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING FROM CONTAMINANTS IN THE GAS WAYS. SUCH FOULING Contact your local gas service company to ensure that adequate MAY CAUSE IMPROPER OPERATION, FIRE OR EXPLOSION. gas service is available and to review applicable installation codes for your area.
Page 13: Purging
PRESSURES OF 1/2 PSIG (3.45Kpa) OR LESS, THE APPLIANCE In addition to the appliance relief valve, each remote storage tank NEED NOT BE DISCONNECTED, BUT MUST BE ISOLATED which may be used in conjunction with this appliance shall also be FROM THE SUPPLY PRESSURE TEST BY CLOSING THE installed with a properly sized, rated and approved temperature MANUAL GAS SHUTOFF VALVE.
Page 14: Heater Wiring
2. Toxic chemicals, such as those used for boiler treatment, GENERATES EMF OF RFI INTERFERENCE CAN CAUSE THE shall NEVER be introduced into this system. CONTROLLER TO MALFUNCTION. A HIGH QUALITY POWER CONDITIONER MUST BE INSTALLED IF THE ABOVE 3. This unit may never be connected to any existing heating CONDITIONS EXIST.
Page 15: Operation
be closed, and the blower will continue to run for approximately 10 seconds. The control will then return to step 2. If a flame is confirmed, the control will enter the heating mode where it will continue heating the tank water until the setpoint temperature plus differential is reached.
Page 16: Error Codes
ERROR CODES Possible Cause Remedy The following Error Codes are external to the controller. 01 Pressure Switch Fail On, should be Off 1. No Input Power 1. Apply Power 11 Pressure Switch Fail Off, should be On 02 Ignition Fail after 3 attempts 2.
Page 17: Switch Open
Display Flashes “05” when button is pressed: Possible Cause Remedy 1. Temperature Probe wiring 1. Repair Wiring open 2. Defective probe 2. Replace probe Display Flashes “15” when button is pressed: Possible Cause Remedy CONTROL BAD, All LEDs Flashing 1. No water in tank and tank 1.
Page 18: Prior To Start-Up
PRIOR TO START UP - REQUIRED ABILITY DO NOT USE THIS HEATER IF ANY PART HAS BEEN UNDER WATER. IMMEDIATELY CALL A QUALIFIED SERVICE INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES TECHNICIAN TO INSPECT THE HEATER AND TO REPLACE ANY ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL THE FIELD INVOLVED.
Page 19: Lighting Instructions
e. Repeat steps (c) and (d) until the specified input rate is Remove the pressure regulator cover screw (Figure 16) and achieved. adjust the pressure by turning the adjusting screw with a small screwdriver. In this example, with heater running on natural gas, do not exceed 5.0"...
Page 20: Cathodic Protection
HIGH ALTITUDE INSTALLATIONS WARNING UNDER NO CIRCUMSTANCES SHOULD THE INPUT EXCEED WARNING THE RATE SHOWN ON THE HEATER RATING PLATE. BTH HEATERS ARE CERTIFIED FOR USE WITHOUT OVERFIRING COULD RESULT IN DAMAGE OR SOOTING OF MODIFICATION FOR ALTITUDES UP TO 2000 FEET. THE HEATER.
Page 21: Flushing
FLUSHING 1. Turn off the heater electrical disconnect switch. 2. Open the drain valve and allow water to flow until it runs clean. 3. Close the drain valve when finished flushing. 4. Turn on the heater electrical disconnect switch. DRAINING The heater must be drained if it is to be shut down and exposed to freezing temperatures.
Page 22: Drain Valve And Access Panels
POWERED ANODE OPERATION If water does not flow, remove and inspect for obstructions or corrosion. Replace with a new valve of the recommended size as necessary. Inspection of the valve should be performed at least To insure a long, trouble-free operating life, the BTH-300 & 400 every three years.
