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American Water Heater (A)BCG3 85T500

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1. See WATER TEMPERATURE Main manual gas shutoff valve Open main manual gas shutoff l se WARNING on page partially closed valve to fullest extent Space usage to give heater time teater too Small for demand o restore water temperature Check gas input If incorrect adjust gas pressure or replace burner orifices Water temperature too hot Thermostat set too high Set thermostat to a lower setting W h h h Aw Condensation on outside of Heater makes sounds sizzling ank IERI Drain a quantity of water through drain valve If rumbling persists Delime heater call a service agent T Expansion and contraction Ticking or metallic sounds eral Drain piping system and refill Heater must be off while this is being done Too much primary air Call service agent GW ss Overfired heater Incorrect burners or orifice for type of gas Call service agent Check and correct as necessary used l If drain valve cannot be closed Drain valve not closed tightly tightly replace Possible condensation if tank nere ase tany pere setting have service agent add is undersized or stored water is w I Water leaks a mixing valve if setting will be below 110 degrees above 120 degrees If leakage source cannot be Shut off gas supply to heater Repair or in case of suspected tank corrected or identified call and close cold water inlet valve leakage be certain to confirm before service agent to heater replacing
2. Ignition Switch power on Control Board to unit opens Gas Valve Ignition Control Board shuts off Thermostat calls Silicon Nitride Wait 1 hour for heat Igniter after 3 seconds Ignition Control Board performs diagnostic check on components Ignition Control Board waits 3 more seconds to monitor Flame Sensor Ignition Control Board sends power to Exhaust Inducer Ignition Control NO Board shuts off Gas Valve and allows the Did Main Burner Light Exhaust Inducer to purge appliance for 20 seconds Exhaust Inducer engages Prover Switch YES Ignition Control Board provides power to Silicon Nitride Igniter Ignition Control Board monitors Is this the third ignition trial units until Thermostat is satisfied YES Silicon Nitride Igniter warms up for 20 seconds NO FIGURE 29 32 OPERATIONAL CHECKLIST REMEDY e CAUSE ERA SERVICE AGENT e E E Set thermostat dial to a higher temperature Upper and or lower temperature Water not hot enough Check continuity and resistance Ohms Call service agent of upper and lower temperature probes Replace probes if out of specification Een Set thermostat dial to a higher temperature Check continuity and resistance Ohms Upper and or lower temperature E obe out al calibration Call service agent of upper and lower temperature probes Insufficient hot water P Replace probes if out of specification
3. L A l k 49 COMMERCIAL STORAGE TANK WARRANTY A WHO IS COVERED AMERICAN WATER HEATER COMPANY herein collectively referred to as Manufacturer warrants only to the original purchaser hereinafter Owner of the storage tank for the period specified below This warranty is not transferable The warranty is restricted to the storage tank used in a commercial application in the United States of America B WHENIT IS COVERED The storage tank is warranted only when it is installed operated and maintained in accordance with the printed instructions accompanying the storage tank A storage tank should be installed in such a manner that if the tank or any connection thereto should leak the resulting flow of water will not cause damage to the area in which it is installed A systems temperature and pressure relief valve must be piped to the nearest drain to avoid damage in the event the valve is actuated For detailed instructions read the manual accompanying the water heater and review drawings in the manual C WHAT THE MANUFACTURER WILL DO AND THE PERIOD OF COVERAGE 1 The Inner Tank If the inner tank leaks within three years after the original installation Manufacturer will furnish a new storage tank of Manufacturer s then prevailing comparable model If industry standards product improvements or product obsolescence prohibits Manufacturer from furnishing an identical model replacement water he
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5. 1 External fire 2 Damage 3 Firing without water GROUNDING INSTRUCTIONS This water heater must be grounded in accordance with the National Electrical Code and or local codes These must be followed in all cases This water heater must be connected to a grounded metal permanent wiring system or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the water heater see Figure 20 HYDROGEN GAS FLAMMABLE AWARNING Explosion Hazard e Flammable hydrogen gases may be present e Keep all ignition sources away from faucet when turning on hot water Hydrogen gas can be produced in a hot water system served by this appliance that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable To reduce the risk of injury under these conditions itis recommended that a hot water faucet served by this appliance be opened for several minutes before using any electrical appliance connected to the hot water system If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow THERE SHOULD BE NO SMOKING OR OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN INTRODUCTION Thank You for purchasing this water heater Properly installed and maintained it should give you years of trouble free service ABBREVIATIONS USED Abbrev
