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BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 Clearances 3-4 Pilot Spark 34 Air Requirements 5-9 Pilot Valve 35-36 Contaminated Air 10 Main Burner Test 37 Flammable 10 Flame Rectification 38 Gas Pressure 11 IID Module 39 Gas Valve 12 Main Gas Valve 40-41 Venting 13-15 Wiring Schematics Natural and Propane Gas 42 Sequence of Operation Mechanical 16 Service Charts 43 Electrical 17-18 General Questions & Answers 44 Troubleshooting Transformer 19 Parts List 45-50 High Limit 20-21 Damper (on Standby) 22 Component Part Information 51 PC Board 22-23 Thermostat 24 Service Check List 52-53 Damper (call for heat) 25-26 Effikal Damper 27 Comments 54 Effikal Harness Test 28 Normal Operation 28-29 BTR WORKBOOK INTRODUCTION This service handbook is designed to aid in servicing and troubleshooting A.O. Smith BTR water heaters in the field. No duplication or reproduction of this book may be made without the express written authorization of the A.O. Smith Water Products Company. The following text and illustrations will provide you with a step by step procedure to verify proper installation, operation, and troubleshooting procedures. Additional quick reference data is included to assist you in servicing this product. The information contained in this handbook is designed to answer common questions encountered in the operation of the BTR product line and is not meant to be all inclusive. If you are experiencing a problem not covered in this handbook, please contact the A.O. Smith Technical Information Department at 1-800-527- 1953 or your local A.O. Smith Water Products Company representative for further assistance. This handbook is intended for use by licensed plumbing professionals and reference should be made to the installation manual accompanying the product. This handbook contains supplemental information to the BTR installation and operation manual. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 1 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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, gas supply and electrical testing skills are required. Tools Required: • Phillips head screwdriver • standard screwdrivers • a 3/8 and 7/16 inch open end wrench • set of marked drill bits • an electrical multimeter tester capable of measuring continuity • gas pressure gauge or manometer (gauge - AOS pt. no. 8099-2) • water pressure gauge (AOS pt. no. 4798) • thermometer (AOS pt no. 4870 - range 0 - 220 degree F) • 1/2 inch socket with extension for removal of the clean out cover, • 1 1/16 inch socket with extension for anode removal. MISC: TC-043 Revision 1 vs. TC-043 Revision 1: • Adds Additional model's information. • Adds cover statement this Handbook's also a Service Handbook for many BTC Models. • Includes Power vent kit information. • Includes BTR/C-500 gas valve information. • Updated Damper illustrations. Revision2: • Revised Part Numbers on Page 15 Revision 3: • Adds information unique to the Efflkal damper equipped (Series 110, 111 and Retrofit) models A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 2 BTR TANK TYPE HEATERS SERVICE HANDBOOK INSTALLATION This portion of the handbook will review some often overlooked installation considerations, taking note of necessary installation requirements for the BTR 120 through 500 model heaters. The installation manual covers most of these items in detail. CLEARANCES FROM COMBUSTIBLES Clearance to Combustibles Table MODEL A B C 120 - 200 1" (2.54CM) 1" (2.54CM) 1" (2.54CM) 250 - 305 2" (5.08CM) 2" (5.08CM) 2" (5.08CM) 365 - 500 3" (7.75CM) 3" (7.75CM) 3" (7.75CM) A 24 inch clearance for all serviceable parts is recommended. Clearances may vary between BTR models – See instruction manual or the label on the heater, for clearances applicable to your specific model. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 3 BTR TANK TYPE HEATERS SERVICE HANDBOOK EXTERIOR CLEARANCE "Copyright by the American Gas Association. Used by permission of the copyright holder". 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 it passes through a roof of a building, and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet (for vents of 12" in diameter or less). (NFPA 54 ANSI Z 223.1 SEC 7.5.2a). (Sec 7.6.2a may allow reduction to 8 feet with a " Listed vent cap"). A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 4 BTR TANK TYPE HEATERS SERVICE HANDBOOK AIR FOR COMBUSTION 10 CUBIC FEET OF AIR PER 1,000 BTU 1 ,0 0 0 + 10 CU. FT. COMB. AIR B T U 2.5 CU. FT. EXCESS AIR Stoichiometric or theoretical complete combustion requires 10 cubic feet of air per 1000 BTUH input of the gas input. The National Fuel Gas Code also recommends an additional 2.5 cu.ft. of "excess" air. This 12.5 cu.ft minimum supply air per 1000 BTUH input applies to natural and propane gas models. The National Fuel Gas Code also specifies minimum make-up air opening sizes for various building installations. (Ref: NFPA 54, ANSI Z223.1, sec 5.3) A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 5 BTR TANK TYPE HEATERS SERVICE HANDBOOK MAKE-UP AIR DIRECT COMMUNICATION 1 Square Inch Per 4,000 BTUH 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 doors. Two openings are required - one within 12 inches of the top of the enclosure and one within twelve inches of the bottom of the enclosure. Each