Page 23: Installation Diagrams
INSTALLATION DIAGRAMS ONE TEMPERATURE - ONE HEATER VERTICAL STORAGE TANK FORCED CIRCULATION WITH OR WITHOUT BUILDING RECIRCULATION CAUTION: IF BUILDING COLD WATER SUPPLY HAS A BACK- FLOW PREVENTER, CHECK VALVE OR WATER METER WITH CHECK VALVE PROVISIONS FOR THERMAL EXPANSION OF WATER IN THE HOT WATER SYSTEM MUST BE PROVIDED NOTE: CONNECT RETURN...
Page 24 TWO TEMPERATURE - ONE HEATER HIGH TEMPERATURE WITH OR WITHOUT BUILDING RECIRCULATION DANGER PIPE RELIEF VALVE TO OPEN DRAIN. TEMPERATURE SETTING SHOULD NOT EXCEED SAFE NOTE: TEMPERED WATER TEMPERATURE FIXTURES. WATER RECIRCULATED, RETURN LINE SHOULD BE TEMPERATURE CONTROL WARNING ON PAGE 3. IF CONNECTED AT POINT “A”.
Page 25 TWO TEMPERATURE - TWO HEATERS HIGH TEMPERATURE WITH OR WITHOUT BUILDING RECIRCULATION TWO TEMPERATURE - THREE HEATERS (TWO PRE-HEATERS/ONE BOOSTER HEATER) WITH OR WITHOUT BUILDING RECIRCULATION MUST BE IDENTICAL HEATERS DANGER FOR MULTIPLE HEATER INSTALLATION SEE MANIFOLD KIT TEMPERATURE SETTING SHOULD NOT EXCEED SAFE SPECIFICATIONS, PAGE 28.
Page 26 TWO TEMPERATURE - TWO HEATERS (ONE PRE-HEATER/ONE BOOSTER HEATER) WITH OR WITHOUT BUILDING RECIRCULATION DANGER * PIPE RELIEF VALVE TO OPEN DRAIN TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE CONTROL WARNING ON ** 140°F (60°C)TO 150°F (66°C) SHOULD BE MAXIMUM WATER PAGE 3.
Page 27 TWO TEMPERATURE - ONE HEATER HIGH TEMPERATURE WITH RECIRCULATION OF SANITIZING LOOP DANGER NOTE 1: TOGGLE SWITCH CONTROLS 180°F (82°C) WATER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE CIRCULATION. INSTALL ON OR CLOSE TO DISHWASHER. TEMPERATURE AT FIXTURES. SEE WATER TEMPERATURE TOGGLE SWITCH MUST BE CLOSED (ON) DURING THE RINSE CONTROL WARNING ON PAGE 3.
Page 28: Manifold Kits
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. Unions shown in piping diagrams are not included in the manifold kits.
Page 29: Checklist And Service Information
CHECKLIST AND SERVICE INFORMATION 2. Some of the electrical components of the water heater make sounds which are normal. • Contacts click or snap as the heater starts and stops. IMPORTANT • Transformers often hum. The installer may be able to observe and correct certain problems which might arise when the unit is put into operation or when it is WATER LEAKAGE IS SUSPECTED re-fired after a prolonged shutdown.
Page 30: Replacement Parts
MOTOR WILL NOT RUN in Table 4: that is, for Natural Gas, 6.2" (1.54 kPa) W.C. pressure. Also, the manifold pressure should rise during the three (3) 1. Confirm 120V AC to the controller. Also, to verify correct polarity, second trial for ignition to the manifold pressure value for the check for 120 V AC between hot supply and ground.
Page 31: Limited Warranty
Model BTH Limited Warranty A. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this water heater. THE TANK If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable water therein, during the first THREE years after initial installation, the warrantor will supply a replacement tank less burner and controls or a complete new A.O.
Page 32 A.O. SMITH WATER PRODUCTS CO., INC. 5621 W. 115TH STREET • ALSIP, ILLINOIS 60803 PHONE: 1-800-433-2545 • FAX: 1-800-433-2515 www.hotwater.com • E-mail: parts@hotwater.com...