6. The discharge opening of the temperature and pressure relief valve must be piped to an open drain and should not be subject to freezing temperatures Install in accordance with all local codes INSTALLATION DIAGRAMS TOP INLET OUTLET USAGE Use of the top inlet water connection requires installation of an inlet dip tube refer to figure 19 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 TUBE INLET INSTALLATION TOP INLET EXTENTION FIGURE 19 20 CODE RESTRICTIONS Use of the top inlet water connection is not permitted on installations in the state of North Carolina due to the material of the tube Polypropylene Where such code restrictions exist use only lower inlet tank connection This may also require a heat trap check local codes The Top Outlet connection may still be used on these applications Plug or cap all unused openings in the tank before filling with water TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES SEE WATER TEMPERATURE CONTROL AND MIXING VALVE WARNING ON PAGE 12 IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES HEATER WIRING All electrical work must be installed in accordance with the latest version of the National Electrical Code ANSI NFPA No 70 and must c
7. If you do not understand the instructions given in this manual do not attempt to perform any procedures outlined in this manual FEATURES AND COMPONENTS THE ELIMINATOR SELF CLEANING SYSTEM These units include The Eliminator Self Cleaning System installed in the front water inlet See Figure 1 The Eliminator inlet tube can only be used in the front water inlet connection Do not install the Eliminator inlet tube in either the top or back inlet water connection The Eliminator must be oriented correctly for proper function There is a marked range on the pipe nipple portion of the Eliminator that must be aligned with the top of the inlet spud A label above the jacket hole has an arrow that will point to the marked portion of the pipe nipple if the orientation is correct If the arrow does not point within the marked range on the pipe nipple adjust the pipe nipple to correct A pipe union is supplied with the Eliminator to reduce the probability of misaligning the Eliminator accidentally while tightening the connection to the inlet water supply line Improper orientation of the Eliminator can cause poor performance of the heater and can significantly reduce outlet water temperatures during heavy draws Note The Eliminator may have 1 3 or 7 cross tubes FIGURE 1 HIGH LIMIT SWITCH The digital thermostat Figure 2 contains the high limit energy cutoff switch The high limit switch interrupts main burner gas flow should the wat
8. air must be provided that accommodate the requirements for all appliances in the room and the exhaust fan Undersized openings will cause air to be drawn into the room through the water heater s vent system causing poor combustion Sooting serious damage to the water heater and the risk of fire or explosion may result It can also create a risk of asphyxiation LOUVERS AND GRILLES The free areas of the fresh air openings in the instructions that follow do not take in to account the presence of louvers grilles or screens in the openings The required size of openings for combustion ventilation and dilution air shall be based on the net free area of each opening Where the free area through a design of louver or grille or screen is known it shall be used in calculating the size of opening required to provide the free area specified Where the louver and grille design and free area are not known it shall be assumed that wood louvers will have 25 free area and metal louvers and grilles will have 75 free area Non motorized louvers and grilles shall be fixed in the open position VENT ADAPTER The A BCG385T500 8N A BCG385T500 8P model is shipped with a 6 to 8 diameter vent adapter Fig 11 The vent adapter fits on top of the installed blower exhaust Use only vent adapters supplied with the unit The venting must comply with the NATIONAL FUEL GAS CODE ANSI Z223 1 NFPA 54 and for Canadian installations consult the Canadian
9. allow all the water to drain from the storage tank 8 Close the water heater drain valve when all water in the storage tank has drained 9 Close the hot water faucet opened in Step 4 10 If the water heater is going to be shut down for an extended period the drain valve should be left open TO FLUSH THE WATER HEATER STORAGE TANK Turn off the electrical supply to the water heater 2 Ensure the cold water inlet valve is open 3 Open a nearby hot water faucet and let the water run until the water is no longer hot Then close the hot water faucet 4 Connect a hose to the drain valve and terminate it to an adequate drain 5 Ensure the drain hose is secured before and during the entire flushing procedure Flushing is performed with system water pressure applied to the water heater 6 Open the water heater drain valve to flush the storage tank 7 Flush the water heater storage tank to remove sediment and allow the water to flow until it runs clean 8 Close the water heater drain valve when flushing is completed 9 Remove the drain hose 10 Fill the water heater see Filling The Water Heater in this manual 11 Turn on the electrical supply to place the water heater back in operation 12 Allow the water heater to complete several heating cycles to ensure it is operating properly RECOMMENDED PROCEDURE FOR PERIODIC REMOVAL OF LIME DEPOSITS FROM TANK TYPE COMMERCIAL WATER HEATERS The amount of calcium carbonate
