Bock Water heaters OT600-A, Installation And Operation Instruction Manual

Page 1: ...oroughly before attempting installation or operation of your water heater Keep these instructions for future reference Local plumbing and electrical codes must be followed in the installation of this water heater In the absence of a local code use the UNIFORM PLUMBING CODE and the NFPA Code Local codes may supersede instructions in this installation manual These instructions are a guide for the co...

Page 2: ... injury NOTICE calls attention to observe a specified procedure SAVE THESE INSTRUCTIONS DANGER Water heaters utilizing Liquefied Petroleum gas LP are different from natural gas models A natural gas heater will not function safely on LP gas and vice versa To avoid possible equipment damage personal injury or fire DO NOT connect this water heater to a fuel type not in accordance with the rating labe...

Page 3: ...ations 4 Section II General Information 5 Section III Pre Installation 11 Section IV Installation 14 Section V Operation 42 Section VI Maintenance 46 Section VII Troubleshooting 50 Section VIII Parts List 56 Section IX Warranty 60 Page 3 ...

Page 4: ...mic A i r I n t a k e P V C G a s N P T E x h a u s t V e n t P V C S h i p p i n g W e i g h t L B S k g For LP gas MINIMUM GAS SUPPLY PRESSURE at gas control 8 W C dynamic MAXIMUM GAS SUPPLY PRESSURE at gas control 14 W C static or dynamic Note Dynamic pressure is measured while gas is flowing and static pressure is measured while gas is not flowing All Bock products meet or exceed current ASHRA...

Page 5: ...emperature setpoint and controls the burner power on off and modulation accordingly The manual reset temperature limiting safety function is managed by the main operating control In the event that the tank temperature sensor reads 190 F the control will shut off all gas to the water heater Manually reset the control to allow the heater to resume normal operation Should overheating occur and the ga...

Page 6: ...by local codes and no less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials as meeting the requirements for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems ANSI Z21 22 This valve must be marked with a maximum set pressure not...

Page 7: ... expansion in a closed water supply system Contact the water supplier or local plumbing inspector for information about thermal expansion tanks Note Working pressure of the water heater is 150 PSI Do not exceed 150 PSI CONDENSATION Condensation of flue gases will occur in the exhaust vent and portions of the heat exchanger during burner operation Condensate is considered acidic based on its typica...

Page 8: ...ent or falling during a seismic event Figures 2 and 3 show common approaches to bracing and are provided only as concepts Refer to state and local codes and follow specific instructions for correct installation LOWER STRAP UPPER STRAP METAL FRAMING Figure 2 Seismic Restraints to Support Framing LOWER STRAP UPPER STRAP METAL FRAMING UPPER STRAP LOWER STRAP WALL Figure 3 Seismic Restraints to Wall ...

Page 9: ...ing control The red pair will typically be used in series to switch the hot side of a low voltage supply to an input on the draft control The black white BK W pair labeled Burner Release Input is controlled by a volt free contact on the draft control and typically connected to an output on the draft control This circuit is closed when the draft control has satisfied its safeties and is allowing th...

Page 10: ... demand for hot water open a faucet or increase the setpoint temperature by 10 F 2 Using the display navigate to the Settings tab Select the Test option and then select High Limit Commissioning Test 3 With the water heater running in DEMAND press the Start button from the High Limit Commissioning Test screen 4 Return to the Home screen and a yellow message will appear below the power bar that read...

Page 11: ...tending beyond the full width and depth of the water heater by at least 3 inches 76 2 mm in any direction or if the water heater is installed in an alcove the entire floor shall be covered by the panel The panel must be strong enough to carry the weight of the heater when full of water Locate the heater so it is not subject to physical damage from moving vehicles or flooding Do not locate the wate...

Page 12: ...s supply pressure shall never be greater than 14 W C Refer to Section IV Installation Gas Connections for further installation instructions Page 12 Figure 4 Minimum Clearance From Combustibles Figure 5 Recommended Minimum Access Clearances Nominal Iron Pipe Size inches Internal Diameter inches Length of Pipe feet 10 20 30 40 50 60 70 80 90 100 125 150 175 200 1 1 4 1 380 1 050 730 590 500 440 400 ...

