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A.O. Smith CYCLONE Xi BTH 500A User Manual

A.O. Smith CYCLONE Xi BTH 500A
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1
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED 0307 197373-003
CYCLONE Xi
®
Model BTH 300A, 400A, 500A
COMMERCIAL GAS WATER HEATER
GAS-FIRED POWER BURNER
FOR DOMESTIC HOT WATER
Thank you for buying this energy efcient water heater from
A.O. Smith Water Products Company. We appreciate your
condence in our products.
CAUTION
TEXT PRINTED OR OUTLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY. PLEASE
READ THOROUGHLY BEFORE INSTALLING AND USING
THIS APPLIANCE.
• INSTALLATION • OPERATION • SERVICE • MAINTENANCE • LIMITED WARRANTY
WARNING: If the information in these
instructions is not followed exactly, a re
or explosion may result causing property
damage, personal injury or death.
Do not store or use gasoline or other
ammable 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 re department.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
www.hotwater.com

Table of Contents

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A.O. Smith CYCLONE Xi BTH 500A Specifications

General IconGeneral
CategoryWater Heater
BrandA.O. Smith
ModelCYCLONE Xi BTH 500A
Gas TypeNatural Gas
Fuel TypeNatural Gas

Summary

General Safety Warnings and Precautions

WARNING: Fire and Explosion Risk

Precise adherence to instructions is vital to prevent fire or explosion, averting property damage, injury, or death.

What to Do If You Smell Gas

Immediate actions for gas detection: do not use electricity/phones, call supplier from neighbor's phone.

Safety Information Highlights

Red text indicates critical safety information that must be read and understood before installation and use.

Technical Specifications and Capacities

Rough-In Dimensions Diagram

Illustrates critical installation clearances, connection points, and overall unit dimensions.

Recovery Capacities Table

Provides water recovery rates (GPH/LPH) across a range of temperature rises for different models.

Unit Features and Temperature Control

Water Temperature Control System

Details the system for adjusting and monitoring water temperature, including safety considerations.

DANGER: Hot Water Scalding Hazard

Emphasizes severe burn risk from hot water, especially for vulnerable individuals; advises on safe usage.

Quick Installation Overview and Venting

Quick Installation Tips Diagram

Visual guide to essential installation points, connections, and clearances for rapid setup.

Venting Installation Guidelines

Illustrations showing requirements for sidewall and rooftop venting, crucial for safe exhaust and air intake.

Temperature Settings and Safety Limits

Adjusting Water Temperature Setpoint

Procedure to set desired water temperature and understand scald risk factors related to usage patterns.

High Limit Switch (E.C.O.) Function

Explains the high limit switch's safety role in preventing overheating by shutting off the burner.

Dishwashing Machine Requirements

Specifies water pressure and temperature needs for effective dishwashing sanitation.

Installation Requirements and Location Safety

Circulating Pump Installation

Guidance on electrical hookup and code compliance for installing a circulating pump.

Required Installer Ability

Defines the essential skills equivalent to a licensed tradesman for installation and service.

Insulation Blankets Advisory

Information on the use of insulation blankets, including restrictions and potential risks if improperly applied.

Heater Location Guidelines

Critical warnings on safe placement, avoiding physical damage, noise, flammable materials, freezing, and leaks.

Condensate Drain Requirements

Instructions ensuring proper condensate drainage to prevent unit malfunction and operational hazards.

Installation Clearances and Air/Vapor Concerns

Minimum Installation Clearances

Diagram and details for maintaining required clearances from combustible materials and for service access.

Hard Water Treatment Recommendations

Advice on water softening or treatment to protect equipment from hard water deposits.

Air Supply Requirements

Crucial information on providing adequate combustion and ventilation air to prevent hazardous conditions.

Chemical Vapor Corrosion Warning

Alerts regarding corrosive chemicals that can damage the vent system and pose asphyxiation risks.

State-Specific Installation and Venting Rules

Massachusetts CO Detector and Signage Rules

Mandatory requirements for CO detectors, signage, and inspection in Massachusetts installations.

Gas Equipment Venting System Requirements

Manufacturer guidelines for installing provided or external venting systems for gas appliances.

Venting System Safety Warning

Critical warning to follow venting instructions to avoid combustion issues, fire, or asphyxiation.

Direct Vent Terminal Location Requirements

US Direct Vent Terminal Clearances

Diagrams detailing minimum clearances for direct vent terminals in US installations, covering various scenarios.

Canadian Direct Vent Terminal Clearances

Diagrams detailing minimum clearances for direct vent terminals in Canadian installations, covering various scenarios.

Air Intake Caution for Venting

Warning to maintain maximum practical distance between air intake and exhaust to prevent recirculation.