10. appliances are installed through openings not furnished with doors are considered a part of the unconfined space Makeup air requirements for the operation of exhaust fans kitchen ventilation systems clothes dryers and fireplaces shall also be considered in determining the adequacy of a space to provide combustion ventilation and dilution air UNUSUALLY TIGHT CONSTRUCTION In unconfined spaces in buildings infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases However in buildings of unusually tight construction for example weather stripping heavily insulated caulked vapor barrier etc additional air must be provided using the methods described in the Confined Space section that follows CONFINED SPACE A Confined Space is one whose volume IS LESS THAN 50 cubic feet per 1 000 Btu hr 4 8 cubic meters per kW of the total input rating of all appliances installed in the space Openings must be installed to provide fresh air for combustion ventilation and dilution in confined spaces The required size for the openings is dependent on the method used to provide fresh air to the confined space AND the total Btu hr input rating of all appliances installed in the space EXHAUST FANS Where exhaust fans are installed additional air shall be provided to replace the exhausted air When an exhaust fan is installed in the same space with a water heater sufficient openings to provide fresh
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12. is made with any live electrical part The discharge opening must not be blocked or reduced in size under any circumstances Excessive length over 30 feet 9 14 m or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve No valve or other obstruction is to be placed between the Temperature Pressure Relief Valve and the tank Do not connect discharge piping directly to the drain unless a 6 15 2 cm air gap is provided To prevent bodily injury hazard to life or property damage the relief valve must be allowed to discharge water in adequate quantities should circumstances demand If the discharge pipe is not connected to a drain or other suitable means the water flow may cause property damage CAUTION e Temperature Pressure Relief Valve discharge pipe must terminate at adequate drain T amp P Valve Discharge Pipe Requirements e Shall not be smaller in size than the outlet pipe size of the valve or have any reducing couplings or other restrictions Shall not be plugged or blocked Shall not be exposed to freezing temperatures Shall be of material listed for hot water distribution Shall be installed so as to allow complete drainage of both the Temperature Pressure Relief Valve and the discharge pipe Must terminate a maximum of six inches above a floor drain or external to the building In cold climates it is recommended that the discharge pipe be terminated at an adequate dra
13. limited warranty Thermal expansion can also cause intermittent Temperature Pressure Relief Valve operation water discharged from the valve due to excessive pressure build up This condition is not covered under the limited warranty The Temperature Pressure Relief Valve is not intended for the constant relief of thermal expansion A properly sized thermal expansion tank must be installed on all closed systems to control the harmful effects of thermal expansion Contact a local plumbing service agency to have a thermal expansion tank installed See Water Line Connections on page 19 and the Water Piping Diagrams beginning on page 34 TEMPERATURE PRESSURE RELIEF VALVE AWARNING e Temperature Pressure Relief Valve must comply with ANSI Z21 22 CSA 4 4 and ASME code e Properly sized temperature pressure relief valve must be installed in opening provided e Can result in overheating and excessive tank pressure e Can cause serious injury or death This water heater is provided with a properly rated sized and certified combination Temperature Pressure Relief Valve T amp P valve by the manufacturer The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems ANSI 221 22 CSA 4 4 and the code requirements of ASME If replaced the new T amp P valve must meet
14. supplier 1 Set the thermostat to lowest setting 3 Push in gas control knobs slightly and turn clockwise 4 to OFF Do not force 2 Turn off all electric power to appliance if service is to be performed FIGURE 22 24 CHECK VENTING The following steps shall be followed with each appliance connected to the venting system placed in operation while any other appliances connected to the venting system are not in operation 1 2 Seal any unused openings in the venting system Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI Z223 1or the CAN CGA B149 Installation Codes and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition So far as is practical close all building doors and windows and all doors between the space in which the water heater s connected to the venting system are located and other spaces of the building Turn on all appliances not connected to the venting system Turn on all exhaust fans such as range hoods and bathroom exhausts so they shall operate at maximum speed Close fireplace dampers Follow the lighting instruction Place the water heater being inspected in operation Adjust thermostat so appliance shall operate continuously lest for spillage at the burner level after 5 minutes of main burner operation After it ha
