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  5. Service Handbook

A.O. Smith 120 trough 500 Service Handbook

Manual is about: Series 100-109

Summary of 120 trough 500

  • Page 2

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 1 btr handbook table of contents page page troubleshooting (continued) introduction 1-2 troubleshooting the efflkal 30-31 wire harness test 32 installation iid module 33 clearanc...

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 2 qualifications: installation or service of this water heater requires ability equivalent to that of a licensed tradesman in the field involved. Plumbing, air supply, venting, g...

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 3 installation this portion of the handbook will review some often overlooked installation considerations, taking note of necessary installation requirements for the btr 120 thro...

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 4 exterior clearance this illustrates the exterior roof clearances for btr units with natural draft venting. The vent shall extend at least 3 feet above the highest point where i...

  • Page 6: 10 Cu.

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 5 air for combustion 10 cubic feet of air per 1,000 btu stoichiometric or theoretical complete combustion requires 10 cubic feet of air per 1000 btuh input of the gas input. The ...

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 6 make-up air direct communication a fresh supply of make-up air for combustion can be supplied to the heater through make-up air ducts which directly communicate with the out of...

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 7 make-up air vertical ducts often it is more practical to install vertical make-up air ducts to the out doors. Again, two openings are required - one within 12 inches of the top...

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 8 make-up air horizontal ducts when the heater is installed in an interior room with no roof access for vertical ducts, horizontal make-up air ducts should be installed. When usi...

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 9 insufficient make-up air backdraft insufficient make-up air is a major cause of combustion problems. One common example is in a restaurant installation where exhaust vent equip...

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 10 contaminated air along with adequate make-up air, the quality of the air is important. Contaminants in combustion air can lead to premature heater failure. Vapors from bleache...

  • Page 12: Supply Gas

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 11 gas pressure requirements natural gas propane gas maximum supply pressure 13.8" w.C. 13.8" w.C. Minimum supply pressure 4.5" w.C. 11" w.C. Manifold pressure 3.5 " w.C. 10" w.C...

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 12 btr gas valve the gas valves used on all btr water heaters are 24 volt ac combination step opening gas valves. They incorporate the pilot valve, main valve, and gas pressure r...

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 13 venting atmospheric multiple heaters all btr water heaters are classified by ansi as category i (non-condensing, negative pressure venting) appliances. They are approved for t...

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 14 draft inducer draft inducers can be used with btr water heaters to mechanically aid a lazy chimney in vertical vent applications. They are not designed to allow “through-the-w...

  • Page 16

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 15 power vent kits for sidewall venting water heater models part number btr-120-200 193933-0 btr-250-500 193933-1 btr water heaters can be used with power vent kits for sidewall ...

  • Page 17

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 16 btr sequence of operation 1. Thermostat calls for heat 2. Flue damper opens 3. Intermittent ignition control 5. Main gas valve opens 7. Thermostat satisfies 4. Pilot gas opens...

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 17 btr electrical sequence 100 – 109 series.

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 18 btr electrical sequence of operation m o to r o p e n s d a m p e r p o w e r to d a m p e r # 2 in te rru p te d s e rie s 1 1 0 a n d 1 1 1 e ffika l s e rie s 1 1 0 a n d 1...

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 19 troubleshooting btr water heaters to troubleshoot a btr water heater check that: • 120 vac is supplied to the heater • the tank is full of water • gas is supplied to the unit ...

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 20 step 2 high limit, left terminal test step 2. High limit, left terminal test. Test for 24 vac between the left high limit terminal and ground. If then the meter does not read ...

  • Page 22

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 21 step 3 test high limit right terminal step 3. To test high limit right terminal. Ensure that the jumper wire between the high limit and thermostat is connected, and the damper...

  • Page 23

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 22 step 4 inspect the damper step 4. Inspect the damper. Lower the thermostat setting so the unit will not be calling for heat, then inspect the damper. If then if the damper is ...

  • Page 24

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 23 step 6 pc board motor test step 6. Pc board/motor test. Check for 24 vac between the two motor lead terminals of the pc board. Disconnect the wires for this test. If then 24 v...

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    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 24 step 7 thermostat test step 7. Thermostat test. Set the thermostat to call for heat. Using your multimeter, test for 24 vac between right terminal and ground. If then the mete...

  • Page 26

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 25 go to page 27 for damper tests of effikal equipped (series 110, 111 and retrofit) models step 8 damper input test step 8. Damper input test. Test for 24 vac between the yellow...

  • Page 27

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 26 step 10 test damper output step 10. Test damper output. On a call for heat, the damper relays receives power through the yellow wire and power to the motor is interrupted. The...

  • Page 28

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 27 damper 1 2 3 4 bl a c k red ye llo w wh it e orange brown yellow black male plug from heater 2 1 3 4 female plug effikal damper btr series 110 and 111 began using the motor op...

  • Page 29

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 28 harness chart heater harness function damper harness black 24v hot 1-brown yellow 24v from therm 2-orange red 24v from damper 3-yellow white 24v common 4-black series 110 and ...

  • Page 30

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 29 normal operation (continued) condition: • thermostat closed, damper in process of opening step b test for 24vac between black and orange if then 24vac is present continue to s...