Horizontal Vent Terminal Location Requirements

US Horizontal Vent Terminal Clearances

Diagrams showing minimum clearances for horizontal vent terminals in US installations.

Canadian Horizontal Vent Terminal Clearances

Diagrams showing minimum clearances for horizontal vent terminals in Canadian installations.

Venting Distance Recommendation

Advice to maximize distance between terminals to prevent air intake contamination in windy/cold conditions.

Vent Pipe Installation and Direct Venting

Vent Pipe Termination Guidelines

Instructions for determining and installing vent pipe termination points, avoiding noise and vibration.

Direct Venting Requirements

Specific instructions for direct venting, including removing guards and connecting intake pipes.

Direct Vent Terminal Installation

Notes and specifications for installing direct vent terminals on sidewalls.

Vent Terminal Installation Procedures

Sidewall Vent Terminal Installation Sequence

Step-by-step guide for installing vent terminals through sidewalls, including cutting openings.

Vertical Vent Terminal Installation Requirements

Specifications for terminating vent pipes through roofs, ensuring proper support and sealing.

Vent System Installation Details

Vent System Installation Warning

Critical warning to keep venting separate from other systems to prevent operational hazards, fire, or explosion.

Vent Pipe Length and Elbow Limitations

Table and guidelines on maximum vent pipe lengths and the number of elbows allowed for intake and exhaust.

Vent Pipe Material and Slope

Information on approved PVC, CPVC, ABS pipe materials and the required downward slope for condensate drainage.

Controls, Switches, and Vent Pipe Prep

Vent Pipe Preparation and Material Selection

Detailed steps for preparing PVC, ABS, or CPVC pipes and selecting appropriate primers and cements.

Pressure Switch Functions

Explanation of the four pressure switches (Blower Prover, Blocked Outlet, Blocked Inlet, Low Gas) and their safety roles.

On/Off Switch Operation

Description of the ON/OFF switch's function for powering the unit on and off.

Gas Piping and Ignition System

Hot Surface Igniter Operation

Explanation of the hot surface igniter's role in lighting the main burner safely and efficiently.

Gas Piping Installation and Sizing

Guidelines for gas piping installation, including sizing based on capacity tables and pressure drop.

Gas Supply Pressure Warnings

Critical warnings regarding maximum gas supply pressures and potential hazards of overpressure or underpressure.

Gas Pipe Connections and Leak Testing

Instructions for connecting gas pipes, including the use of dirt legs and performing essential leak tests.

System Connections and Safety Devices

Relief Valve Installation and Maintenance

Details on the temperature and pressure relief valve, its function, and critical warnings about its use and maintenance.

Water Line Connections

References to installation diagrams for proper water line connections.

Closed System Considerations

Explanation of potential issues with closed water systems, thermal expansion, and required precautions.

Gas Line Purging and Safety

Instructions and safety warnings for properly purging gas lines to remove air before operation.

Electrical and System Operation

Water Heating and Space Heating Applications

Guidelines for using the unit for potable water and space heating, including chemical restrictions.

Heater Wiring and Electrical Requirements

Instructions for wiring the heater, emphasizing clean electricity, polarity sensitivity, and code compliance.

BTH 300 Wiring Diagram

BTH 300 Electrical Connections

Detailed wiring diagram showing connections for the BTH 300 model, including all components and terminals.

BTH 400 & 500 Wiring Diagram

BTH 400/500 Electrical Connections

Detailed wiring diagram illustrating connections for the BTH 400 and 500 models, covering all components.

Electronic Control and Operation Sequence

Sequence of Appliance Operation

Step-by-step description of the water heater's operating sequence from startup to shutdown.

Electronic Control Overview

Introduction to the electronic control interface, buttons, and display screens for operation.

Status Icons and Operating States

Explanation of the graphical icons and text descriptions indicating the heater's current operational status.

Adjusting Operating Set Point and Temperatures

Adjusting the Operating Set Point

Procedure for changing the water temperature setpoint and understanding related temperature readings displayed.

Display Settings and Fault/Warning Conditions

Changing Display Units and Settings

Instructions for customizing display units (Fahrenheit/Celsius), backlight, and contrast on the LCD screen.

Fault and Warning Condition Types

Explanation of the two types of conditions (Warnings and Faults) detected by the control system and their implications.

Fault Handling and Diagnostics

Fault Condition Details

Description of fault conditions that halt heating, requiring correction, and accessing advanced diagnostics for resolution.

Fault History and Heater Information

Viewing the Fault History

How to access and review a log of past faults and warnings, including diagnostic details for each event.

Viewing Heater Information

Accessing detailed operational data and status of specific conditions through the control interface menus.

Pre-Startup Procedures and Initial Adjustment

Required Ability for Startup

Specifies the essential skills and test equipment necessary for performing initial startup procedures safely.