15. the requirements of local codes but not less than a combination Temperature Pressure Relief Valve rated sized and certified as indicated in the above paragraph The new valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater 150 psi 1 035 kPa and a discharge capacity not less than the water heater Btu hr or kW input rate as shown on the water heater s model rating label NOTE In addition to the factory installed Temperature Pressure Relief Valve on the water heater each remote storage tank that may be installed and piped to a water heating appliance must also have its own properly sized rated and approved Temperature Pressure Relief Valve installed Call the toll free technical support phone number listed on the back cover of this manual for technical assistance in sizing a Temperature Pressure Relief Valve for remote storage tanks For safe operation of the water heater the Temperature Pressure Relief Valve must not be removed from its designated opening nor plugged The Temperature Pressure Relief Valve must be installed directly into the fitting of the water heater designed for the relief valve Install discharge piping so that any discharge will exit the pipe within 6 inches 15 2 cm above an adequate floor drain or external to the building In cold climates it is recommended that it be terminated at an adequate drain inside the building Be certain that no contact
16. to the pipe pressure drop Also refer to the latest version of the National Fuel Gas Code Schedule 40 Metallic Pipe is the preferred material for the gas line of this water heater It is imperative to follow the sizing recommendations in the latest version of the National Fuel Gas Code if Corrugated Stainless Steel Tubing CSST is used as the gas line for this water heater THE HEATER IS NOT INTENDED FOR OPERATION AT HIGHER THAN 14 0 W C NATURAL GAS 1 2 POUND PER SQUARE INCH GAGE SUPPLY GAS PRESSURE EXPOSURE TO HIGHER SUPPLY PRESSURE MAY CAUSE DAMAGE TO THE GAS VALVE WHICH COULD RESULT IN FIRE OR EXPLOSION IF OVERPRESSURE HAS OCCURRED SUCH AS THROUGH IMPROPER TESTING OF GAS LINES OR EMERGENCY MALFUNCTION OF THE SUPPLY SYSTEM THE GAS VALVE MUST BE CHECKED FOR SAFE OPERATION MAKE SURE THAT THE OUTSIDE VENTS ON THE SUPPLY REGULATORS AND THE SAFETY VENT VALVES ARE PROTECTED AGAINST BLOCKAGE THESE ARE PARTS OF THE GAS SUPPLY SYSTEM NOT THE HEATER VENT BLOCKAGE MAY OCCUR DURING ICE STORMS TABLE 9 GAS SUPPLY PIPE LENGTH FEET 500 000 btu hr input rate Schedule 40 deer MAXIMUM EQUIVALENT PIPE LENGTH FEET OS Ap sw 1 1 4 _ 6 f ee Natural Gas 0 60 Specific Gravity 0 50 W C pressure drop Propane Gas 1 50 Specific Gravity 0 50 W C pressure drop IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING FROM CONTAMINANTS IN THE GAS WAYS SUCH FOULING MAY CAUSE IMPROPER OPERATION FIRE OR EXPLOSION IF COPPER SUPPL
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18. 2 Is the water temperature in tank below the thermostat dial setting on the appliance thermostat calling for heat It is possible that the high limit E C O has functioned to shut off the appliance See High Limit page 7 High Limit Switch for reset procedure Contact your service agent if limit continues to function to shut off appliance SYSTEM DIAGNOSTICS Your water heater is equipped with an ignition module that incorporates a diagnostic system to assist in troubleshooting the appliance The indicator codes on the ignition module are as follows TABLE 11 1 FLASH System lockout retries or cycles exceeded 7 FLASHES Low flame sense signal make sure flame sensor is in burner flame 8 FLASHES Check ignitor continuous flash gt continuous flame sensed gt 5 seconds without gas valve continuous on gt internal control failure replace ignition control module Use this diagnostic system in conjunction with the OPERATIONAL CHECKLIST and the SEQUENCE OF OPERATION to troubleshoot the appliance SERVICE The installer may be able to observe and correct certain problems which may arise when the unit is put into operation HOWEVER it is recommended that only qualified service agents using appropriate test equipment be allowed to service the heater As preliminary step check wiring against diagram check for grounded broken or loose wires Check all wire ends to be sure that they are making good c
19. 4 4 and ASME code Properly sized temperature pressure relief valve must be installed in opening provided Can result in overheating and excessive tank pressure Can cause serious injury or death HOT WATER ODOR On occasion hot water may develop a strong odor If this occurs drain the heater completely flush thoroughly and refill Ifthe problem persists chlorination of the heater and replacement of magnesium anodes with aluminum anodes may correct the condition Occasionally water softener companies recommend removal of heater anodes for odor reasons Unauthorized removal of the anode s will void the warranty For further information contact your dealer ANODE ROD INSPECTION CAUTION e Avoid water heater damage e Inspection and replacement of anode rod required The heater tank is equipped with anode rods to provide corrosion control At least once a year the anode rods should be checked to determine if replacement is necessary Initially the anode rods are approximately 7 8 in diameter with a 1 8 diameter steel core wire running down the center of the anode material THE ANODES SHOULD BE REPLACED when the 1 8 diameter core wire is visible as this means that the anode material has been expended in the control of corrosion For models with top inlet and outlet it is recommended that before removing the inner cover for cleaning inspection or removal of inner parts you obtain two new nipple collars p