Page 13: ...p and one within 12 inches of the bottom of the enclosure These openings shall lead directly to room s of sufficient volume so that the combined volume of all the space meets the criteria for unconfined space Each opening shall have a minimum free area of 1 square inch per 1000 Btu hr of the combined total input of all fuel burning appliances in the space Each opening shall have an area of not les...

Page 14: ...air from inside the building will be used for combustion air the require ments in Section III Unconfined Space must be met A power direct vent system terminates in a 2 pipe configuration The vent and intake equivalent lengths must comply with minimum and maximum lengths specified in Table 4 The water heater is supplied with a pre assembled PVC condensate assembly that must be installed to the cond...

Page 15: ...40 ASTM F438 ABS Schedule 40 DWV ASTM D2661 AL29 4C Stainless Steel PVC IPEX 1738 UL1738 ASTM D2665 The use of cellular core PVC ASTM F891 cellular core CPVC or Radel polyphenylsul fone in non metallic vent pipe and systems is prohibited Covering non metallic vent pipe and fittings with thermal insulation is prohibited Page 15 NOTICE Installations in Canada must conform to the requirements of CSA ...

Page 16: ...except as shown to increase from 4 to 6 diameter at the point of connection to the water heater Figure 6 shows the proper connections to increase from 4 to 6 plastic pipe on the intake and how to establish the exhaust venting with the factory supplied assembly Prior to connecting the exhaust assembly apply a bead of silicone around the inside of the straight coupling For maximum durability and sea...

Page 17: ...ination fitting For vertical exhaust equivalent length is measured after the factory supplied exhaust assembly to the end of the vertical pipe Shown as a balanced system Vent length may exceed air intake length if total combined length does not exceed 200 ft Intake length cannot exceed exhaust length Model s Fuel Type Vent Arrangement Minimum Equivalent Pipe Length per pipe run Maximum Equivalent ...

Page 18: ... specified in this manual have been used Verify the maximum and minimum vent and combustion air intake equivalent lengths and terminal clearances meet the specifications in this manual Inspect the vent and combustion air intake systems for cracking Pay close attention to joints between elbows and straight pipe Inspect the system for misalignment of components This may lead to sagging and unwanted ...

Page 19: ...nd point the orienter in that direction Install the trap portion by connecting the union parts labeled B so that it is pointing in the proper direction See Figure 7 for a view of how the condensate trap is assembled and Figure 8 for a view of both orientation options Figure 8 Orientation of the Condensate Trap ...

Page 20: ...SILICONE CAULK ALL THE WAY AROUND CONNECTION DETAIL M SCALE 1 16 UNION B EXHAUST VENT Figure 10 Sealing the Connections A detailed view of the condensate trap is shown in Figure 11 The discharge portion of the trap is designed with a vent and threaded female NPT connection The trap may be cleaned by disconnecting union B and the threaded connection then running water through the trap Use rigid PVC...

Page 21: ...ide the building the distance from other buildings proximity to cor ners weather conditions wind patterns and snow depth Periodically check to make sure that flue recirculation is not occurring Signs of flue gas recirculation include frosted or frozen intake terminals condensate in the intake terminal and venting system oxidation or white chalk material on the flame rod or hot surface igniter Corr...

Page 22: ...of the gas supplier J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance 6 in 15 cm for appliances 10 000 Btuh 3kW 12 in 30 cm for appliances 10 000 Btuh 3kW and 100 000 Btuh 30 kW 36 in 91 cm for appliances 100 000 Btuh 30 kW 6 in 15 cm for appliances 10 000 Btuh 3kW 9 in 23 cm for appliances 10 000 Btuh 3kW and 50 000 Btuh 15 kW 12 in 30 cm...

Page 23: ...ate near soffit vents or crawl space or other areas where condensate or vapor could create a nuisance hazard or cause property damage Do not locate the exhaust vent terminal where condensate or vapor could cause damage or could be detrimental to the operation of regulators relief valves or other equipment Do not locate the exhaust vent terminal over public areas or walkways where condensate or vap...

Page 24: ...r meter This will allow the condensate in the vent to run back to the condensate drain on the water heater Horizontal sections of air intake piping shall slope downward away from the water heater a minimum of 1 8 per foot NOTE If the air intake and exhaust vent terminations will be located on a side of the building that is frequently subjected to high winds it is recommended that the air intake te...

