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TC-044R6 • Printed in the U.S.A. • 1105 m A.O. Smith Water Heaters BTH Service Handbook TABLE OF CONTENTS Introduction...................2 Installation Clearances.....................3 Gas Requirements...............3 Venting.....................4 - 8 Air Requirements............9-11 Contaminated Air...............12 Flammable Items...............12 Multiple Unit Piping..............13 Condensation..................14 Operation Sequence of Operation..........15 Controls......................16 Circuit Boards..................17 Troubleshooting Pre-Service....................18 120 VAC to Control..............18 Transformer...............19-20 ECO Check...............21-22 Temperature Probe..............23 Pressure Switch Continuity.......24 Blower...................25-26 Pressure Switch Performance .27-28 120 VAC to Ignitor..........29-30 Ignitor Resistance...............31 Gas Valve Test.................32 Gas Pressure Check............33 Component Information Orifice Tables..................34 Pressure Switches..........35-36 Wiring Diagrams ..............37 Service Aids..................38 BTH Muffler...................39 Questions & Answers..........40 Error Codes...................41 Service Checklist..............42 Parts Lists 970 & 973 Series...........43-47 966 & 967 Series...........48-59 960 Series................60-63 962 Series................64-71 BTH SERVICE HANDBOOK INTRODUCTION INTRODUCTION This service handbook is designed to aid in servicing and troubleshooting A. O. Smith BTH 120 - 250 water heaters. 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 commonly faced situations encountered in the operation of the BTH 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 instruction manual accompanying the product. This handbook contains supplemental information to the BTH instruction manual. Qualifications: Installation or service of this water heater requires ability equivalent to that of a licensed tradesman in the field involved. Plumbing, venting, gas supply and electrical testing skills are required. Tools Required: • Phillips head and flat tip screw drivers • Set of marked drill bits • Electric multimeter tester • Gas pressure gauge or manometer (gauge — AOS part number 8099-2) • Water pressure gauge (A OS part number 4798) • Digital manometer or draft gauge • Thermometer (AOS part number 4870 — range 0 thru 220°F) • 1/2”, 1” and 11/8” sockets • Pipe wrench for union disconnect NOTE Also, have a copy of the instruction manual for the model and series BTH that you are servicing. Revision 2 includes: • an added Multiple Venting statement on page 3 and a new Blower Motor Ohms Resistance Table on page 25. The Pressure Switch Table on page 32 was expanded/revised. Revision 3 includes: • clarification to Step 13, 14 and 15 Test. • BTH 120 Propane information on pages 31, 32, and the Parts List. • revised part number — page 34, Step 11. Revision 4 dated 04/02 includes: • expanded error code information on page 36. ^Revision 4 dated 04/03 includes: • revised sequence of troubleshooting. Minor corrections. Revision 6 includes: • 970 & 973 Series product information. Minor corrections. f. Handbook cover should have stated revision 5. Technical Training Department TC-044 Revision 6 A. O. Smith Water Products Co. Ashland City, Tennessee © 2004 BTH SERVICE HANDBOOK LEFT INSTALLATION INSTALLATION CLEARANCES This portion of the handbook will review often overlooked installation requirements. The installation manual covers these items in detail. BTH water heaters are approved for installation on combustible flooring. The minimum clearance to combustibles or noncombustibles is 0 inches from the sides waLl and rear, 0 inches from vent piping, and 1.5 inches from the top cover. A 24 inch clearance for all serviceable parts is recommended. Clearances may vary between BTH models. See installation manual or the label on the heater for your specific model. GAS REQUIREMENTS NOTE: Pressure without capacity will result in lockout. Follow the piping guidelines in the installation manual. The supply gas pressure is normally measured at the dirt leg or at the inlet gas pressure tap on the gas valve. This re...