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A.O. Smith BTR 120-400 - User Manual

A.O. Smith BTR 120-400
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COMMERCIAL GAS HIGH EFFICIENCY WATER HEATERS
Service Handbook
PRINTED IN THE U.S.A. 1016 100277701_2000536453_Rev A
500 Tennessee Waltz Parkway
Ashland City, TN 37015
FOR MODELS:
BTR 120 thru 400(A) Series 118 & 119
INSTALLATION CONSIDERATIONS - PRE SERVICE CHECKS -
CONSTRUCTION - OPERATION & SERVICE - TROUBLESHOOTING
SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN

Questions and Answers

  • K
    Katie WiseAug 12, 2025
    Why is there insufficient hot water from my A.O. Smith BTR 120-400 Water Heater?
    • T
      Tamara GriffinAug 12, 2025
      If you're not getting enough hot water from your A.O. Smith Water Heater, first, make sure the thermostat isn't set too low by adjusting it to a higher temperature. Also check if the main manual gas shutoff valve is fully opened. If the heater is too small for your needs, try spacing out your usage to allow the heater more time to reheat the water.
  • W
    William WrightAug 16, 2025
    How to fix not hot enough water in A.O. Smith BTR 120-400?
    • V
      Victor ButlerAug 16, 2025
      If your A.O. Smith Water Heater isn't heating water enough, try adjusting the thermostat to a higher temperature. If the problem persists, it could be due to upper or lower temperature probes being out of calibration, in which case you should call a qualified service agency to check and replace them if necessary.
  • S
    Sherry KellyAug 19, 2025
    How to stop water leaks from A.O. Smith BTR 120-400?
    • D
      Desiree DavenportAug 20, 2025
      If your A.O. Smith Water Heater is leaking water, it might be due to the drain valve not being closed tightly. Try closing it tightly, and if it still leaks, replace the valve. If you cannot identify the source of the leak, shut off the gas and cold water supply to the heater and call a qualified service agency.
  • J
    Joshua SavageAug 23, 2025
    What to do if water temperature is too hot in A.O. Smith Water Heater?
    • M
      Michael BrownAug 23, 2025
      If the water from your A.O. Smith Water Heater is too hot, the thermostat might be set too high. Try setting the thermostat to a lower setting.
  • S
    stokesrobertAug 27, 2025
    What to do if I smell gas odors from A.O. Smith Water Heater?
    • B
      bcampbellAug 27, 2025
      If you notice gas odors coming from your A.O. Smith Water Heater, it could be due to the heater being overfired or possible gas leaks. Immediately shut off the gas supply to the heater and call a qualified service agency or your gas company.
  • K
    Kimberly ScottAug 31, 2025
    Why is my A.O. Smith BTR 120-400 Water Heater rumbling?
    • V
      valdezangelaAug 31, 2025
      If your A.O. Smith Water Heater is making rumbling noises, it's likely due to sediment accumulation at the bottom of the tank. Try draining some water through the drain valve to remove the sediment. If the rumbling continues, you may need to call a qualified service agency to delime the heater.
  • C
    Christian MasonSep 4, 2025
    What causes pounding or water hammer in A.O. Smith Water Heater?
    • A
      Amy KingSep 4, 2025
      If your A.O. Smith Water Heater is making pounding or water hammer noises, it could be because the air chambers in the piping have become waterlogged, or the thermal expansion tank is damaged, improperly charged, or improperly sized. Try draining the piping system and refilling it, making sure the heater is off during this process. Also, check the thermal expansion tank charge pressure when the water system pressure is zero.
  • L
    lesliebrownSep 7, 2025
    What causes combustion noises in A.O. Smith BTR 120-400?
    • F
      Frank JacksonSep 8, 2025
      Combustion noises in your A.O. Smith Water Heater may be caused by too much primary air. Try adjusting the shutters. Alternatively, the heater might be overfired or have incorrect burners for the gas type used, which requires a call to a qualified service agency for checking and correction.

