American Water Heater BCG3-85T390-6NOX manual

1 MODELS BCG3 & ABCG3 LOW NOx COMMERCIAL GAS, GLASS-LINED, TANK-TYPE WATER HEATER • INSTALLATION • OPERATION • MAINTENANCE • LIMITED WARRANTY PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE. CAUTION TEXT PRINTED OR OUTLINED IN RED CONT AINS INFORMA TION RELA TIVE TO YOUR SAFETY . PLEASE READ THO[...]

2 ROUGH-IN-DIMENSIONS FRONT VIEW TO P VIEW BACK VIEW F TOP OUTLET 1 1/2” NPT TOP INLET 1 1/2” NPT T ABLE 1. ROUGH-IN-DIMENSIONS T ABLE 2. RECOVERY CAP ACITIES, based on 80% efficiency T ABLE 3. GAS AND ELECTRICAL CHARACTERISTICS[...]

3 T ABLE OF CONTENTS ROUGH-IN-DIMENSIONS -------------------------------- 2 FOREWORD ------------------------------------------------- 3 GENERAL SAFETY INFORMA TION ------------------- 4 Precautions --------------------------------------------------- 4 Grounding Instructions ------------------------------------- 4 Chemical V apor Corrosion --------[...]

4 GENERAL SAFETY INFORMA TION PRECAUTIONS DO NOT USE THIS APPLIANCE IF ANY P AR T HAS BEEN UNDER WA TER. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water . IF THE UNIT IS EXPOSED TO THE FOLLOWING , DO NOT OPERA TE HEA TER UNTIL ALL C[...]

5 HIGH AL TITUDE INST ALLA TIONS WARNING INST ALLA TIONS ABOVE 2000 FEET (610 METERS) REQUIRE REPLACEMENT OF THE BURNER ORIFICE IN ACCORDANCE WITH SECTION 1 1.1.2 OF THE NA TIONAL FUEL GAS CODE (ANSI Z223.1). F AILURE TO REPLACE THE ORIFICE WILL RESUL T IN IMPROPER AND INEFFICIENT OPERA TION OF THE APPLIANCE RESUL TING IN THE PRODUCTION OF INCREASE[...]

6 The exhaust inducer is equipped with a gravity controlled damper to reduce the amount of heat loss through the flue, improving efficiency . EXHAUST INDUCER FIGURE 4 CIRCULA TING PUMP A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the heater . Refer to the piping diagrams in[...]

7 length and width at least 2" greater than the diameter of the heater and must be piped to an adequate drain. The pan must not restrict combustion air flow . LEVELING If the unit is not level, insert the bolts which were used in crating into the legs to correct this condition. CLEARANCES These heaters are approved for installation on combusti[...]

8 BURNERS AND FLUE TUBES AND CREA TES A RISK OF ASPHYXIA TION. Where an exhaust fan is supplied in the same room with a heater , sufficient openings for air must be provided in the walls. UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRA WN INTO THE ROOM THROUGH THE CHIMNEY , CAUSING POOR COMBUSTION. SOOTING MA Y RESUL T IN SERIOUS DAMAGE TO THE HEA TER[...]

9 TYPE B GAS VENT Multiple Gas Fired T ank-T ype Heaters When venting multiple tank type heaters using T ype B vent pipe, follow the installation diagram (figure 4) and tables below which give sizing and dat a based upon NFP A 54/ANSI Z223. 1992. T ABLE 6. TECHNICAL DA T A VENTING MODEL BCG3-80T150-6NOX Input: 154,000 Btu/hr T otal V ent Height (Fe[...]

10 W A TER LINE CONNECTIONS This manual provides detailed installation diagrams (see p ages 13-19 of this manual) for typical methods of application for the water heater(s). The water heater may be installed by itself, or with a separate storage tank, on both single and two-temperature systems. When used with a separate storage tank, the circulatio[...]

11 INST ALLA TION DIAGRAMS-TOP INLET/OUTLET USAGE Use of the top inlet water connection requires installation of an inlet dip tube (refer to figure 8). The tube is supplied in the heater . Follow caution labels if applying heat to this fitting. Do not allow pipe dope to contact the plastic tube during installation. CODE RESTRICTIONS Use of the top [...]

12 VERTICAL ST ORAGE T ANK AND FORCED CIRCULA TION DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERA TURE A T FIXTURES. SEE WA TER TEMPERA TURE CONTROL WARNING ON P AGE 25. IF HIGHER PREHEA T TEMPERATURES ARE NECESSARY TO OBT AIN ADEQUATE BOOSTER OUTPUT , ADD AN ANTI-SCALD V AL VE FOR HOT WA TER SUPPLIED TO FIXTURES. HORIZONT A L STORA[...]

13 DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERA TURE A T FIXTURES. SEE WA TER TEMPERA TURE CONTROL WARNING ON P AGE 25. IF HIGHER PREHEAT TEMPERA TURES ARE NECESSARY TO OBT AIN ADEQUA TE BOOSTER OUTPUT , ADD AN ANTI- SCALD V AL VE FOR HOT W A TER SUPPLIED TO FIXTURES. TWO TEMPERA TURE - ONE HEA TER HIGH TEMPERA TURE STORAGE WITH R[...]

14 INST ALLA TION DIAGRAMS-SIDE INLET/OUTLET USAGE DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERA TURE A T FIXTURES. SEE WA TER TEMPERA TURE CONTROL WARNING ON P AGE 25. IF HIGHER PREHEAT TEMPERA TURES ARE NECESSARY T O OBT AIN ADEQUA TE BOOSTER OUTPUT , ADD AN ANTI- SCALD V AL VE FOR HOT WA TER SUPPLIED TO FIXTURES. A listed temper[...]