Page 25: ...side the building for combustion air A single hole through the exterior of the building is required for the vent pipe Note If air from inside the building will be used for combustion air the require ments in Section III Unconfined Space must be met All clearances must comply with local codes or the latest edition of NFPA 54 ANSI Z223 1 or CSA B149 See Figure 16 and Table 6 for vent terminal cleara...

Page 26: ...rtical Clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft 61 cm from the center line of the terminal 12 in 30 cm 12 in 30 cm E Clearance to unventilated soffit 12 in 30 cm 12 in 30 cm F Clearance to outside corner 2 ft 60 cm 2 ft 60 cm G Clearance to inside corner 18 in 45 cm 18 in 45 cm H Clearance to each side of center line extended above meter regula...

Page 27: ...te near soffit vents or crawl space or other areas where condensate or vapor could create a nuisance hazard or cause property damage Do not locate the exhaust vent terminal where condensate or vapor could cause damage or could be detrimental to the operation of regulators relief valves or other equipment Do not locate the exhaust vent terminal over public areas or walkways where condensate or vapo...

Page 28: ... system and attach to the water heater as shown in Figure 18 Horizontal sections of the exhaust vent shall slope upward away from the water heater a minimum of 1 8 per foot 10 mm per meter This will allow the condensate in the vent to run back to the condensate drain on the water heater Horizontal sections of air intake piping shall slope downward away from the water heater a minimum of 1 8 per fo...

Page 29: ...ent and combustion air intake terminal centerlines Note It is best practice to locate the intake and exhaust terminations on a common plane CAUTION Never install air intake terminal above vent exhaust terminal Install piping through the roof as shown in Figure 19 Adequate length of pipe must protrude beyond the exterior of the roof see dimension Y Two 90 elbows are recommended for the intake termi...

Page 30: ...w for proper evacuation of exhaust gas See Figure 21 for details SECTION IV INSTALLATION Figure 20 Vertical Direct Vent Arrangement TERMINATE EXHAUST VENT WITH STRAIGHT PIPE OR FACTORY SUPPLIED TEE AIR INTAKE TERMINAL 90 FACTORY SUPPLIED CONNECT 4 X6 INCREASER FACTORY SUPPLIED TO 4 AIR INTAKE PIPE TURN INTAKE VENT 90 FOR A SHORT DISTANCT TO ALLOW FOR REQUIRED INTAKE DRAIN FACTORY SUPPLIED NOTICE P...

Page 31: ... pipe termination In this case the water heater will be utilizing air from inside the building for combustion air A single hole through the roof of the building is required for the vent pipe Note If air from inside the building will be used for combustion air the require ments in Section III Unconfined Space must be met All clearances must comply with local codes or the latest edition of NFPA 54 A...

Page 32: ...PEX 1738 PVC use UL1738 certified cement and primer that also meets the performance requirements of ASTM D2564 and for ABS use ASTM D2235 grade cement The following steps should be taken when connecting plastic pipe and fittings Cut pipe square with hand saw and remove burrs from inside and outside edges Clean fitting socket and pipe joint area of all dirt grease or moisture Check dry fit Pipe sho...

Page 33: ...l a vertical Ø6 pipe of a convenient length not to exceed 5 into the Ø6 end of the increaser Use a Ø6 90 elbow to create a horizontal section of length pointing in a convenient direction Note The horizontal portion of the intake vent must be installed in such a manner to allow enough room for removal of the water heater top pan Install the supplied drain tee with the drain barb pointing directly d...

Page 34: ...ry installed pipe nipples at the hot outlet and cold inlet connections These pipes were tightened to proper orientation at the factory DO NOT ROTATE THESE PIPES WHEN CONNECTING FITTINGS IN THE FIELD The black indicator line on the factory installed pipe nipple must be in line with the arrow on the label shown in Figure 25 If orientation is not correct there will be a reduction in water heater perf...

Page 35: ...SECTION IV INSTALLATION Page 35 Figure 26 Piping Diagram One Unit Figure 27 Piping Diagram Two Units ...

Page 36: ...SECTION IV INSTALLATION Page 36 Figure 28 Piping Diagram Three Units Figure 29 Piping Diagram One Unit with Storage Tank ...

Page 37: ...t be connected to any heating system or component s previously used with a non potable water heating appliance If the space heating requires water at a temperature higher than required for other uses a tempering valve shall be installed to reduce the water temperature for those uses in order to lessen scald hazard potential This water heater cannot be used for space heating applications only Space...