Operating Instructions and Filling Procedure

Essential steps for filling the heater with water, purging air, and preparing it for initial operation.

Initial Start-Up Adjustment Procedure

Detailed steps for adjusting gas pressure and checking operation during the initial startup phase.

Lighting and Safe Operation

Safety Precautions Before Operation

Crucial safety warnings and immediate actions for gas leaks, hot surface igniters, and general operation procedures.

Operating Instructions Step-by-Step

Numbered steps for safely operating the water heater, including thermostat setting and gas control knob usage.

High Altitude, Protection, and Maintenance

High Altitude Installation Considerations

Information on heater certification for altitudes up to 10,000 feet and requirements for higher installations.

Cathodic Protection and Hydrogen Gas Hazard

Warnings about hydrogen gas production in idle systems and precautions to take before using hot water.

General Maintenance Overview

Introduction to maintenance tasks including flushing, cleaning, inspection, and component checks.

Maintenance Schedule

A table outlining the recommended maintenance schedule for various components of the water heater.

Tank Flushing, Draining, and Scale Removal

Flushing Procedure

Steps for flushing the water heater to remove sediment and debris from the tank.

Draining Procedure

Instructions for draining the heater, essential for shutdown, freezing prevention, or maintenance.

Sediment and Lime Scale Removal

Methods for removing sediment and lime scale from the tank, including product recommendations and scheduling.

System Components and Vent Maintenance

Powered Anode System

Description of the powered anode system designed to ensure a long, trouble-free operating life.

Drain Valve and Access Panels

Information on the location and function of the drain valve and access panels.

Relief Valve Checking and Troubleshooting

Procedure for checking the relief valve's operation and addressing potential issues like thermal expansion or faulty valves.

Vent System Inspection and Cleaning

Guidelines for inspecting and cleaning the vent system components to ensure proper operation and safety.

Installation Diagrams - Single Heater Systems

Vertical Storage Tank Diagram

Diagram showing installation for a single heater with a vertical storage tank, including circulation options.

Horizontal Storage Tank Diagram

Diagram illustrating installation for a single heater with a horizontal storage tank, including circulation options.

Installation Diagrams - Two Temperature Systems

One Heater, High Temp System Diagram

Diagram for a two-temperature, one-heater system with high temperature capabilities and recirculation options.

Installation Diagrams - Multi-Heater Systems

Two Heaters, High Temperature Diagram

Diagram for a two-heater system with high temperature output, with or without recirculation.

Three Heaters (Two Pre-Heaters/One Booster) Diagram

Diagram for a three-heater system configuration, including pre-heaters and a booster.

Installation Diagrams - Special Multi-Heater Configurations

One Pre-Heater/One Booster Heater Diagram

Diagram for a system with one pre-heater and one booster heater, detailing connections and temperature settings.

Installation Diagrams - Recirculation Systems

Sanitizing Loop Recirculation Diagram

Diagram illustrating a two-temperature system with recirculation of a sanitizing loop, including dishwasher connections.

Multiple Unit Installation Guidelines

Multiple Unit Installation Overview

General principles for installing multiple water heaters to ensure balanced flow and storage potential.

Two, Three, and Four Unit Installation Layouts

Diagrams showing minimum space requirements and manifold connections for two, three, and four unit installations.

Troubleshooting and Service Checklist

Burner Operational Problems

Guidance on diagnosing and resolving issues related to burner operation, including no hot water or improper firing.

Water Heater Sounds and Leakage

Information on common sounds and potential water leakage issues, including causes and checks.

General Troubleshooting Steps

A checklist of common troubleshooting steps for various operational issues, including vent, gas supply, and polarity checks.

Advanced Troubleshooting - Motor and Flame Issues

Motor Will Not Run Troubleshooting

Steps to diagnose why the motor is not running, checking voltage, polarity, and VFD status.

Flame Establishment Issues

Troubleshooting steps for when the burner lights but fails to sustain ignition, checking gas pressure and igniter.

Momentary Burner Ignition Lockout

Guidance for issues where the burner lights briefly then shuts down, focusing on gas pressure and polarity.

Operation Issues and Replacement Parts

Noisy Burner Operation

Information on causes of noisy burner operation and methods to mitigate it, including air/gas ratio tuning.

Gas Shutoff Failure

Troubleshooting steps for when the gas fails to shut off, focusing on defective valves or thermostats.

Ordering Replacement Parts

Instructions on how to order replacement parts from A.O. Smith, including necessary information.

Limited Warranty Information

Tank and Parts Warranty Coverage

Details on the warranty coverage for the tank and other parts, including conditions, exceptions, and limitations.

Warranty Service and Claims Procedure

Information on how to initiate a warranty claim and the responsibilities of the owner and warrantor.

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