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A.O. Smith BTH 300 User Manual

A.O. Smith BTH 300
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COMMERCIAL GAS WATER HEATERS
Instruction Manual
PRINTED 1216 100233746
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
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Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
MODELS
BTH 300(A)/400(A)/500(A)
SERIES 300 & 301
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 neighbors phone. Follow the
gas suppliers 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.
ANSI/NSF-5
LOW LEAD
CONTENT
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$VKODQG&LW\71
www.hotwater.com

Table of Contents

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A.O. Smith BTH 300 Specifications

General IconGeneral
ModelBTH 300
Fuel TypeNatural Gas
Thermal Efficiency96%
Ignition TypeElectronic
Voltage120V
BTU Input300, 000 BTU/hr

Summary

COMMERCIAL GAS WATER HEATERS

MODELS BTH 300(A)/400(A)/500(A) SERIES 300 & 301

Specifies the model series covered by the manual.

INSTALLATION - OPERATION - SERVICE

Outlines the primary functions covered in the manual.

MAINTENANCE - LIMITED WARRANTY

Covers upkeep, repairs, and warranty information.

SAFE INSTALLATION, USE AND SERVICE

SAFETY ALERT SYMBOL

Explains the purpose of the safety alert symbol.

DANGER, WARNING, CAUTION Definitions

Defines hazard levels indicated by safety symbols.

APPROVALS

GENERAL SAFETY INFORMATION

PRECAUTIONS

Lists general precautions before operating the appliance.

GROUNDING INSTRUCTIONS

Details requirements for proper electrical grounding.

HYDROGEN GAS FLAMMABLE

Warns about the hazard of hydrogen gas in water systems.

GENERAL SAFETY INFORMATION (cont.)

FIRE OR EXPLOSION HAZARD

Details hazards related to flammable materials and gas.

BREATHING HAZARD - CARBON MONOXIDE GAS

Warns about carbon monoxide hazards and detector requirements.

PROPERTY DAMAGE HAZARD

Covers potential property damage from leaks or improper installation.

ELECTRICAL SHOCK HAZARD

Warns about electrical hazards during installation and service.

INTRODUCTION

ABBREVIATIONS USED

Lists common abbreviations used throughout the manual.

QUALIFICATIONS

Defines requirements for qualified installers and service agencies.

ICOMM

Describes the remote monitoring system's capabilities.

ICC

Explains connectivity to BACnet or Modbus systems.

PREPARING FOR THE INSTALLATION

FEATURES AND COMPONENTS

BASIC OPERATION

Explains how the water heater's heat exchanger and burner work.

MODULATION

Describes the water heater's ability to modulate firing rate.

BLOWER/BURNER ASSEMBLY DETAIL

Details the components of the blower and burner assembly.

TOP VIEW

COMPONENTS (All Models)

Identifies and describes all major components of the water heater.

SIDE VIEWS

SIDE VIEWS (cont.)

Provides detailed descriptions of components visible from the sides.

INSTALLATION CONSIDERATIONS

ROUGH IN DIMENSIONS

Specifies required dimensions for installation space.

GAS LINE CONNECTION SIZE

Details the required sizes for gas line connections.

STORAGE CAPACITIES

Lists the storage capacities in gallons and liters.

RECOVERY CAPACITIES

Shows recovery capacities at various temperature rises.

GAS PRESSURE REQUIREMENTS

Specifies required gas pressures for operation.

MINIMUM SUPPLY GAS LINE SIZE

Lists the minimum supply gas line sizes for different models.

LOCATING THE WATER HEATER

CAUTION PROPERTY DAMAGE HAZARD

Warns about potential property damage from leaks.

CLEARANCE TO COMBUSTIBLE MATERIALS

Details required clearances from combustible materials.

SERVICE CLEARANCE

Specifies required clearance for servicing the unit.

INTAKE AIR AND VENT PIPE CLEARANCES

Outlines clearances for vent and intake air pipes.

EXTENDED VENT TERMINATIONS

Information on extending vent pipe lengths with different pipe sizes.

OPTIONAL DIRECT VENT TERMINATIONS

HARD WATER

CIRCULATION PUMPS

INSULATION BLANKETS

INSTALLATION REQUIREMENTS

GAS SUPPLY SYSTEMS

Details requirements for low and high pressure gas supply systems.