Page 38: ...ot be less than the minimum gas supply line size for the water heater The Maxitrol 325 7 series of regulators with 1 1 2 or 2 connections is recommended For ease of measurement install a tee with a pipe fitting and a manual shutoff valve between the main manual shut off valve to the water heater and the pressure regulator The pipe fitting should be adaptable to a pressure gauge for measuring incom...

Page 39: ...t the power cord from the wire nut connection inside the junction box located on the control panel Pull the power cord up through the upper jacket and then out the hole where the strain relief was located Run the 120V 60 Hz power supply conduit up to the upper jacket hole and secure in place The new power cable can then be routed to match the placement of the old cord and run into the junction box...

Page 40: ...Page 40 SECTION IV INSTALLATION Figure 32 Component Wiring Diagram ...

Page 41: ...Page 41 Figure 33 Schematic Wiring Diagram SECTION IV INSTALLATION ...

Page 42: ... installer or service agency to replace a flooded water heater Do not attempt to repair the unit It must be replaced FOR YOUR SAFETY READ BEFORE OPERATING OPERATING INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE 2 Set the main power switch located to the left of the control display to the OFF position 3 This appliance is equipped with a device which automatically lights the burner DO NOTTRY TO LIGHT TH...

Page 43: ... heater See Troubleshooting section of this manual for solutions to error codes Page 43 Igniter sparks for 3 seconds prior to gas valve opening reset button Are the gas pressure switches Gas valve is closed and blower goes to post purge Gas supply pressure rises above 4 0 WC or gas supply pressure falls below 18 WC or air switch closes and clears blocking error ...

Page 44: ...epeatedly tap the up or down arrow to adjust the setpoint After the temperature shows the desired setpoint press the SAVE SETPOINT button Press the Home button to go back to the Home screen If the setpoint temperature was increased enough the Home screen will now display the heater status as Demand The main control should now be running through the ignition sequence and eventually light the burner...

Page 45: ...led on all domestic hot water lines MEASURING THE POINT OF USE WATER TEMPERATURE The thermostat is factory set at 120 F for domestic use It is the responsibility of the building owner to verify that the installer follows the recommended quantitative testing for measuring the point of use water temperature To make sure that the system works properly after instal lation and in the future it is recom...

Page 46: ... water and the heater is connected to the power supply the status LED will be green If the LED is flashing red this indicates a system error Refer to Table 11 in Section VII Troubleshooting for possible causes and remedies when the LED is flashing red Check the status LED every three months to ensure proper operation NOTICE TO THE OWNER The water heater must be connected to the power supply for th...

Page 47: ...al gas and 8 W C LP gas when the burner is operating at high fire Gas pressure shall not exceed 14 W C when the burner is off Measure the products of combustion in the exhaust vent At maximum input the O2 in the exhaust gas should be in the range of 3 0 4 5 CO should be less than 25 ppm If adjusting the combustion is necessary it will require adjustments to the throttle and or offset settings At h...

Page 48: ...em to draw combustion air to the burner and remove exhaust gas from the vent The combustion air intake is under a negative pressure which may cause unwanted objects to be pulled into the intake vent pipe Over time these objects may collect in the burner and affect burner ignitions and water heater performance While not required as a periodic maintenance item inspecting the burner for blockage shou...

Page 49: ... burner assembly mounting flange with four nuts and lock washers Remount the blower assembly to the transition tube with the nuts bolts and lock washers Confirm that the 2 3 8 o ring is seated properly in the gas control and reconnect the control to the flange with the four screws Reattach the air intake piping to the blower Finally reinstall the ignitor and flame rod Connect the wiring harnesses ...

Page 50: ...uild up in tank 1 Drain the water heater to remove scale and sediment Insufficient hot water 1 Heater undersized for load 1 Reduce hot water usage rate 2 Check display for error code 1 See Tables 9 and 10 3 Temperature setting of control is too low 3 Adjust setting as required Water too hot or not hot enough 1 Control temperature setting is too high or low 1 Adjust setting as required T P relief v...

Page 51: ...ontrol Description Various errors caused by E2PROM file Causes Actions Contact a qualified agency to inspect the control Description Internal software error Causes Actions Contact a qualified agency to inspect the control Description The sensor temperature reached the high limit temperature setting during burner operation Causes Actions Contact a qualified service agency to inspect the control Des...