15 ONE OR TWO TEMPERATURE - ONE HEATERS,HIGH TEMPERATURE STORAGE WITH OR WITHOUT RECIRCULATION HEATER WITH OR WITHOUT MIXING VALVE HEATER WITH MIXING VALVE AND RECIRCULATED SANITIZING LOOP NOTE 1: T OGGLE SWITCH CONTROLS 180°F (82°C) WA TER CIRCULA TION. INST ALL ON OR CLOSE TO DISHW ASHING MACHINE. T OGGLE SWITCH MUST BE CLOSED (ON) DURING THE R[...]

16 TWO TEMPERATURE - TWO PRE-HEATERS WITH MIXING VALVE OR BOOSTER HEATER WITH OR WITHOUT BUILING RECIRCULATION TWO PRE-HEATERS WITH MIXING VALVE TWO PRE-HEATERS WITH BOOSTER HEATER DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERA TURE A T FIXTURES. SEE W A TER TEMPERA TURE CONTROL W ARNING ON P AGE 25. IF HIGHER PREHEA T TEMPERA TURES[...]

17 MEDIUM TEMPERATURE - ONE HEATER WITH AUXILIARY STORAGE TANK FORCED CIRCULATION WITH OR WITHOUT BUILDING RECIRCULATION VERTICAL STORAGE TANK HORIZONTAL STORAGE TANK DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERA TURE A T FIXTURES. SEE WA TER TEMPERA TURE CONTROL W ARNING ON PAGE 25. IF HIGHER PREHEA T TEMPERA TURES ARE NECESSARY T[...]

18 FIGURE 9 - SINGLE UNIT WIRING DIAGRAM[...]

19 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 T able 3. The figures shown are for straight lengths of pipe at 0.5 in. W .C. pressure drop, which is considered normal for low pressure systems. N[...]

20 correct water column pressure allowing for a nominal pressure drop through the controls. The minimum gas supply pressure for input adjustment must not be less than 4.5" w .c. (1.12 kPa) for natural gas. Do not subject the combination gas valve to inlet gas pressures of more than 14.0" W .C. (3.48 kPa) - natural gas. A service regulator[...]

21 SEQUENCE OF OPERA TION The following information will describe the Sequence of Operation for this appliance. 1. Switch power on to unit. 2. Thermostat calls for heat. 3. Ignition Control Board performs diagnostic check on system component s. 4. On completion of diagnostics check, the Ignition Control Board sends signal to Exhaust Inducer . 5. Ex[...]

22 A . This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner . Do not try to light the burner by hand. B. BEFORE OPERA TING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor . “WHA T TO DO IF[...]

23 W A TER TEMPERA TURE CONTROL DANGER THIS W ATER HEA TER IS EQUIPPED WITH AN ADJUST ABLE THERMOST A T TO CONTROL W A TER TEMPERA TURE. HOT W A TER TEMPERA TURES REQUIRED FOR AUT OMA TIC DISHW ASHER AND LAUNDR Y USE CAN CAUSE SCALD BURNS RESUL TING IN SERIOUS PERSONAL INJURY AND/ OR DEA TH. THE TEMPERA TURE A T WHICH INJURY OCCURS V ARIES WITH THE[...]

24 Servicing of the ignitor assembly includes keeping the ignitor free of lint, scale or any other foreign debris. FIGURE 11, IGNITOR MAIN BURNER The main burner , fig.12, should display the following characteristics: • Cause rapid ignition and carry across entire burner . • Give reasonably quiet operation during ignition, burning, and extincti[...]

25 When the heater is operating at full capacity , or full gas input, it should consume 1 cu. ft. of gas in time indicated on T able 9. VENTING SYSTEM Examine the venting system every six months for obstructions and/or deterioration of the vent piping. Remove all soot or other obstructions from chimney which will ret ard free draft. REMOTE STORAGE [...]

26 1. Once a month the heater should be flushed. Open the drain valve and allow two gallons of water to drain from the heater . Inlet water valve should remain open to maint ain pressure in tank. 2. A cleanout opening is provided for periodic cleaning of the t ank. Gas must be shut off and heater drained before opening cleanout. T o clean heater th[...]

27 — It is possible that the high limit (E.C.O.) has functioned to shut off the appliance. See FEA TURES — Water T emperature Control for reset procedure. Contact your serviceman if limit continues to function to shut off appliance. SYSTEM DIAGNOSTICS Y our water heater is equipped with an ignition module that incorporates a diagnostic system t[...]

28 SEQUENCE OF OPERA TION FLOW CHART Description of this flow chart can be found in the “SEQUENCE OF OPERA TION” section. Switch power on to unit. Thermostat calls for heat. Ignition Control Board performs diagnostic check on components Ignition Control Board sends power to Exhaust Inducer Exhaust Inducer engages Prover Switch Ignition Control [...]

29 REMEDY COMPLAINT CAUSE USER SERVICEMAN *W ater not hot enough. Thermostat set too low. Set thermost at dial to a higher temperature. Thermostat out of calibration. Call serviceman Recalibrate thermostat. If thermostat cannot be recalibrated, replace. *Insufficient hot water Thermostat set too low. Set thermost at dial to a higher *See WA TER TEM[...]

30 NOTES:[...]

31 Model BCG3 & ABCG3 Limited Warranty American W ater Heater, the warrantor , extends the following LIMITED W ARRANTY to the owner of this water heater . 1. THE T ANK If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable water therein, during the first TH[...]

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