opening shall have a free area of not less than 1 square inch per 4000 BTUH of the total input of all appliances within the enclosure. The lower opening is primarily providing combustion air. The upper opening is providing vent dilution air and acts as a relief opening for flue gases should the vent become obstructed or a downdraft condition occur. Additionally, when the heater is installed in a confined space and communicating with the outdoor air, one permanent opening, commencing within 12 in. (30 cm) of the top of the enclosure, shall be permitted where the equipment has clearances of at least 1 in. (2.5 cm) from the sides and back and 6 in. (16 cm) from the front of the appliance. The opening shall directly communicate with the outdoors and shall communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors, and shall have a minimum free area of: a. 1 sq. in. per 3000 BTU per hr (7 cm2per kW) of the total input of all equipment located in the enclosure, and b. Not less than the sum of the areas of all vent connectors in the confined space. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 6 BTR TANK TYPE HEATERS SERVICE HANDBOOK MAKE-UP AIR VERTICAL DUCTS 1 Square Inch Per 4,000 BTUH 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 of the enclosure and one within twelve inches of the bottom of the enclosure. Each opening shall have a free area of not less than 1 square inch per 4000 BTUH of the total input of all appliances within the enclosure. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 7 Daily Schedule BTR TANK TYPE HEATERS SERVICE HANDBOOK MAKE-UP AIR HORIZONTAL DUCTS 1 Square Inch Per 2,000 BTUH 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 using horizontal ducts, two openings are required - one within 12 inches of the top of the enclosure and one within twelve inches of the bottom of the enclosure. Each opening shall have a free area of not less than 1 square inch per 2000 BTUH of the total input of all appliances within the enclosure. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 8 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 equipment was not considered in sizing make-up air requirements. This may result in air being backdrafted by the restaurant exhaust equipment through the heater causing flue gas spillage, flame roll out, improper combustion, inconsistent pilot operation, and/or erratic heater shut down. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 9 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 bleaches, soaps, waxes, salts, etc. are drawn into the combustion chamber with the make-up air and, once fired, mix with water vapor in the gases to form extremely corrosive hydrochloric or hydrofluoric acid and other corrosive byproducts. AIR FOR COMBUSTION Flammable Items Flammable items, pressurized containers or any other potentially hazardous articles must never be placed on or adjacent to the heater. Open containers of flammable material should not be stored or used in the same room with the heater. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 10 Supply Gas BTR TANK TYPE HEATERS SERVICE HANDBOOK GAS PRESSURE REQUIREMENTS Dirt Leg Manifold Gas Port Manifold Pressure Tap 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. The supply gas pressure is normally measured at the dirt leg or at the gas pressure tapping on the gas supply shutoff valve. This reading must be measured with 'flowing' gas. The manifold gas pressure is measured at the manifold pressure tap of the gas valve when the gas is flowing. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 11 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 regulators into one body. The inlet view of the valve features a filter screen and the top knob. The top knob is a manual on/off gas control for both the pilot and main gas valves. When the top knob is placed on the black mark, gas is supplied only to the pilot valve. On the top view, we see the pilot solenoid and pilot and main gas regulators. The top view also displays the "TH and "TR" terminals. The pilot gas regulator is found under its cover screw. It is factory preset at 3.5"w.c. but can be adjusted from 2.5 to 5 inches water column. The main gas regulator is found under its cover screw. It is factory preset to 3.5 inches w.c. and adjusts gas pressure output from 2.5 to 5 inches water column. The two electrical terminals are marked TH and TR. The TH terminal is the common between the pilot valve solenoid coil and the main valve solenoid coil. The other wire emerging from the pilot solenoid connects to the pilot valve electrical output on the IID (terminal PV). The TR terminal connects directly to the main valve electrical output from the IID module (terminal MV). On the outlet view of the gas valve, we see the pilot gas connection port, manifold gas connection port, a limited bleed vent port, the manifold gas and pressure tap. See step 18 for BTR-500 gas valve illustration A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 12 BTR TANK TYPE HEATERS SERVICE HANDBOOK VENTING Atmospheric Multiple Heaters Chimney A minimum of ¼" rise per foot of horizontal vent is required. All BTR water heaters are classified by ANSI as category I (non-condensing, negative pressure venting) appliances. They are approved for type B vent. For larger applications, BTR water heaters can be