Summary

INTRODUCTION

QUALIFICATIONS

Required skills and expertise for installation and service personnel.

SERVICE WARNING

Crucial advisory against non-qualified service personnel performing tasks.

SERVICE REMINDER

Advice on performing troubleshooting steps carefully and inspecting connections.

TOOLS RECOMMENDED

List of essential tools required for servicing the water heater.

INSTALLATION CONSIDERATIONS

INSTRUCTION MANUAL

Reference to the primary installation guide for comprehensive instructions.

CLOSED WATER SYSTEMS

Discussion of implications for water systems configured as closed loops.

THERMAL EXPANSION

Explanation of water expansion upon heating and its potential effects.

AIR REQUIREMENTS

Importance of adequate combustion and ventilation air for safety and performance.

CONTAMINATED AIR

Impact of air quality on heater components and lifespan.

VENTING

POWER VENT KITS FOR SIDEWALL VENTING

Information regarding the use and installation of sidewall power vent kits.

GAS SUPPLY SYSTEMS

SUPPLY GAS REGULATOR

Guidelines for selecting and installing gas pressure regulators.

GAS PIPING

GAS PIPING AND SEDIMENT TRAP INSTALLATION

Details on gas line setup, including sediment trap installation.

PURGING

Procedure for safely removing air from gas supply lines.

FEATURES AND COMPONENTS

THE ELIMINATOR (SELF-CLEANING SYSTEM)

Explanation of the self-cleaning feature for water inlet.

AUTOMATIC FLUE DAMPER

Description of the component that reduces heat loss during off cycles.

UNCRATING

Initial steps for unpacking and preparing the water heater.

GAS CONTROL VALVE

GAS PRESSURE SPECIFICATIONS

Required gas pressures for natural and propane operation.

WHITE RODGERS INTEGRATED TEMPERATURE CONTROL-HIGH LIMIT SWITCH

STATUS LEDS

Explanation of the indicator lights on the control unit.

ELECTRONIC IGNITION CONTROL;IGNITION MODULE

SEQUENCE OF OPERATION FLOW CHART

TROUBLESHOOTING CHECKLIST

GENERAL SERVICE CHART

FAULT AND WARNING CODES - CONTINUED

STEP 1. TROUBLESHOOTING THE BTR WATER HEATERS

Initial step in diagnosing issues with BTR water heaters.

EFFIKAL DAMPER

Specific troubleshooting information for the Effikal damper component.

EFFIKAL RVGP-KSF-SERIES FLUE DAMPER TROUBLESHOOTING GUIDE

STEP 2: TEST FOR 24 VAC BETWEEN BLACK AND ORANGE ON DAMPER PC BOARD

Diagnostic test for voltage on the damper PC board.

STEP 3: TEST THE THREE AMP FUSE

Procedure to check the integrity and function of the main fuse.

STEP 4: TEST FOR 24 VAC BETWEEN BLACK AND YELLOW ON DAMPER PC BOARD

Diagnostic test for specific voltage points on the damper PC board.

STEP 5: WIRE HARNESS TEST

Checks continuity and connections within the wire harness system.

STEP 6: IID MODULE TEST (POWER TO THE PILOT VALVE)

Tests the ignition module's output to the pilot valve.

STEP 7: PILOT SPARK TEST

Verifies that the pilot assembly is generating a spark.

STEP 8: FLAME RECTIFICATION

Checks for proper pilot flame sensing by the ignition module.

STEP 9: IID MODULE TEST

Further diagnostic tests for the Ignition Interruption Device (IID) module.

STEP 10: MAIN BURNER TEST

Confirms proper ignition and operation of the main burner.

WIRING DIAGRAM - BTR 118;119 SERIES

WIRING DIAGRAM - BTR 118;119 SERIES CONTROLS

NOTES

A.O. Smith BTR 120-400 Specifications

General IconGeneral
BrandA.O. Smith
ModelBTR 120-400
CategoryWater Heater
LanguageEnglish

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