SUPPLY GAS REGULATOR

Specifies requirements for installing a supply gas regulator.

POWER SUPPLY

Covers power supply requirements and electrical grounding.

DEDICATED POWER WIRING AND BREAKERS

Emphasizes dedicated wiring and breakers for optimal performance.

POWER FLUCTUATIONS AND ELECTRICAL NOISE

Addresses potential issues with power supply quality.

MIXING VALVES

DANGER BURN HAZARD

Warns about severe burn risks from hot water.

DISHWASHING MACHINES

Provides guidelines for connecting to dishwashing machines.

CLOSED WATER SYSTEMS

Explains closed systems and their implications.

THERMAL EXPANSION

Discusses thermal expansion and necessary precautions.

TEMPERATURE-PRESSURE RELIEF VALVE

WARNING EXPLOSION HAZARD

Highlights explosion risks related to the T&P valve.

CAUTION WATER DAMAGE HAZARD

Warns about water damage from improper discharge pipe installation.

T&P VALVE DISCHARGE PIPE REQUIREMENTS

Details specific requirements for the T&P discharge pipe.

DANGER BURN HAZARD

Warns about burn hazard from hot water discharge.

CONDENSATE DRAIN

CONDENSATE DRAIN WATER TRAP

Explains the built-in trap and its importance.

CONDENSATE PH LEVEL

Discusses condensate pH and material compatibility for drain lines.

COMBUSTIBLE MATERIAL STORAGE

CONTAMINATED AIR

WARNING BREATHING HAZARD - CARBON MONOXIDE GAS

Warns about CO hazard from contaminated air.

AIR REQUIREMENTS

WARNING BREATHING HAZARD - CARBON MONOXIDE GAS

Reinforces CO hazard warning and air intake needs.

UNCONFINED SPACE

Defines requirements for unconfined installation spaces.

UNUSUALLY TIGHT CONSTRUCTION

Discusses air supply needs in tightly constructed buildings.

CONFINED SPACE

Defines confined spaces and air supply requirements.

DIRECT VENT APPLIANCES

Notes DV appliances are not factored into confined space calculations.

EXHAUST FANS

Addresses air replacement needs when exhaust fans are used.

LOUVERS AND GRILLES

Explains how to calculate opening sizes based on louvers/grilles.

FRESH AIR OPENINGS FOR CONFINED SPACES

OUTDOOR AIR THROUGH TWO OPENINGS

Illustrates and describes two-opening air intake methods.

OUTDOOR AIR THROUGH ONE OPENING

Illustrates and describes single-opening air intake methods.

OUTDOOR AIR THROUGH TWO VERTICAL DUCTS

AIR FROM OTHER INDOOR SPACES

INSTALLATION REQUIREMENTS - COMMONWEALTH OF MASSACHUSETTS

INSTALLATION OF CARBON MONOXIDE DETECTORS

Mandates CO detector installation per MA codes.

APPROVED CARBON MONOXIDE DETECTORS

Specifies standards for approved CO detectors.

SIGNAGE

Requires specific signage for vent termination locations.

INSPECTION

Outlines inspector's role in verifying MA requirements.

EXEMPTIONS

Lists exemptions from specific MA installation requirements.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED

Manufacturer's requirements for provided venting systems.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED

Manufacturer's requirements for systems not provided.

VENTING INSTALLATION

WARNING BREATHING HAZARD - CARBON MONOXIDE GAS

Reinforces CO hazard warning related to venting.

GENERAL VENTING INFORMATION

Provides general information on venting requirements.

APPROVED MATERIALS

Lists approved materials for vent and intake air piping.

VENTING REQUIREMENTS

FIELD SUPPLIED FITTINGS

Details equivalent lengths for field-supplied fittings.

PRIMER AND CEMENT

Specifies types of primer and cement for pipe connections.

PIPE SIZE REQUIREMENTS

Outlines requirements for vent and intake air pipe sizes.

MAXIMUM EQUIVALENT LENGTHS

Specifies maximum allowed equivalent lengths for pipes.

MINIMUM EQUIVALENT LENGTHS

Lists minimum equivalent lengths for vent pipes.

MAXIMUM NUMBER OF ELBOWS

Details the maximum allowed number of elbows in vent piping.