20. 45 cm2 OUTDOOR AIR THROUGH ONE OPENING 8 EE E des E Dp EN GESTERN a NEE eee Ae a ss AS E a M 9 SS Alternatively a single permanent opening commencing within 12 inches 300 mm of the top of the enclosure shall be provided See Figure 15 The water heater shall have clearances of at least 1 inch 25 mm from the sides and back and 6 inches 150 mm from the front of the appliance The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of the following 1 1 square inch per 3000 Btu hr 733 mm per kW of the total input rating of all appliances located in the enclosure and 2 Not less than the sum of the areas of all vent connectors in the space OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS TI IO ne it S ceam FIGURE 16 The confined space shall be provided with two permanent horizontal ducts one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm of the bottom of the enclosure The horizontal ducts shall communicate directly with the outdoors See Figure 16 Each duct opening shall have a minimum free area of 1 square inch per 2 000 Btu hr 1100 mm per kW of the aggregate input rating of all appliances installed in the enclosure When ducts are used they shall be of the sa
21. ADJACENT TO THE HEATER OPEN CONTAINERS OR FLAMMABLE MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM WITH THE HEATER THE HEATER MUST NOT BE LOCATED IN AN AREA WHERE IT WILL BE SUBJECT TO FREEZING LOCATE IT NEAR A FLOOR DRAIN THE HEATER SHOULD BE LOCATED IN AN AREA WHERE LEAKAGE FROM THE HEATER OR CONNECTIONS WILL NOT RESULT IN DAMAGE TO THE ADJACENT AREA OR TO LOWER FLOORS OF THE STRUCTURE WHEN SUCH LOCATIONS CANNOT BE AVOIDED ASUITABLE DRAIN PAN SHOULD BE INSTALLED UNDER THE HEATER Such pans should be fabricated with sides at least 2 deep with 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 CLEARANCES This water heater is approved for installation on combustible flooring with NSF Leg Kit 9003425205 in an alcove when the minimum clearance from any combustible construction is as indicated in Figure 6 and Table 4 In all installations the minimum combustible clearances from vent piping shall be 6 15 2 cm Vent piping passing through a combustible wall or ceiling must be a continuous run no joints and retain the 6 15 2 cm clearance unless an approved reducing thimble is used A service clearance of 24 61 cm should be maintained from serviceable parts such as relief valves flue baffles thermostats cleanout openings or drain valves The units are approved for installation with side rear an
22. AS PRESSURE REQUIREMENTS Natural gas models require a minimum gas supply pressure of 4 5 W C Propane gas models require a minimum gas supply pressure of 11 W C The minimum supply pressure is measured while gas is not flowing static pressure AND while gas is flowing dynamic pressure The supply pressure static and dynamic should never fall below the specified minimum supply pressure The supply pressure should be measured with all gas fired appliances connected to the common main firing at full capacity If the supply pressure drops more than 1 5 W C as gas begins to flow to the water heater then the supply gas system including the gas line and or the gas regulator may be restricted or undersized See Supply Gas Regulator section and Gas Piping section of this manual The gas valve on all models has a maximum gas supply pressure limit of 14 W C The maximum supply pressure is measured while gas is not flowing static pressure AND while gas is flowing dynamic pressure SUPPLY GAS REGULATOR The water heater covered by this manual may require the installation of a supply gas regulator If the supply gas pressure exceeds 14 inches W C a supply gas regulator must be used If the gas supply pressure exceeds 14 W C in a multiple water heater installation each water heater must have its own supply gas regulator If required the supply gas regulator shall be rated at or above the Btu hr input rating of the water heater it suppl
23. AS SHUTOFF VALVE GAS PIPING AND DIRT LEG INSTALLATION lt REGULATED GAS SUPPLY LINE REDUCER COUPLING rx La Ra vro anv er D d Q y TEZ Be gt ae D PIPE CAP FIGURE 21 PURGING Gas line purging is required with new piping or systems in which air has entered PURGING SHOULD BE PERFORMED BY PERSONS EXPERIENCED IN THIS TYPE GAS SERVICE TO AVOID RISK OF FIRE OR EXPLOSION PURGE DISCHARGE MUST NOT ENTER CONFINED AREAS OR SPACES WHERE IGNITION CAN OCCUR THE AREA MUST BE WELL VENTILATED AND ALL SOURCES OF IGNITION MUST BE INACTIVATED OR REMOVED GAS METER SIZE NATURAL GASES ONLY Be sure the gas meter has sufficient capacity to supply the full rated gas input of the water heater as well as the requirements of all other gas fired equipment supplied by the meter If gas meter is too small ask the gas company to install a larger meter having adequate capacity GAS PRESSURE REGULATOR The gas pressure regulator is built into the gas valve and is equipped to operate on the gas specified on model and rating plate The regulator is factory adjusted to deliver gas to burner at 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 or 11 0 W C 2 74 kPa for propane gas Do not subject the combination gas valve to inlet gas p