Page 52: ...on Various WD communication errors Causes Actions Contact a qualified agency to inspect the control Description The polarity at the main power supply is reversed Causes Actions The hot and neutral wires are reversed Contact a qualified agency to inspect the installation Description A faulty earth ground connection is detected Causes Actions Improper wiring check all green wires Description The wat...

Page 53: ... present there has been a problem with lighting the burner Two possible causes for this error are a dirty or faulty flame rod or a faulty ignitor Each component can be checked for proper operation The hot surface ignitor can be checked with a visual inspection through the burner assembly sight glass Before the gas valve opens in the ignition sequence the ignitor will warm up for 20 seconds During ...

Page 54: ...green if the magnitude of the current is acceptable If the heater is in error the type of error error code and description are displayed on the Home screen The Status screen contains useful real time information pertaining to fan speeds and sensor values The History screen contains useful real time information about burner run time successful and failed ignitions and flame failures It also gives t...

Page 55: ...three options for power settings Select either MAX PWR IGNITION PWR or MIN PWR These settings are synonymous with maximum ignition and minimum fan speeds Press Start Test to finish the selection The water heater will operate at this fan speed for up to one hour or until the call for heat is satisfied Temperatures flame signal and the power level are available from the System Test screen The Home s...

Page 56: ...l Pnl Right 17123 22 Cover Ctrl Pnl Left 17122 6 Tasseron Duplex Sensor 0 25NPT Brass 21594 23 Burner Bracket Refractory Disc 18008 7 T P Valve 1 5 FVX 4 21800 24 Blower Fasco GPM 7 0 7H 19903 8 Anode 200mm 15151 25 optiTHERM Flame Rod 4 19853 9 Cap Plastic for 3 hole 17593 26 8 32 x 1 4 Socket Head Cap Screw 25137 10 Hand Hole Gasket 15560 27 Gasket optiTHERM Flame Rod 18209 11 Cover Plate 8 1719...

Page 57: ...V 20A 9 CKT 15 xxxxxx 300V AC 300V DC Terminal Block 16 17437 Harness Control OT600 900 17 20257 Control ProtoAir FPA W44 BACnet 18 19911 Board Control LWCO 19 21621 Transformer 24V WHT Rogers Figure 41 optiTHERM Control Panel Parts Table 13 optiTHERM Control Panel Parts ITEM NO PART NUMBER DESCRIPTION 1 19912 Display 2 19907 Control EPHS 850MN 3 21680 Control EPHS 850IF 4 15156 DEV ICCP Control M...

Page 58: ...ner Mounting 13 17850 Switch Low Gas Pressure Dungs GA 3 17037 Burner Mount Assembly 14 17810 Inlet Flange GV 4 17925 Gasket Burner 15 17860 BSP Needle Valve Dungs Valve 5 19843 Burner 16 25016 Bolt 1 4 20 x 7 8 6 17055 Transition Tube Assembly 17 25080 Washer Flat Zinc plated 1 4 7 19903 Blower Fasco GPM 7 0 7H 18 25147 1 4 20 Hex Nut Zinc 8 17905 Gasket Blower transtube 19 25102 1 4 Lock Washer ...

Page 59: ...creen 850 IF Control Modbus and Touchscreen 17437 3 Low Water Cut Off Safety Switches Main Control LWCO board Pressure Sensors and switches 17437 4 Temperature Sensors Main Control Exhaust and Tank Temp Sensor HX Sensor 17435 5 Gas Valve Flame Rod Main Control Flame Rod Gas Valve Harness 17435 6 Anode Main Control Titanium Anode Rods 21662 USB Connection Main Control USB Part Description Connectio...

Page 60: ...If a replacement tank is provided it will remain warranted under this section as if it were the original tank For example if we send you a replacement tank under this limited warranty two years after the original installation date then the replacement tank will remain warranted for the remaining three years after the original installation date HOW DO YOU GET SERVICE UNDER THE LIMITED WARRANTY In o...

Page 61: ...er Transfer or sell the water heater Remove the water heater from its original location and install it somewhere else Fail to follow the care and maintenance instructions provided with the water heater Alter disable or in any way cause the Impressed Current Cathodic Protection system to be inoperable Fail to maintain in continuous good working condition the Impressed Current Cathodic Protection sy...

Page 62: ...Page 62 ...