FACTORY SUPPLIED FITTINGS

Discusses factory-supplied fittings and their use.

COMMON VENTING

Information on using a common horizontal direct vent kit.

VENTING INSTALLATION SEQUENCE

POWER VENT INSTALLATION

Step-by-step instructions for power vent installations.

DIRECT VENT INSTALLATION

Step-by-step instructions for direct vent installations.

INTAKE AIR CONDENSATE TEE INSTALLATION

VERTICAL TERMINATION INSTALLATION

DIRECT VENT AIR INTAKE MOISTURE PROTECTION

Details moisture drain requirements for DV intake air.

VERTICAL TERMINATION(S) INSTALLATION

VERTICAL TERMINATION(S) FLAT ROOF CLEARANCE

Specifies flat roof clearances for vertical terminations.

VERTICAL TERMINATION - DIRECT VENT STANDARD TERMINATIONS

Instructions for direct vent vertical terminations.

SIDEWALL TERMINATION INSTALLATION

SIDEWALL TERMINATION INSTALLATION INTAKE AIR AND/OR VENT (EXHAUST)

Details sidewall termination installation for intake and vent pipes.

POLYPROPYLENE INSTALLATIONS

AL29-4C® VENT INSTALLATIONS

COMMON VENTING

CONCENTRIC TERMINATION INSTALLATION

CONCENTRIC TERMINATION(S) FLAT ROOF CLEARANCE

Specifies flat roof clearances for concentric terminations.

6 INCH CONCENTRIC TERMINATION INSTALLATION

6 INCH CONCENTRIC TERMINATION VERTICAL INSTALLATION

Instructions for vertical installation of 6-inch concentric kits.

6 INCH CONCENTRIC TERMINATION SIDEWALL INSTALLATION

Instructions for sidewall installation of 6-inch concentric kits.

MULTIPLE CONCENTRIC TERMINATION CLEARANCES

Close Proximity & Standard Clearance

Details clearance requirements for multiple concentric terminations.

Four Concentric Terminations

Arrangement and clearance for four concentric terminations.

Three Concentric Terminations

Arrangement and clearance for three concentric terminations.

Groups Of Terminations

Arrangements for multiple groups of concentric terminations.

MULTIPLE CONCENTRIC TERMINATION ARRANGEMENTS

Two Concentric Terminations

Installation arrangements for two concentric terminations.

Four Concentric Terminations

Installation arrangements for four concentric terminations.

Eight Concentric Terminations

Installation arrangements for eight concentric terminations.

LOW PROFILE VENT INSTALLATION

Low Profile Termination Kits - Dimensions

Dimensions and specifications for low profile termination kits.

VENTING ARRANGEMENTS

Power Vent Vertical

Diagram for Power Vent vertical venting configuration.

Power Vent Horizontal

Diagram for Power Vent horizontal venting configuration.

Direct Vent Vertical

Diagram for Direct Vent vertical venting configuration.

Direct Vent Horizontal

Diagram for Direct Vent horizontal venting configuration.

Direct Vent Vertical Vent Horizontal Intake

Diagram for DV with vertical vent and horizontal intake.

Direct Vent Horizontal Vent Vertical Intake

Diagram for DV with horizontal vent and vertical intake.

VENTING ARRANGEMENTS (cont.)

Direct Vent Vertical Concentric

Diagram for DV vertical concentric venting.

Direct Vent Horizontal Concentric

Diagram for DV horizontal concentric venting.

Direct Vent Horizontal Low Profile

Diagram for DV horizontal low profile venting.

TERMINATION CLEARANCES SIDEWALL POWER VENT

Vent terminal clearances for "Power Vent" installations.

Clearances for sidewall vent terminations in power vent configurations.

TERMINATION CLEARANCES SIDEWALL DIRECT VENT

Vent terminal clearances for "Direct Vent" installations.

Clearances for sidewall vent terminations in direct vent configurations.

WATER HEATER INSTALLATION

CONDENSATE DRAIN INSTALLATION

Instructions for installing the condensate drain.

INSTALLATION NOTES

Notes regarding condensate pH and drain line materials.

SUPPLY GAS LINE INSTALLATION

GAS LINE SIZING

Details requirements for sizing gas supply lines.