24. CAL ASSISTANCE SERVICE OR WARRANTY INFORMATION PHONE TOLL FREE 1 800 456 9805 MONDAY THROUGH FRIDAY 8 00 AM to 8 00 PM EASTERN STANDARD TIME OR Write to American Water Heater Company ATTN PRODUCT SERVICES COMMERCIAL DEPARTMENT P O BOX 1597 JOHNSON CITY TN 37605 1597 50 NOTES Ze eege WATER HEATERS P O Box 1597 Johnson City TN 37605 Phone 800 456 9805 Fax 800 999 5210 www americanwaterheater com Copyright 2010 American Water Heater Company All rights reserved
25. ER USAGE E LY Z ZZ GE A ge ms L dl E W S E SS E a a Li m 1500 2100 2700 2700 3800 WATER USAGE IN GALLONS PER DAY m FIGURE 27 DELIMING SOLVENTS A O Smith recommends the use of UNeLIME for deliming UNeLIME is a patented food grade acid which is safe to handle and does not create the harmful fumes which are associated with other products UNeLIME may be obtained from your dealer distributor or A O Smith Product Service Division Order Part Number 9005416105 1 gallon packed 4 gallons per case or Part Number 9005417105 5 gallon container 28 NOTE UneLime is not available for use in Canada Hydrochloric base acids are not recommended for use on glass lined tanks Observe handling instructions on label of product being used TANK CLEANOUT PROCEDURE The following practices will ensure longer life and enable the unit to operate at its designed efficiency 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 maintain pressure in tank A cleanout opening is provided for periodic cleaning of the tank Gas must be shut off and heater drained before opening cleanout To clean heater through cleanout opening proceed as follows 3 4 9 Drain heater Remove outer cover plate from lower side of heater jacket Remove six 6 hex head screws securing t
26. Indoor Gpaces F Technical Data Venting 18 WATER HEATER INSTALLATION 19 Water Line Connections nnns 19 TAP Valve Discharge Pipe 19 Installation Diagrams Top Inlet Outlet Usage 20 Foo de NONS TT TT T T OT 20 E PI An 21 A o 22 An e ONE UP TM 22 Gas Pressure Regulator 22 OPERATION cola 23 a rhw ETT 25 PUG one gita an etan e be O A 23 SEQUENCE OF OPERAT H e E 23 Lighting amp Operation Label 24 CHECK Venting uuu e 25 Check the Igniter Assembly 25 Igniter Assembly EE 25 bis E 25 Gas SS eege 25 Checking the DU EE 26 MAINTENANCE uA u u ana raini hibet 26 Venting o br hts babe 26 Remote Storage Tank Temperature Control 26 Temperature Pressure Relief Valve Test 26 Hot EE 27 Anode Rod Inspection 2f Draining and FIUSHINO E 27 Recommended Procedure for Periodic Removal of Lime Deposits from Tank Type Commercial Water Heate
27. Installation Code CAN CSA B149 1 00 FIGURE 11 VENTING INSTALLATION VENTING THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST BE FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULATION OF FLUE GASES SUCH CONDITIONS CAUSE SOOTING OR RISKS OF FIRE AND ASPHYXIATION Heater must be protected from freezing downdrafts Remove all soot or other obstructions from the chimney that will retard a free draft Type B venting is recommended with these heaters For typical venting application see TECHNICAL DATA VENTING on page 18 This water heater must be vented in compliance with all local codes the current revision of the National Fuel Gas Code ANSI Z223 1 and with the Category Venting Tables If any part of the vent system is exposed to ambient temperatures below 40 F it must be insulated to prevent condensation Do not connect the heater to a common vent or chimney with solid fuel burning equipment This practice is prohibited by many local building codes as is the practice of venting gas fired equipment to the duct work of ventilation systems CORRECT METHOD OF VENT PIPE i INSTALLATION INCORRECT INSTALLATION WITH NO UPWARD ANGLE PROVIDE MAXIMUM VERTICAL RISE OF VENT PIPE DIRECTLY ABOVE HEATER BEFORE TURNING INTO HOIZONTAL RUN FIGURE 12 Where a separate vent connection is not available and the vent pipe from the heater must be connected to a common vent with an oil burning furnace the vent pipe should
28. Instruction Manual AVA lt OCA MODELS A BCG3 85T500 8N 8 A BCG3 85T500 8P 2 7 2 2 2 SERIES 120 121 WATER HEATERS INSTALLATION OPERATION SERVICE P O Box 1597 MAINTENANCE LIMITED WARRANTY Johnson City TN 37605 SEDE n LISTED warERQUALITY ASME CRN Low Lead Content WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier AWARN l N e call the fire department I Read and understand this instruction Installation and service must be manual and the safety messages performed by a qualified installer herein before installing operating or service agency or the gas supplier servicing this water heater Failure to follow these instructions and safety messages could result in death or serious injury Thank you for buying this energy efficient water heater Eet We appreciate your confidence in our products water heater PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NO