common vented together either in a tapered manifold or constant size manifold. (Follow National Fuel Gas Code requirements for sizing and installation.) BTRs may be common vented only with other category I appliances. (See venting section in the National Fuel Gas Code). A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 13 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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-wall" vent installations. (See Power Venter) SINGLE UNIT INSTALLATION When mechanically venting, the following items are required: Qty Description Part No. 1 Draft Inducer (up to 300,000Btuh) 90909 1 Draft Inducer (up to 305,000 thru 500,000 Btuh) 90910 1 Draft Prover Switch 95220 1 Relay Switch 96695 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 14 BTR TANK TYPE HEATERS SERVICE HANDBOOK POWER VENT KITS FOR SIDEWALL VENTING Female plug to Damper 40', Power Venter cable with "Y" connect Male plug to Cable 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 venting. A.O. Smith offers power vent kits for use on installations with a maximum of 100 equivalent feet of vent piping. The power vent kits also use type B vent materials. When power venting, specific exterior clearances must be maintained, as outlined in the National Fuel Gas Code. (NFPA 54, ANSI A223.1, sec 7.8) A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 15 BTR TANK TYPE HEATERS SERVICE HANDBOOK BTR SEQUENCE OF OPERATION 9. Flue damper closes 1. Thermostat calls for heat 2. Flue damper opens 7. Thermostat satisfies 4. Pilot gas opens, Pilot sparks and flame proves 3. Intermittent Ignition Control 6. Main burner ignites 5. Main gas valve opens 8. Main and pilot burners "OFF" SEQUENCE OF OPERATION To understand BTR tank type water heaters, an examination of their sequence of operation is necessary. When the thermostat calls for heat, the relay in the draft hood assembly activates, de energizing the flue damper motor. The damper opens and power flows to the IID (Intermittent Ignition Device). This activates the IID module to open the pilot valve and begin sparking at the pilot burner assembly. Once the pilot flame is established and confirmed back to the IID, the sparking is stopped and the main gas valve is opened, allowing gas flow to the main burner. When the thermostat satisfie's, main and pilot gas is shut off. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 16 BTR TANK TYPE HEATERS SERVICE HANDBOOK BTR ELECTRICAL SEQUENCE 100 – 109 Series A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 17 BTR TANK TYPE HEATERS SERVICE HANDBOOK BTR ELECTRICAL SEQUENCE OF OPERATION 120 Vac to Junction Box O n / O FF Switch "O N" 2 4V Transform er Series 110 and 111 E ffikal Motor Opens Damper Tank Tem perature High L im it Closed Therm ostat Closed M otor Relay Interrupts Power to Motor Dam per Spring O pens Dam per Blade Cam O n Dam per Blade Closes Proving End S witch IID M odule (24V) Receives Voltage Tank Tem perature Satisfied High Lim it (ECO ) Closed M otor Closes Damper M odule (P V) Tem inal Sends 24V to Pilot Coil M odule (Spark) Sends 10,000V Spark to Pilot Pilot Ignites and Proves Flam e Spark Stops M odule (M V) Term inal Sends 24V To M ain G as Coil Main Burner Heats Tank Them ostat Opens Power to Dam per Relay (4) Interupted Dam per Motor Energized and Dam per Closed 90 Second Trial / 5 M in ute D elay B etween Trials - Continuously Series 110 and 111 E ffikal Power to Dam per #2 Interrupted A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 18 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 STEP 1 TEST THE TRANSFORMER STEP 1 - TO TEST THE TRANSFORMER - Using a multimeter, test for 24 VAC between the secondary transformer terminals. IF THEN The meter does not read 24 VAC: • Check that the 120 VAC is supplied from the On/Off Switch – if not, replace switch. • Check that the 120 VAC is supplied from transformer. The meter reads 24 VAC: • Go to step 2. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 19 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 24 VAC: • Check wiring between transformer and high limit. The meter reads 24 VAC: • Go to Step 3. Note: The high limit (Energy Cut Off) opens if the tank water temperature exceeds 205 degrees. The control is resettable (manually) when the tank water temperature drops below 185 degrees. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 20 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 motor power line is connected. Test for 24 VAC between the high limit right terminal and ground. IF THEN The meter does not read 24 VAC: • Push the reset button and redo the test (storage water temperature below 185 degrees). The meter reads 24 VAC: • Go to step 4. After Push in Reset - 24 VAC is now present Reasons For Resetting Condition Cause Solution High limit open Never set on initial installation Push high limit button Excessive water temperature Faulty thermostat Replace dual control Heater shut down before reaching thermostat setting Faulty high limit Replace dual control Note: The right terminal of the high limit has a jumper wire connected to the left terminal of the thermostat. There is also a black wire connecting to the damper motor assembly. This black wire supplies power to the motor to close the damper during periods of standby. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 21 BTR TANK TYPE HEATERS SERVICE HANDBOOK STEP 4 INSPECT THE DAMPER Effikal Damper Open 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 open: • Go to step 5. If the damper is closed: • Go to step 7. Note: If the water temperature in the tank is below 120 degrees F, temporarily disconnect the jumper wire between the high limit and thermostat to simulate a satisfied thermostat. STEP 5 CHECK THE PC BOARD STEP 5. CHECK THE PC BOARD. Test for 24 VAC between the black PC board wire connection and ground. IF THEN 24 VAC is not present: • Check the black wire connections between PC Board and high limit. 24 VAC is present: • Go to step 6. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 22 BTR TANK TYPE HEATERS SERVICE HANDBOOK STEP 6 PC BOARD MOTOR TEST Motor Lead Service Switch Terminals 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 VAC is not present: • Replace the board (AOS part # 6522) and go to step 7. The board and relay are one piece. Regardless of which part is defective, both parts should be changed. Voltage is present: • This verifies that the motor is receiving power but not closing the damper. • Replace the motor (AOS part # 6521) and go to step 7. Note: The service switch may be used to bypass the damper, while waiting for a replacement part. WARNING - In the event of damper motor failure, verify that the damper is in the "open" position before utilizing the service switch. (BTR Series 106/107 and some prior series – changed from momentary push button to service switch). A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 23 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 meter does not read 24 VAC and the jumper wire between the high limit and the thermostat is in place: • Replace the thermostat The meter reads 24 VAC: • Go to step 8. Note: If the high limit to thermostat jumper wire was disconnected earlier to simulate a satisfied thermostat, reconnect the jumper to the terminals. Note: A yellow wire from this thermostat terminal connects to the damper PC board. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 24 BTR TANK TYPE HEATERS SERVICE HANDBOOK GO TO PAGE 27 FOR DAMPER TESTS OF EFFIKAL EQUIPPED (SERIES 110, 111 AND RETROFIT) MODELS STEP 8 DAMPER INPUT TEST Test from Orange wire to Black (neutral) STEP 8. DAMPER INPUT TEST. Test for 24 VAC between the yellow wire on the PC board and ground. Effikal – Check from orange wire to neutral IF THEN 24 VAC is not present: • Check the black wire connections between the PC board and high limit. 24 VAC is present • Go to step 6. STEP 9 TEST THE DAMPER STEP 9. TEST THE DAMPER. Visually check the damper blade position. IF THEN The damper does NOT open fully: • Replace the damper assembly The damper DOES open fully: • Go to step 10. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 25 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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. Then, the motor clutch is disengaged and the damper opens. The damper proves it is open via an end switch before power flows through the red wire from the PC board. Place the red test probe on the solder joint of the red wire connection to the damper PC board. IF THEN The meter does not read 24 VAC and the end switch is closed: • Replace the PC board The meter reads 24 VAC • Go to step 11. Note: The spring rotates the damper blade assembly to the open position. This closes an end switch. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 26 BTR TANK TYPE HEATERS SERVICE HANDBOOK EFFIKAL DAMPER BTR Series 110 and 111 began using the motor open; motor close, Effikal Damper. The wiring colors from the damper PC Board are different from previous series BTR(C) and BTC Models. Service Switch Adapter Plug Heater Harness Motor Service Lead Switch Motor Lead Motor Terminal Effikal Control Cover (Photo of kit mounting) Effikal Style The heater harness wires still serve the same function: Black – 24V Constant if high limit closed Yellow – 24V To damper if the thermostat is closed Red – 24V From damper to IID if damper closes end switch White – Neutral (common) Damper 2 34 1 Orange Brown Yellow Black From Heater w k o l c l a l e B Y 2 1 Male Plug 4 3 d e R e t i h W Female Plug A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 27 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 111 heaters and converted model BTR(C) and BTC heaters with Effikal Dampers. NORMAL OPERATION Condition: • Heater on standby • Damper closed • High Limit closed Wires are from left to right: Black i Yellow i Brown i White STEP A TEST FOR 24VAC BETWEEN BLACK (COMMON) AND BROWN STEP A. TEST FOR 24VAC BETWEEN BLACK (COMMON) AND BROWN IF THEN 24VAC is present Continue to Step B. 24VAC is not present See Troubleshooting Step A1 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 28 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 Step C. 24VAC is not present See Troubleshooting Step A2 Condition: • Thermostat closed, damper fully open STEP C TEST FOR 24VAC BETWEEN BLACK AND YELLOW IF THEN 24VAC is present Continue to Step 11 24VAC is not present See Troubleshooting Step A3 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 29 BTR TANK TYPE HEATERS SERVICE HANDBOOK TROUBLESHOOTING THE EFFIKAL STYLE DAMPER Condition: Thermostat closed, damper Wires are from left to right: Black i Yellow i Brown i White STEP A1 