  • Page 31

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 30 troubleshooting the effikal style damper condition: thermostat closed, damper step a1 test between black (common) and brown on the damper board if then 24vac is present this i...

  • Page 32

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 31 troubleshooting the effikal style damper (continued) condition: thermostat closed, damper is open fully step a3 test for 24vac between black and yellow if then 24vac is presen...

  • Page 33

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 32 step 11 wire harness test step 11. Wire harness test. Test for 24 vac between terminal 24v on the iid module, and 24v (gnd). If then 24 vac is not present: • check the wiring ...

  • Page 34

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 33 step 12 iid module test step 12. Iid module test (power to the pilot valve). Using a multimeter, test for 24 vac between terminal pv and 24v (gnd) on the iid during the 90 sec...

  • Page 35

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 34 step 13 pilot spark test step 13. Pilot spark test. Visually check for spark at the pilot assembly. Note: the pilot burner mounts on the left side of the main burner. If then ...

  • Page 36

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 35 step 14a pilot valve - ohm test btr 120 – 400 gas valve step 14a. Pilot valve - ohm test. If pilot assembly is sparking but no pilot flame is established, disconnect the pilot...

  • Page 37

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 36 step 14b pilot valve test – btr 500 only step 14b. Pilot valve test – btr 500 only. Testing the two coils of the honeywell vr8404p 5004 gas valve used on the model btr 500 onl...

  • Page 38

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 37 step 15 main burner test note: btr series 108 and 109 implemented a new main burner stamping process – burners appear the same as illustrated. Step 15. Main burner test. Visua...

  • Page 39

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 38 step 16 flame rectification step 16. Flame rectification note: flame rectification means that an alternating current (ac) signal is changed to a direct current (dc) signal. Th...

  • Page 40

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 39 step 17 iid module test pilot is lit - sparking has stopped. Step 17. Iid module test (power to the main valve). Using a multimeter, test for 24 vac between terminal mv on the...

  • Page 41

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 40 step 18a main gas valve check btr 120 – 400 gas valve step 18a. Main gas valve check. Disconnect wires from gas valve th and tr terminals. Using a multimeter, test for 68 ohms...

  • Page 42

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 41 step 18b main gas valve coil check step 18b. Main gas valve coil check – btr 500 only condition: • pilot lights • sparking stops • no main burner ignition test procedure: • po...

  • Page 43

    Btr tank type heaters service handbook a.O. Smith water products service handbook irving, texas ©2000 training department 42 btr wiring diagram - natural and propane gas honeywell ignition system (110 – 109 series) if any of the original wire as supplied must be replaced, use only type 105° c thermo...

  • Page 44

    Btr tank type heaters service workbook a.O. Smith water products service handbook irving, texas ©2000 training department 43 general service chart condition cause solution damper opens no power to iid module . Damper not fully open . Defective protector switch .Effikal – replace damper control assem...

  • Page 45

    Btr tank type heaters service workbook a.O. Smith water products service handbook irving, texas ©2000 training department 44 general questions and answers q. What changes caused series 106/107 and 108/109 to be implemented? A. The 106 and 107 series units changed from the momentary push button to a ...

  • Page 46

    Btr tank type heaters service workbook a.O. Smith water products service handbook irving, texas ©2000 training department 45 btr models 197 and 198 series 100-101.

  • Page 47

    Btr tank type heaters service workbook a.O. Smith water products service handbook irving, texas ©2000 training department 46 btr models 197 and 198 (continued) series 100-101.

  • Page 48

    Btr tank type heaters service workbook a.O. Smith water products service handbook irving, texas ©2000 training department 47 parts list for btr models 197 and 198 series 100 & 101 item parts description btr 197 btr 198 1 bracket for main burner orifice............... 098044(5) 098044(5) 2 main burne...

  • Page 49

    Btr tank type heaters service workbook a.O. Smith water products service handbook irving, texas ©2000 training department 48 btr models 120 through 500 series 104-105.

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    Btr tank type heaters service workbook a.O. Smith water products service handbook irving, texas ©2000 training department 49 btr models 120 through 500 (continued) series 104-111.

  • Page 51

    Btr tank type heaters service workbook a.O. Smith water products service handbook irving, texas ©2000 training department 50 parts list for btr models 120 through 500(a) series 104 through 109 series (series 106/107 have a service switch on circuit board 6522; series 108/109 have new main burner pro...

  • Page 52

    Btr tank type heaters service workbook a.O. Smith water products service handbook irving, texas ©2000 training department 51 component part information name specifications aos part numbers dual controller thermostat 120-180 o range, + 4 o , 5 o differential, liquid filled, anti- stacking aos # 19282...

  • Page 53

    Btr tank type heaters service workbook a.O. Smith water products service handbook irving, texas © 1999 training department 52 btr service checklist (this service checklist may be photo copied to assist with btr service call.) this checklist is intended to aid the service agent in determining that th...

  • Page 54

    Btr tank type heaters service workbook a.O. Smith water products service handbook irving, texas © 1999 training department 53 is the system properly sized? Yes no is the system properly installed? Yes no are there any water leaks? Yes no does the installation have a recirculating system? Yes no if s...

  • Page 55

    Btr tank type heaters service workbook a.O. Smith water products service handbook irving, texas © 1999 training department 54 comments author: terry mulder.