29. LVWINOUIO S3ONVNIGSO ONV S3QOOO TVOO 1 HLIM MO3HO S3OIA3Q YSHLO ANY NOILVYNSISANOO SNIdld UJILSITDONS SMOHS SNIMV8SG SIHL ONINSHVM JAVA 4338 3unssaud FATWA 03H0 ON l JA TIWA 33 1138 e IN393 MNVL JOVYUOLS TV LNOZINOH HLIM SLINA 3N14 1LINW ow o NY 45 eBesn 1194 UJSAOB eus sapos e20 USA AOH jun GUIDIAJSS JO UMOUS 9Je SSAJLA BDIAIOS E Ulojs s ay ui jueuoduuJoo Aug jo Hues aunssald pasoxe Jou eys Gunjes AJLA Lola eunsseJd pue n jej duu9 oul e wesBeip Buidid palajald SALON gt ANVL NOISNVdX3 2 2 J CET T Iw Alddns YILVM 07109 men 9 N NaNLAY a A A nan YALVM LOH NIV30 N3dO OL d 81 Adid NIVHGO NIDO OL d 81 3dld NIV30 N3dO OL d81 3dld NIV30 N3dO OL d81 3dld STANLXIFJ OL 3l VM LOH NIVad HOLIMS MOT H31VM S TOUYLNOD SYNLVYSdWSL MNVL SLNAWSYINOAY WNOILIGGV HOJ S3JONVNIQSHO ANY SACO9 TVOO 1 HLIM MOSHO S3OIA3Q YSHLO ANY NOLLVHOOI3NOO SNIdld J9V9 dgMWniVveadimWa L dt d DNILLWINOIO QALSSADONS SMOHS ONIMYAU SIHL ONINAVA JAYA MOJHO SJ JAVA 33 7138 IYNASSIYA SAWA Jal T38 JATVA TIVA 1Y0d TINA C AYNSSAYd 8 JANIVAIdWNIL IN39431 SLINA pl 30714 an13 ILINW uec o H 46 JoJ3u02 e4njejeduje yue y uey JeyBiy d s 1B p jas eq pinous je1souueu Gunelado s Jajesy ejem ay s yue eBeJ01s ou pue s 1ajesy Jajem ou usam aq dwnd au o1juo9 pue 0 paJim eq pinous o41u02 ou
30. MENTS ARE NECESSARY 1 CHECK MANIFOLD AND INLET GAS PRESSURES 2 CYCLE CHECK CHECK AT LEAST ONE BURNER OPERATION WHEN THERMOSTAT IS SATISFIED BURNER WILL SHUT OFF AND INDUCER WILL STOP RUNNING ON CALL FOR HEAT THE INDUCER WILL COME ONAND CLOSE THE PRESSURE SWITCHAND THE IGNITION SEQUENCE DESCRIBED ABOVE WILL BEGIN SEE SEQUENCE OF OPERATION SEQUENCE OF OPERATION 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 components 4 Oncompletion of diagnostics check the Ignition Control Board sends signal to Exhaust Inducer 5 Exhaust Inducer begins drawing air through appliance closing the Prover Switch 6 On completion of Prover Switch engagement the Ignition Control Board begins the ignition cycle 7 The Ignition Control Board provides power to the Silicon Nitride Ignitor 8 The Silicon Nitride Ignitor heats up for approximately 17 to 20 seconds 9 At the end of Silicon Nitride Ignitor s warm up the Ignition Control Board opens the Gas Valve 10 From the time the Gas Valve opens the Ignition Control Board waits 3 seconds and then shuts off power to the Silicon Nitride Ignitor 11 From the time the Silicon Nitride Ignitor s power is shut off the Ignition Control Board waits 3 more seconds to monitor the Flame Sensor 12 If the F
31. N NIV30 N3dO NIV30 N3dO OL d8L Jdid OL d8L Jdid ME AA C oul s O O AN STANLXIF OL Y3ILVM LOH SLNAWSYINOAY WNOILIGGV HOJ SSAONVNIGHO ANY 3009 TVOO 1 HLIM 493H9 S3OIA3Q YSHLO ANV NOILVYNSISANOO ONI did QALSSADONS SMOHS 9NIMV8SGO SIHL ONINSHVM SLINN Z ana IANN 37 JoJ3u02 SIN essdw9 qUe ay uey JeyBiy 4 seslbap 1es eq pinous je souou Gunelado s jajeoy Jajem ay e s 4ue1 aBeJo s ou pue s 1a esy Jejem ou ussm aq dund ay ojlluo2 pue 0 paJiM eq pinoys OJU0J aunjejadwsa yuej ay y eDesn 11y Uano6 eus sapos e20 Janamoy JUN HUIDIAJOS JOJ UMOUS Je SBAJCA BDIAIOS ulojs s ay ui jueouodwoo ue jo Huel euynsseJd pasoxa jou peys Buas anea Lola aunssald pue aunjeladuwa ayi Z wesBeip Buidid pallajaelgd SILON dr Ee a enn HOO1J sivi JFN gt GSHSINI4 NOISNVdX3 NOILOANNOO E P H31VM 0109 EE FIVNYILIV Na i YALVM 0709 ew eme NT z lt NIVYd N3dO NIVYa N3dO Ly Ol d81 Adid Ol d81 3dld NYNLIY N lt e 3LV3H e 3LV3H YILVM LOH HD O E n DN Di ct m CA CO lo l SIYN1XIW OL YALVM LOH nivaa E A ese e JOMINOO 3H lVHSdWSLXNVL SIN3IN3HIOQO38 IWNOILIGGV HOJ 39V9 3univs3dWa dWnd ONILVINOMID p gt SHONVNIGHO ANY S3009 1V907 HLIM MOSHO S3OIA3Q YSHLO ANY NOILVYNDSISNOO SNIdid OJIISIADONS SMOHS SNIMV O SIH L ONINSVM 3NIVA MOIHO PN 3ATVA 3431138 JanssJ d Yo JA WA 33l 138 AAWA TIV8 LAOd TINA
32. NLXIF OL SJANLXIF OL A dH3lVM LOH YALVM YJILSOOH Nivaa E EE JOMINOO FANIVHFAWALYNYL SININJFANODOIJTA IWNOILIGGV YOS 39V9 3univ3dlWa3 L B dWNd 9NILVTIOYOMIO o SAONVNIGHO ANY S3QdO2O 1V90O1HLIM A93H9 SIDIAIFJA YSHLO GNV NOILVHOO9IJNOO SNIdld aalsaoeons SMOHS 9NIAWSCGO SIHL ONINSHVM awa wan gt l 3A1VA 431138 JYNSSIYA Yo AAA 431138 3ATVA Ti LHOd TINS e FYNSSIY Y JAN IVAUIJWIL Yo AIYNLVYAdWAL OML SLINN Z 30713 LINN IN393 41 eDesn 1194 UJ9SAOB eus sapos EJO AABMOH YUN Bursialas 10 UMOUS Je SBAJBA BJIAJBS E ulojs s ay ui jueuoduJoo Aug jo Bulnes inss id peoeoxe Jou eys Bulnes AJLA Lola eunsseJd pue ouinjeledwaj ay e wesBeip Buidid pousoyosd SALON SYSLVAH WOILNSC 38 LSNW AAA enn O Y0014 Q3HSINIJ A AS ANVL Em NOISNVdX3 YILVIH P ualsoog WOIdAL Alddns p ualvM G109 rm ic YILVM uie 0S aF1soog S GEI ET Halv3H 34d H31VM LOH Sal M Nivad N3dO Ol At did OL d 1 3dld OL 481 3dld x A qasn aln CS A Wen Sg Ft NN LY Y31S008 gt 3YNLVYIANAL d3YOLS LV 137110 LOH NIVYC HOLIMS MO 14 H31VM c TOULNOD FYNLWYAdWAL xNV L SINAWSYINOAY WNOILIGGV HOJ FOVS AMNIVYAdWAL diNid ONILVINOUID SAONVNIGHO ANY S3I009 TVOO 1H LIM MOSHO S3OIA3Q Y3H1O ANY NOILVHOOIJ3NOO ONIdld QALSADONS SMOHS 9S9NIMVSO SIHL DNINYVM 3A VA 33l 138 IYNASSIYA FATWA M03H9 ON JATVA d3I 1334 O IN39431 3univuadWal OML YALSOO H LIM SLINN Z 3N14 ILINW oe o H 42
33. O N3dO NIVHO N3dO NIVHO N3dO m Ol 48 1 3dld OL d 81 3dld Ol 48 1 3dld NMALIY W lt Y31V3H GEIER H3lvaH d YALVM LOH 4 i o EJ gt Il SE NIVHO N3dO Ol 48 1 3dld S38N1XIW OL YILVM LOH NIV amp C HOLIMS MO 13 41M L TOYLNO9 SYNLWYAdWAL ANVL SLNAWSYINOAY TWNOILIGGV HOJ 3Jov JYNIVYIUNAIL dWNd DNILVINIDAIO SAONVNIGHO ANY Sd3GOO TVOO 1 HLIM MOSHO S3OIA3d YSHLO ANY NOILVHOOIJ3NOO ONI did QALSASDONS SMOHS SNIMV8SG SIHL ONINAVAN 3A VA 33l 138 JansSSJAJ 3NIVA A93H9 ON 3ATVA 33 1138 C OIN393 MNVL 39VYO LS 1V2ILH3A HLIM SLINN 3013 111nN teo NY 44 JONJUOD SIN Jessdws9 qUe ay uey JeyBiy 4 s 1B p jas eq pinous je1souueu Gunelado e ajesy Jajem ay L s yue aBeJo s ou pue s 1a esy Jejem ou ussm aq duund ay o juos pue 0 paJim eq pinoys o43u02 ounjeledwe yue sy eDesn 11y ui AOB eus sapos eso Janamoy YUN HUIDIAJOS 10 UMOUS Je SGAJBA 92IAJ9S ulojs s ay ui jueouodwoo ue jo Gune euynsseJd pasoxa jou Jeys Bulnes Ajea Jer aJ aunssald pue sunjeladua sy wesBeip Buidid pawajaid SALON CN oO TW E DARE _ YOO H Q3aHSINIA MNV L NOISNVdX3 Alddns YALVM MOS Va NOLLV2OJ cuelgo 31VNY311V NIVYd N3dO NivYa N3dO OL d ddld OL d ddld 3JILVIH gt gt e N3NL3Y SIM LOH NIV30 N3dO OL dal Jdid STJANLXIF3 OL YSALVM LOH e NIYNG HOLIMS MO 13 41M u JOH 1NOO SYNLWYAdWAL ANVL SININ3YINO3Y IWNOILIGGV HOJ 39V9 AYNLVYAdWAL dINNd ONI