TEST BETWEEN BLACK (COMMON) AND BROWN ON THE DAMPER BOARD IF THEN 24VAC is present This is correct 24VAC is not present • See Steps 1 thru 4 Check the harness plugs connecting heater and damper for looseness or damage. Condition: Thermostat closed, damper in process of opening. STEP A2 TEST FOR 24VAC BETWEEN BLACK AND ORANGE IF THEN 24VAC is present This is correct 24VAC is not present • See Step 7 • Check the harness plug connecting heater ----or damaged A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 30 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 present This is correct – continue to Step 11 24VAC is not present • See Step 9 • Check the harness plug connecting ---- • Check that cam on shaft rotates with shaft • Replace the damper board A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 31 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 harness. 24 VAC is present: • Go to step 12. Note: This test may be easier to conduct by removing the red wire from the IID terminal. Test for 24 VAC between the red wire and ground. Reconnect the red wire to the 24V terminal after the test. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 32 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 second trial for ignition. IF THEN The meter does not read 24 VAC and the IID module is not between ignition trials: • Replace the module. The meter does read 24 VAC: • Go to step 13 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 33 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 The igniter is not sparking: Check for: • A 7/64" spark gap • Spark cable continuity • Ground cable continuity Sparking is present: • Go to step 14. Power To Module May Be Interrupted To Reset . Trial for Ignition 90 sec. 5 min. 90 sec. 5 min. 90 sec. Continuous Call for heat Sparking No Sparking Sparking No Sparking Sparking Trial Sequence A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 34 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 valve solenoid leads. Using a multimeter, (set to read ohms) test for 20* ohms resistance +/- 5 through the solenoid coil. IF THEN The meter dose not read 20 ohms plus or minus 5: • Replace gas valve The meter does read 20 ohms plus or minus 5: • Gas valve should work. Also check that pilot gas is present and pilot tube or orifice are not blocked A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 35 BTR TANK TYPE HEATERS SERVICE HANDBOOK STEP 14B PILOT VALVE TEST – BTR 500 ONLY PILOT GAS MANIFOLD PRESSURE TAP BLUE WHITE RED The MV/PV wire on the IID is connected to the white wire The MV wire on the IID is connected to the red wire. MANIFOLD GAS MANIFOLD PRESSURE TAP 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 only. Because of built in diodes, it is difficult to test for ohms resistance through these coils. The following is a DC amperage check of the main and pilot coils. Condition: • Tank calls for heat • PV terminal of module has 24 Vac • No Pilot flame Test Procedure: • Turn off power to heater • Meter set to test for DC amperage (on AOS meters, the black wire is in the "com" port, the red wire is in the "10A" port, the dial is set to 20M/10A in the DC AMP test area). • Blue "PV" wire is disconnected from the ignition PV terminal. • Install meter in series between gas valve and ignition module – 10A wire to blue gas valve lead, common wire to PV module terminal. • Turn power on to heater, after module receives 24V Test DC Amperage through Pilot coil of gas valve IF THEN .75 to .85 DCA is not present: • Replace the gas valve .75 to .85 DCA is present • Pilot should work if gas (not air) is present to pilot Power off, reattach blue gas valve wire to PV terminal of module. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 36 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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. Visually check for main burner. IF THEN The main burner ignites: • Sequence is complete The main burner does not ignite • Go to step 16 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 37 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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. The pilot flame is the 'switch' which connects the pilot hood to the igniter and ground. If the pilot hood and igniter sensor had the same surface area, the flame 'switch' would conduct an AC signal. Because the pilot surface is greater than the igniter surface, the signal becomes a DC current that the module can interpret. The pilot hood must be properly grounded and the pilot flame must remain in contact with both surfaces for the flame proving signal to remain constant. If the signal is broken for just 8 tenths of a second, the heater will cycle off. Sparking at the pilot will continue if an insufficient signal is received by the module. Sparking at the pilot will stop almost immediately after the ignition module senses the pilot flame. IF THEN Sparking continues after pilot is established: • Check wire connections • Check flame contact between hood and lighter • Clean pilot burner surfaces • Replace pilot assembly Sparking stops: • Go to step 17. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 38 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 IID and 24V (GND). IF THEN 24 VAC is not present: • Replace the IID module. Conduct Step 18 before applying power to replacement module. 