GAS LINE CONNECTION

GAS LINE LEAK TESTING

Procedures for leak testing gas connections.

PURGING

Instructions for purging gas lines.

ELECTRICAL WIRING

General electrical wiring requirements.

DEDICATED POWER WIRING AND BREAKERS

Requirements for dedicated power wiring.

POWER SUPPLY CONNECTIONS

Details on connecting the power supply.

ENABLE/DISABLE CIRCUIT

CONNECTING AN EXTERNAL SUPERVISORY CONTROL

How to connect external controls to the enable/disable circuit.

WATER LINE CONNECTIONS

WATER PIPING DIAGRAMS

References for water piping diagrams.

THERMOMETERS (NOT SUPPLIED)

WATER (POTABLE) HEATING AND SPACE HEATING

T&P VALVE DISCHARGE PIPE

CAUTION WATER DAMAGE HAZARD

Warns of water damage from improper discharge pipe setup.

T&P Valve Discharge Pipe Requirements

Details specific requirements for the T&P discharge pipe.

TEMPERATURE REGULATION

HIGH TEMPERATURE LIMIT CONTROL (ECO)

Details the high temperature limit control (ECO).

THERMOSTAT CONTROL

Explains thermostat control and scald hazard warnings.

MODULATION

Describes the modulation feature of the water heater.

HIGH TEMPERATURE APPLICATIONS

Advice for high temperature applications.

CONTROL SYSTEM OPERATION

THE DESKTOP SCREEN

Describes the default screen on the LCD touch display.

CONTROL SYSTEM NAVIGATION

Explains how to navigate the control system menus.

STATUS ICONS

TABLE 16

Lists and describes status icons displayed on the unit.

OPERATING STATES

TABLE 17

Details the common operational states of the water heater.

CONTROL SYSTEM MENUS

TABLE 18

Lists and describes the available control system menus.

USER SETTINGS & CONTROL SYSTEM MENUS

TEMPERATURES MENU

Accesses settings for operating setpoint and differential.

TEMPERATURES MENU (CONT)

Differential

Adjusts tank temperature differential for heating cycles.

Tank Temperature

Displays non-adjustable sensed tank temperature.

Tank Probe Offset

Calibrates temperature sensing and compensates for recirculation.

HEATER STATUS MENU

Status

Displays current operating state of the water heater.

DISPLAY SETTINGS

Temperature Units

Allows selection of temperature units (°F or °C).

Backlight Delay

Adjusts LCD backlight illumination duration.

Contrast

Adjusts the LCD screen contrast.

HEATER INFORMATION

Elapsed Time

Total time the control system has been energized.

Burner On Time

Total time the control system has been in heating state.

Total Cycle Count

Total accumulated count of heating cycles.

CURRENT FAULT

Blocked Exhaust

Fault for restrictions in the exhaust pipe.

FAULT HISTORY

Fault History

Lists past Fault and Alert messages with timestamps.

FAULT OCCURRENCE

Fault Occurrence

Running total of how many times each fault condition occurred.

SERVICE CONTACT INFORMATION

Contact Information

Screen for entering customer contact information for alerts.

START UP

PRIOR TO START UP

Essential checks and preparation before initial start-up.

REQUIRED TEST EQUIPMENT

Lists necessary test equipment for start-up.

PREPARATION

Steps to prepare the water heater for initial start-up.

LIGHTING & OPERATION LABEL

FOR YOUR SAFETY READ BEFORE LIGHTING

Safety warnings and instructions before lighting the appliance.

OPERATING INSTRUCTIONS

Step-by-step guide for operating the water heater.

TO TURN OFF GAS TO APPLIANCE

Procedures for safely turning off gas supply.

SUPPLY GAS PRESSURE ADJUSTMENT

CHECKING THE FIRING RATE

How to determine the actual firing rate of the water heater.

TO TURN OFF GAS SUPPLY

Instructions to safely turn off the gas supply.

HIGH ALTITUDE INSTALLATIONS

WARNING FIRE AND EXPLOSION HAZARD

Safety warnings specific to high altitude installations.

WARNING BREATHING HAZARD - CARBON MONOXIDE GAS

CO hazard warning for high altitude installations.

TROUBLESHOOTING

INSTALLATION CHECKLIST

Checklist for common installation errors and requirements.

