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A.O. Smith BTR 118 SERIES Service Handbook

Manual is about: COMMERCIAL GAS HIGH EFFICIENCY WATER HEATERS

Summary of BTR 118 SERIES

  • Page 1

    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 & servic...

  • Page 2: Table of Contents

    1 table of contents introduction .......................................................................................2 qualifications ................................................................................2 service warning ....................................................................

  • Page 3: Introduction

    2 servicing should only be performed by a qualified service technician introduction this service handbook covers the water heater model and series numbers listed on the front cover only. The instructions and illustrations contained in this service handbook will provide you with troubleshooting proce...

  • Page 4: Installation Considerations

    3 servicing should only be performed by a qualified service technician installation considerations this section of the service handbook covers some of the critical installation requirements that, when overlooked, often result in operational problems, down time and needless parts replacement. Costs t...

  • Page 5: Venting

    4 servicing should only be performed by a qualified service technician venting this section of the service handbook is not a complete venting installation instruction. Refer to the instruction manual that came with the water heater; ensure the venting has been installed per all instruction manual re...

  • Page 6

    5 servicing should only be performed by a qualified service technician power vent kits for sidewall venting btr water heaters can be used with power vent kits for sidewall venting. A. O. Smith offers power vent kits for use on installations with a maximum of 100 equivalent feet of vent piping. The p...

  • Page 7: Gas Supply Systems

    6 servicing should only be performed by a qualified service technician gas supply systems low pressure building gas supply systems are defined as those systems that cannot under any circumstances exceed 14” w.C. (1/2 psi gauge). These systems do not require pressure regulation. Measurements should b...

  • Page 8

    7 servicing should only be performed by a qualified service technician gas piping contact your local gas service company to ensure that adequate gas service is available and to review applicable installation codes for your area. Size the main gas line in accordance with table below. The figures show...

  • Page 9

    8 servicing should only be performed by a qualified service technician to trap any dirt or foreign material in the gas supply line, a sediment trap must be incorporated in the piping (see figure below). The sediment trap must be readily accessible and not subject to freezing conditions. Install in a...

  • Page 10: Features And Components

    9 servicing should only be performed by a qualified service technician features and components the eliminator (self-cleaning system) these units include the eliminator (self-cleaning system) installed in the front water inlet. The eliminator inlet tube can only be used in the front water inlet conne...

  • Page 11: Gas Control Valve

    10 servicing should only be performed by a qualified service technician gas control valve • inlet screen helps protect from debris. • tamper resistant screws. • conveniently located on/off switch. • inlet and outlet pressure taps. • adjustable gas regulator. Note: on/off switch must be in the on pos...

  • Page 12

    11 servicing should only be performed by a qualified service technician white rodgers integrated temperature control-high limit switch the digital thermostat contains the high limit (energy cutout) switch. The high limit switch interrupts main burner gas flow should the water temperature reach 203°f...

  • Page 13

    12 servicing should only be performed by a qualified service technician electronic ignition control/ ignition module each heater is equipped with a honeywell ignition module. The solid state ignition control ignites the pilot burner gas by creating a spark at the pilot assembly. Pilot gas is ignited...

  • Page 14

    13 servicing should only be performed by a qualified service technician sequence of operation flow chart.

  • Page 15: Troubleshooting Checklist

    14 servicing should only be performed by a qualified service technician troubleshooting checklist complaint cause remedy user qualified service agency water not hot enough. Thermostat set too low. Set thermostat dial to a higher temperature. Upper and/or lower temperature probe out of calibration. C...

  • Page 16: General Service Chart

    15 servicing should only be performed by a qualified service technician general service chart condition cause solution damper opens no power to iid module • damper not fully open • replace damper. • defective protector switch • replace pc board. Pilot lights, sparks continuously pilot flame not prov...

  • Page 17

    16 servicing should only be performed by a qualified service technician fault and warning codes - continued step 1. Troubleshooting the btr water heaters check/repair: • check that 120 vac is supplied to the heater. • make sure the tank is full of water. • make sure the gas is supplied to the unit. ...

  • Page 18

    17 servicing should only be performed by a qualified service technician harness chart heater harness function damper harness black 24v hot 1 - brown yellow 24v from thermostat 2 - orange red 24v from damper 3 - yellow white 24v common 4 - black condition: • damper closed. • high limit closed. Flue d...

  • Page 19

    18 servicing should only be performed by a qualified service technician effikal rvgp-ksf-series flue damper troubleshooting guide do not turn damper open manually or motor damage will result, use the service switch. All readings are taken from harness receptacle. Do not push meter leads into harness...

  • Page 20

    19 servicing should only be performed by a qualified service technician step 2: test for 24vac between black and orange on damper pc board if then 24vac is present - damper not opening • check service switch position. Replace damper assembly. 24vac is not present. • check wiring harness to thermosta...

  • Page 21

    20 servicing should only be performed by a qualified service technician visually inspect the fuse to see if it is blown, the inside of the fuse can appear dark, discolored and burnt. The link also will be broken inside. Symptoms for a blown fuse • power, call for heat, reset status and eco status li...

  • Page 22

    21 servicing should only be performed by a qualified service technician step 4: test for 24vac between black and yellow on damper pc board if then 24vac is present • this is correct - continue to step 5. 24vac is not present. • check service switch position. • check the harness plug connections. • c...

  • Page 23

    22 servicing should only be performed by a qualified service technician step 6: iid module test (power to the pilot valve) condition: • 24vac to module, no pilot. Using a multimeter, test for 24 vac between terminal pv and 24 v (gnd) on the iid during the 90 second trial for ignition. If then the me...

  • Page 24

    23 servicing should only be performed by a qualified service technician step 7: pilot spark test condition: • 24vac at pv, no pilot. Visually/audibly check for spark at the pilot assembly. Note: the pilot burner mounts on the left side of the main burner. If then the igniter is not sparking during t...

  • Page 25

    24 servicing should only be performed by a qualified service technician step 8: flame rectification condition: • pilot flame noted, pilot sparking continues, no main burner. Note: flame rectification means that an alternating current (ac) signal is changed to a direct current (dc) signal. The pilot ...

  • Page 26

    25 servicing should only be performed by a qualified service technician step 9: iid module test condition: • pilot flame noted, no sparking, no main burner. Using a multimeter, test for 24 vac between terminal mv on the iid and 24v (gnd). If then 24 vac is not present: • replace the iid module. Chec...

  • Page 27

    26 servicing should only be performed by a qualified service technician step 10: main burner test condition: • pilot flame noted, main burner check. Visually check for main burner. If then the main burner ignites: • sequence is complete. The main burner does not ignite. • check gas supply. • check g...

  • Page 28

    27 servicing should only be performed by a qualified service technician wiring diagram - btr 118/119 series.

  • Page 29

    28 servicing should only be performed by a qualified service technician wiring diagram - btr 118/119 series controls.

  • Page 30: Notes

    29 servicing should only be performed by a qualified service technician notes.

  • Page 31

    Commercial gas water heaters for additional information contact: a. O. Smith corporation 500 tennessee waltz parkway ashland city, tn 37015 tech support: 800-527-1953 parts: 800-433-2545 www.Hotwater.Com copyright © 2016 a. O. Smith water heater company, all rights reserved..