24 VAC is present: • Go to step 18. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 39 BTR TANK TYPE HEATERS SERVICE HANDBOOK STEP 18A MAIN GAS VALVE CHECK TH TR 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 plus or minus 5 between TH and TR on the main valve coil. IF THEN The meter reads 'O' or infinity • Replace the gas valve The meter reads 68* ohms plus or minus 5 • The main burner will ignite A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 40 BTR TANK TYPE HEATERS SERVICE HANDBOOK STEP 18B MAIN GAS VALVE COIL CHECK PILOT GAS MANIFOLD PRESSURE TAP BLUE WHITE The PV wire is connected to the blue wire The MV/PV wire on the IID is connected to the white wire. The MV wire is disconnected from the gas valve. RED MANIFOLD GAS MANIFOLD PRESSURE TAP STEP 18B. MAIN GAS VALVE COIL CHECK – BTR 500 ONLY Condition: • Pilot lights • Sparking stops • No main burner ignition Test Procedure: • Power off • Disconnect red, main valve wire from module MV terminal • Meter set to test for DC amperage • 10A wire to red gas valve wire, COM wire to MV terminal of ignition module • Turn power on to heater • After pilot lights and sparking stops IF: THEN: .25 to .35 DC Amps is not present • Replace the gas valve .25 to .35DCA is present • Main burner gas should ignite. Be certain to correct you meter wire connections and setting before performing further tests. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 41 BTR TANK TYPE HEATERS SERVICE HANDBOOK 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 THERMOPLASTIC OR BLUE PV EQUIVALENT. WHITE RED MV/ PV MV GAS VALVE FOR BTR-500/A ONLY A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 42 BTR TANK TYPE HEATERS SERVICE WORKBOOK GENERAL SERVICE CHART CONDITION CAUSE SOLUTION DAMPER OPENS NO POWER TO IID MODULE . DAMPER NOT FULLY OPEN .EFFIKAL – REPLACE DAMPER CONTROL ASSEMBLY . REPLACE DAMPER . DEFECTIVE PROTECTOR SWITCH . REPLACE PC BOARD PILOT LIGHTS, SPARKS CONTINUOUSLY PILOT FLAME NOT PROVING SEE FLAME RECTIFICATION - STEP 16 HEATER WILL NOT IGNITE NOT PROVING PILOT FLAME EXISTANCE INTERRUPT 120 VAC POWER . CHECK GROUND WIRE ATTACHMENT . CLEAN OR REPLACE PILOT ASSEMBLY PILOT GAS NOT COMPLETELY INTERRUPTED AT END OF HEATING CYCLE . CHECK SUPPLY GAS PRESSURE . REPLACE GAS VALVE WEEPING TEMPERATURE AND PRESSURE RELIEF VALVE . THERMAL EXPANSION ADD THERMAL EXPANSION TANK . FAULTY VALVE REPLACE RELIEF VALVE LARGE VOLUME WATER RELIEF FROM T&P VALVE . EXCESSIVE WATER TEMPERATURE . CHECK WIRING . REPLACE DUAL CONTROLLER . FAULTY RELIEF VALVE REPLACE RELIEF VALVE PREMATURE TANK LEAKAGE CONDENSATION . INCREASE STORED WATER TEMPERATURE AND CONFIRM PROPERLY SIZED APPLICATION CONTAMINATED AIR . REMOVE CONTAMINANTS. . SUPPLY CLEAN COMBUSTION AIR. WATER HAMMER . ADD WATER HAMMER ARRESTOR. . REDUCE WATER PRESSURE. . REMOVE UNNECESSARY CHECK VALVES. THERMAL EXPANSION ADD THERMAL EXPANSION TANK. DEPLETED ANODES SCHEDULE ANODE CHECKS - REPLACE AS NEEDED. DAMPER WILL NOT OPEN BINDING SHAFT SUPPORT VENTING SHAFT SPRING WEAK/BROKEN REPLACE DAMPER NON-EFFIKALS DAMPER MOTOR REPLACE MOTOR EFFIKAL-REPLACE DAMPER CONTROL ASSEMBLY NO SPARK AT PILOT - DAMPER FULLY OPEN DAMPER ASSEMBLY REPLACE PC BOARD - SEE STEP 10 Services Switch may bypass problem until replacement part is received. (EFFIKAL – REPLACE DAMPER CONTROL ASSEMBLY IID MODULE REPLACE IID STEP 12 SPARK CABLE REPLACE CABLE STEP 13 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 43 BTR TANK TYPE HEATERS SERVICE WORKBOOK 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 slide switch. The 108 and 109 series implemented a new main burner construction process. The damper boards with service switch and new style main burners will automatically be replacement parts for previous series heaters if parts are ordered. Q. What is unique about the Canadian – BTRC – models vs. U.S. BTR models? A. The Canadian models have different dimensions to meet Canadian code requirements. Q: How much electrical power is required for a BTR water heater? A: The BTR models draw approximately .7 Amps at 120VAC. Q: The units require "leg kits" to meet National Sanitation Foundation standards. What are the part numbers for these kits? A: The BTR model heaters need AOS kit numbers: BTR 120-400 (except BTR 197&198 series 100) = Part # 6570-0 BTR 197&198 Series 100 = Part # 6570-5 BTR 500 = Part # 6570-7 Q: When should BTRs be delimed? Many variables affect the liming up process including: water temperature - The amount of lime accumulation during the same period of time will be nearly 2 times greater if water is stored at 140 degrees F than at 120 degrees F. A 180 degree setting will build up lime about seven times as fast as a 140 degree F setting. volume of water - The more gallons flowing through the BTR, the more rapid the accumulation. hardness – The harder the water the faster lime build up occurs. 