SEQUENCE OF OPERATION

Describes the step-by-step operational sequence.

SEQUENCE OF OPERATION FLOW CHART

Sequence is shown with Enable/Disable Switch in the Enable position

Flow chart illustrating the sequence of operation.

OPERATIONAL PROBLEMS

INSTALLATION ERRORS

Common operational problems due to installation errors.

ROUGH STARTING, ROUGH OPERATION

Addresses issues with rough starts or operation.

MOMENTARY IGNITION

Troubleshooting for momentary burner ignition.

NOT ENOUGH OR NO HOT WATER

Troubleshooting steps for insufficient hot water.

ALERT CONDITIONS

RESETTING CONTROL SYSTEM LOCK OUTS

Procedures for resetting system lockouts.

DIAGNOSTIC CHECKS

General checks for diagnosing operational issues.

ELECTRICAL SHOCK HAZARD

Warning about electrical shock during service.

FAULT AND ALERT MESSAGES

Ignition Failure

Fault message for ignition failure.

Low Gas Pressure

Fault message for low gas pressure.

Blocked Air Intake

Fault message for blocked air intake.

FAULT AND ALERT MESSAGES (CONT)

Blocked Air Intake (cont.)

Further causes and checks for blocked air intake.

High Temp Limit Exceeded

Fault message for high temperature limit being exceeded.

No Water

Alert message indicating no water detected.

MAINTENANCE

MAINTENANCE SCHEDULE

Schedule for routine maintenance tasks.

DRAINING AND FLUSHING

Instructions for draining and flushing the tank.

DANGER BURN HAZARD

Warning about burn hazard during drain valve operation.

FILLING THE WATER HEATER

SEDIMENT REMOVAL

Instructions for removing sediment from the tank.

LIME SCALE REMOVAL

Procedures for removing lime scale deposits.

CHEMICAL LIME SCALE REMOVAL

Using chemical solutions for lime scale removal.

TEMPERATURE-PRESSURE RELIEF VALVE TEST

DANGER BURN HAZARD

Warning about burn hazard during T&P valve test.

VENT SYSTEM

Instructions for inspecting the vent system.

DIAGRAMS

CCB - CENTRAL CONTROL BOARD LAYOUT

Diagram showing the layout of the Central Control Board.

WIRING DIAGRAM

Figure 58

Detailed wiring diagram of the water heater components.

CIRCULATION PUMP WIRING DIAGRAMS

CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK OR BUILDING RECIRCULATION

Wiring diagram for storage tank or building recirculation.

CIRCULATING PUMP WIRING DIAGRAM DISHWASHER LOOP WITH TOGGLE SWITCH

Wiring diagram for dishwasher loop with toggle switch.

WATER PIPING DIAGRAMS

ONE WATER HEATER, SINGLE TEMPERATURE WITH BUILDING RECIRCULATION

Piping diagram for single heater with building recirculation.

WATER PIPING DIAGRAMS (cont.)

WATER PIPING DIAGRAMS (cont.)

WATER PIPING DIAGRAMS (cont.)

ONE WATER HEATER, SINGLE TEMPERATURE WITH HORIZONTAL STORAGE TANK FORCED RECIRCULATION WITH BUILDING RECIRCULATION

Piping diagram for single heater with horizontal storage tank recirculation.

WATER PIPING DIAGRAMS (cont.)

TWO WATER HEATERS, SINGLE TEMPERATURE WITH BUILDING RECIRCULATION

Piping diagram for two heaters with building recirculation.

WATER PIPING DIAGRAMS (cont.)

THREE WATER HEATERS, SINGLE TEMPERATURE WITH BUILDING RECIRCULATION

Piping diagram for three heaters with building recirculation.

WATER PIPING DIAGRAMS (cont.)

FOUR WATER HEATERS, SINGLE TEMPERATURE WITH BUILDING RECIRCULATION

Piping diagram for four heaters with building recirculation.

LIMITED WARRANTY

EFFECTIVE

Defines the warranty period for tank and parts.

WHAT'S COVERED

Details what is covered under the limited warranty.

WHAT'S NOT COVERED

Lists exclusions from the limited warranty coverage.

LIMITATIONS

States the limitations and disclaimers of the warranty.

SERVICE INQUIRIES

Provides information for service inquiries.

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