1 to 3.5 grains per gallon is "soft", 3.5 to 7 grains per gallon is "moderate", 7 to 10.5 grains per gallon is "hard" and 10.5 + grains per gallon is "very hard". (An aspirin is about 5 grains. One grain is equal to 17.1 parts per million.) A: Deliming should be done when a slight rumbling or popping sound is detected when the main burners are on. Q: What effect will lime build-up have on the BTR water heater? A: One eighth inch of scale build-up may reduce efficiency as much as 22%; a 1/4 inch build-up, as much as 38%. A: Less efficient heat transfer means more bottom head expansion/contraction stress and premature leakage. A: Heavy build-up on the bottom head and bottom portion of the flue pipes leads to more heat transfer at the top of the flues. This can lead to stacking or erratic thermostat operation. Q: Anode rods provide additional protection against corrosion. When should these be replaced? A: When large gouges or pits appear in the anodes, replace them. It is recommended that these be inspected every 6 months. A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 44 BTR TANK TYPE HEATERS SERVICE WORKBOOK BTR MODELS 197 AND 198 Series 100-101 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 45 BTR TANK TYPE HEATERS SERVICE WORKBOOK BTR MODELS 197 AND 198 (continued) Series 100-101 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 46 BTR TANK TYPE HEATERS SERVICE WORKBOOK 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 Burner............................................. 192322 192322 3 Main Burner w/Pilot Bracket..................... 193873-0 193873-0 4 Pilot Burner Natural ................................. 193314-0 193314-0 5 Pilot Burner Propane ............................... 193314-1 193314-1 6 Gasket..................................................... 99036 99036 7 Pressure Plate......................................... 99037 99037 8 Screws, Self Tapping............................... 69852 69852 9 Control, Ignition Module........................... 193325 193325 10 Control, Dual w/ECO ............................... 192828 192828 11 Drafthood................................................. 192957-4 192957-4 12 Manifold................................................... 76244-2 76244-2 13 Instruction Manual ................................... 193927 193927 14 Main Burner Orifice Natural ..................... 76243-32 76243-32 15 Main Burner Orifice Propane.................... 76243-49 76243-49 16 Anode Rod............................................... 43817-38 (4) 43817-42 (4) 17 T & P Relief Valve ................................... 99465-7 99465-7 18 Transformer............................................. 193444 193444 19 Inlet Tube ................................................ 192626 192626 20 Gas Valve Natural.................................... 192827-2 192827-2 21 Gas Valve Propane.................................. 192827-3 192827-3 22 Off/On Switch .......................................... 193243 193243 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 47 BTR TANK TYPE HEATERS SERVICE WORKBOOK BTR MODELS 120 through 500 Series 104-105 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 48 BTR TANK TYPE HEATERS SERVICE WORKBOOK BTR MODELS 120 through 500 (continued) Series 104-111 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 49 BTR TANK TYPE HEATERS SERVICE WORKBOOK 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 production method. Both parts will automatically be shipped on 104 thru 109 series heaters.) Item Parts Description BTR-120 BTR-154 BTR-180 BTR-199 BTR-200 BTR-250 1 Main Burner, Orifice Bracket 98044(3) 98044(3) 98044(5) 98044(5) 98044(5) 98044(5) 2 Main Burner 192322 98047 192322 192322 192322 098047 3 Main Burner w/Pilot Bracket 193873-0 193873-1 193873-0 193873-0 193873-0 193873-0 4 Pilot Burner, Natural 193314-0 193314-0 193314-0 193314-0 R 193314-4 5 Pilot Burner, Propane 193314-1 193314-1 193314-1 193314-1 193314-1 193314-3 6 Gasket, Cleanout 99036 99036 99036 99036 99036 99036 7 Pressure Plate, Cleanout 99037 99037 99037 99037 99037 99037 8 Screw, Self tapping, Cleanout 69852 69852 69852 69852 69852 69852 9 Control, Ignition Module 193325 193325 193325 193325 193325 193325 10 Control, Dual w/eco 192828 192828 192828 192828 192828 192828 11 Drafthood 193597-0 193597-1 192957-0 192957-0 192957-0 193287 11 Drafthood 110, 111 Series 12 Manifold 76244-0 76244-0 76244-2 76244-2 76244-2 76244-2 13 Instruction Manual, (not illustrated) 193927 193927 193927 193927 193927 193927 14 Main Burner Orifice, Natural 76243-32 76243-30 76243-35 76243-32 76243-32 76243-xx 15 Main Burner, Orifice, Propane 76243-49 76243-46 76243-51 76243-49 76243-48 76243-xx 16 Anode Rod 43817-38 (2) 43817-38 (2) 43817-38 (4) 43817-38 (4) 180618-42 (3) 180618-42 (4) 17 T & P Relief Valve 99465-7 99465-7 99465-7 99465-7 99465-7 192467 18 Transformer 193444 193444 193444 193444 193444 193444 19 Inlet Tube 193729 192626 193729 193729 192626 192626 20 Gas Valve, Natural 192827-2 192827-2 192827-2 192827-2 192827-2 192827-2 21 Gas Valve, LP 192827-3 192827-3 192827-3 192827-3 192827-3 192827-3 22 Off/On Switch 193243 193243 193243 193243 193243 193243 Item Parts Description BTR-251 BTR-275 BTR-305 BTR-365 BTR-400 BTR-500 1 Main Burner, Orifice Bracket 98044(7) 98044(5) 98044(7) 98044(9) 98044(9) 98044(9) 2 Main Burner 98047 98047 192322 192322 192322 192322 3 Main Burner w/Pilot Bracket 193873-0 193873-1 193873-0 193873-0 193873-0 193873-0 4 Pilot Burner, Natural 193314-4 193314-4 193314-4 193314-4 193314-4 193314-4 5 Pilot Burner, Propane 193314-3 193314-3 193314-3 193314-3 193314-3 193314-3 6 Gasket, Cleanout 99036 99036 99036 99036 99036 99036 7 Pressure Plate, Cleanout 99037 99037 99037 99037 99037 99037 8 Screw, Self tapping, Cleanout 69852 69852 69852 69852 69852 69852 9 Control, Ignition Module 193325 193325 193325 193325 193325 193325 10 Control, Dual w/eco 192828 192828 192828 192828 192828 192828 11 Drafthood 193287 193287 193287 193287 193287 193287 11 Drafthood 110, 111 Series 12 Manifold 76244-3 76244-2 76244-3 76244-4 76244-4 76244-4 13 Instruction Manual, (not illustrated) 193927 193927 193927 193927 193927 193927 14 Main Burner Orifice, Natural 76243-xx 76243-xx 76243-37 76243-32 76243-31 76243-28 15 Main Burner, Orifice, Propane 76243-xx 76243-xx 76243-48 76243-49 76243-48 76243-44 16 Anode Rod 43817-38 (4) 180618-42 (3) 43817-38 (4) 180618-42(4) 180618-42 (3) 180618-42 (4) 17 T & P Relief Valve 192467 192467 192467 192467 192467 192467 18 Transformer 193444 193444 193444 193444 193444 193444 19 Inlet Tube NA 192626 NA 192626 192626 192626 20 Gas Valve, Natural 192827-2 192827-2 192827-2 192827-2 192827-2 193366-0 21 Gas Valve, LP 192827-3 192827-3 192827-3 192827-3 192827-3 193366-1 22 Off/On Switch 193243 193243 193243 193243 193243 193243 ∗ For complete parts list call 1-800-433-2545 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 50 BTR TANK TYPE HEATERS SERVICE WORKBOOK COMPONENT PART INFORMATION NAME SPECIFICATIONS AOS PART NUMBERS DUAL CONTROLLER THERMOSTAT 120-180ORANGE, + 4O, 5O DIFFERENTIAL, LIQUID FILLED, ANTI STACKING AOS # 192828 HIGH LIMIT (ECO) OPENS - 205OFIXED, MANUAL RESET BELOW 185O GAS VALVE NATURAL GAS BTR 120-400;24VAC, 60hz, .6A,.7" to 3.5" W.C., STEP OPEN BTR 500; 24VAC, 60hz, Dual Gas Valve, STEP OPEN AOS # 192827-2 AOS # 193366-0 PROPANE GAS BTR 120-400; 2.5 – 10" W.C. STEP OPEN BTR 500; 24VAC, 60hz, Dual Gas Valve, STEP OPEN AOS # 192827-3 AOS # 193366-1 INTERMITENT IGNITION DEVICE CONTROL NATURAL GAS AND PROPANE GAS 24 VAC, 50-60 HZ, .1A; .7 MICROAMP SIGNAL CONTINUOUS RETRIAL AOS 193325 DAMPER COMPLETE ASSEMBLY SEE PARTS LIST MOTOR 24 VAC, 60 HZ, 120 RPM, 5 WATT AOS #6521 P.C. BOARD W/RELAY Service Switch AOS #6522 TRANSFORMER 120 V PRIMARY, 24 VAC SECONDARY, 40 VA, 50-60 HZ, CLASS 2 "B" AOS #193444 A.O. Smith Water Products Service Handbook Irving, Texas ©2000 Training Department 51 BTR TANK TYPE HEATERS SERVICE WORKBOOK 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 the A.O. Smith BTR Water Heater has been properly installed and is operating correctly. Because the circumstances of each installation may vary greatly, it is not intended to be an all inclusive list of the problems that the Service Agent may encounter. Any item checked "no" on this list should be thoroughly investigated and corrective action taken, if required. SERVICE AGENT INSTALLATION DATE MODEL NUMBER SERVICE DATE SERIAL NUMBER LOCATION ADDRESS GAS TYPE - CHECK ONE NATURAL PHONE( ) ___ - ____ PROPANE I. Check Clearances (circle answer) A. Are exterior clearances adequate? yes no B. Are interior clearances adequate? yes no Comments: II. Check Makeup Air Requirements A. Is the quantity of make-up air adequate per the National Fuel Gas Code? yes no Comments: B. Is the quality of make-up air adequate? yes no Comments: III. Gas Pressure (fill in blank) A. Supply gas pressure inches of w.c. B. Manifold gas pressure (main burner) inches of w.c. Comments: IV. Venting (check) A. Properly sized per the National Fuel Gas Code? yes no B. Does the installation have mechanically assisted venting? yes no If so, is it operational? yes no Comments: V. WATER PIPING A.O. Smith Water Products Service Handbook Irving, Texas © 1999 Training Department 52 BTR TANK TYPE HEATERS SERVICE WORKBOOK 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 so, is it operational? yes no VI. PROPER SEQUENCE OF OPERATION During standby does damper close on standby? yes no During standby is pilot flame off? yes no On a call for heat does thermostat close? yes no On a call for heat does damper open completely? yes no Does sparking begin at pilot? yes no Is pilot flame established? yes no If so, does sparking stop? yes no Does main burner ignite? yes no Does the thermostat satisfy? yes no Does damper close? yes no Comments: VII. SAFETY A. Gas Does pilot flame prove before main burner ignites? yes no Does damper blade fully open before ignition sequence occurs? yes no Is burner cover plate in place? yes no Is burner floor shield in place? yes no Does IID lockout occur after 30 sec. trial for ignition? (Propane models only) yes no B. Water Temperature Is the thermostat adjusted to the lowest acceptable temperature? yes no Does the installation have a mixing valve? yes no If so, is it operational? yes no What is the outlet temperature of the mixing valve? NOTE: (To minimize the risk of scalding, the manufacturer recommends storing water at 120°F.) Is a properly rated temperature and pressure relief valve installed? yes no C. Electrical Is the 120 VAC electrical power supply properly wired? yes no Are all the BTR control covers in place? yes no Is the 120 VAC electrical power supply properly fused? yes no D. Flammables Are flammable materials located in the area of the water heater? yes no Are flammable vapors located in the area of the water heater? yes no Comments: (This service checklist may be photo copied to assist with BTR service call.) A.O. Smith Water Products Service Handbook Irving, Texas © 1999 Training Department 53 BTR TANK TYPE HEATERS SERVICE WORKBOOK COMMENTS Author: Terry Mulder A.O. Smith Water Products Service Handbook Irving, Texas © 1999 Training Department 54