34. ONVNIGHO ANY S3I0d09 1V9O1HL LIM MOSHO SIDIAFA YSHLO GNV NOILVYNDSIANOO 9NIdld a31SI99NS SMOHS SNIMVSHCG SIHL ONINSHVM 3ATVA 331138 JansSJAd 3NIVAM93H9 ON 3ATVA 33 1138 C OIN393l ow go ANVL 39VHOLS TVOLLH3A HLIM LINN L ana LLIN 34 JO JUO eunjeJeduje yue y uey JayBiy d seeJDep 19S eq pinous e SOW ISU Bunejedo e Jajesy Jejem ay s 4ue1 aBeJo s ou pue s 1a esy Jajem ou uesm aq duund ay ojlluo2 pue 0 paJim eq pjnous oljuooO ounjeledwe yuej sy aBesn Jou UJ9SAOB eus sapos EJO Janamoy PUN GUIDIAJOSS JO UMOUS Be SALA 9IJIAJBS ulojs s ay ui jueuoduJoo Aue jo Buel nss id pasoxa jou eys Buas AJLA Jeljo aunssald pue aunjejadua ay wesBeip Buidid pallajald SALON QNO TW HOO 14 Q3HSINIJ E DLL i A __ NIVHO N3dO OL d81 3dld pv lt SINTNTFAMNMOJTA TVNOILIQGV HOS SAONVNIGHYO ANY SI0d09 WOOT HLIM MOSHO Y31WM 0109 e EN MNVL NOISNVdX343 A Iddi d LT LI NOILVOOT 31VNMHIL IV STANLXIJ WO 3 NANLJY P YILVM LOH A dINNd S NI LV IO SIYN1XIW OL YSLVM LOH NIVad HOLIMS AO H3 1VM TOULNOD JYNLVYSdWSL ANVL dINNd S NI LV WO ADVS J1YNIVITANIL m pp S3OIA3Q YSHLO ANY NOILLVYNSISANOO ONI did qalsd99fns SMOHS SNIMV8SG SIHL ONINSHVM 3A VA 33l138 34NSSIYUd FATVA MO3HO sec 3ATVA 33 1138 C IN3O 3 ANVL 39VHOLS WLNOZIMOH HLIM LINN L ana LINN
35. TIFY OWNER TO KEEP FOR FUTURE REFERENCE PRINTED 0211 318296 001 TABLE OF CONTENTS SAFE INSTALLATION USE AND SERVICE 3 APPROVARS uuu aa ui eten chi da kaa kose and sitan AEDST 3 GENERAL SAFETY INFORMATION 4 Te 5 Grounding Instructions E 5 Hydrogen Gas Flammabhble 5 INTRODUCTION EE 6 Abbreviations Used 6 a e 6 FEATURES AND COMPONENTS T The Eliminator self cleaning system sess 7 Pigh LIMIE WI DO TI TT TM 7 Electronic lgnition CO rola iaa 7 Exhaust Inducer blower ass 7 INCE lili uuu u ao asasssssuspussasispasnampasssssspapiusapassapaspazanastonsnsasupazppansai 7 INSTALLATION CONSIDERATIONS 8 KOUdh In DIMENSIONS seminario 8 Recovery oe venirse iia 8 Gas and Electrical Characteristics 8 Locating the Water Heater 9 CIO L Tr AM e A T 9 Installation On Combustible Flooring 10 le GR e E El 10 ai e o o PR E OOO O blad date baka tak 10 Circulation Et e CN 10 High Altitude Installations 11 Pr
36. Up N Down Transfer Kit if you have not already done so 1 With the 5 gallon Up N Down container in the vertical position unscrew the plastic vent cap in the handle and pierce the plastic membrane over the vent boss under the cap to allow the container to vent Note If your container does not have the vent cap and vent boss drill a 3 16 hole in the handle When you have finished deliming you will be able to plug this drilled vent with the stainless steel screw that is supplied with the kit Remove the container s cap and cut the plastic membrane located in the 3 4 IPT opening in the cap Take care to not damage the threads Find the 3 4 male adapter apply teflon tape to the threaded end and screw it into the 3 4 IPT opening in the cap Put cap with male adapter back on the container and slide 3 4 hose over end of male adapter and fasten in place using hose clamp provided Delime using Flo Jug Method 5 Slide the hose clamp over end of hose and slide hose over the male adapter in the water heater drain opening and secure in place using hose clamp Lift container to the Pour Position see Figure 28 being careful to keep the vent in the handle above the liquid level and pour the UN LIME into the heater Lower container you may have to place the container on its empty carton to prevent the UN LIME from flowing back into the container Let UNeLIME remain in the heater for 5 minutes and then lower th
37. XHAUST INDUCER BLOWER ASSY All models are equipped with an exhaust inducer The inducer assists in drawing in fresh air to the unit for combustion and then assists in dispensing the combustion by products into the venting leading outside 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 UNCRATING The heater is shipped with the inducer already installed The wiring conduit runs from the thermostat to the inducer Before turning unit on check to make sure the wiring conduit is securely plugged into the inducer INSTALLATION CONSIDERATIONS ROUGH IN DIMENSIONS 1 NPT RELIEF VALVE OPENING K REAR OUTLET 1 1 2 NPT L REAR INLET 1 CLEARANCE B G FRONT VIEW BACK VIEW TOP TOP OUTLET j 4 F INLET 1 1 2 NPT 1 1 2 NPT TOP VIEW FIGURE 5 TABLE 1 ROUGH IN DIMENSIONS I i Connections Input Rate Approximate Dimensions in Inches cm inlet NPT Outlet NPT Approx Ship Weight Btu Hr Tank Cap Gas Vent Std ASME Kw Hr G L A C E F Inlet H Dia J Top Front Back Top Front Back Lbs Lbs G Kos Kos tv 600000 es etso rrso vras jerso 27 13 21 00 100 ferso soo 2775150 150 vo iso 150 50 ew esr A BCG385T500 8P 500 000 85 81 50 17 50 77 25 67 50 27 13 21 00 1 00 67 50 8 00 27 75 1 50 1 50 1 50 1 50 1 50 1 50 812 857 ae
38. Y AND ALL WARRANTIES EXPRESS OR IMPLIED WHETHER WRITTEN OR ORAL INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE 2 MANUFACTURER SHALL NOT BE LIABLE FOR ANY INCIDENTAL CONSEQUENTIAL SPECIAL OR CONTINGENT DAMAGES OR EXPENSES ARISING DIRECTLY OR INDIRECTLY FROM ANY DEFECT IN THE STORAGE TANK OR THE USE OF THE STORAGE TANK 3 Manufacturer shall not be liable for any water damage arising directly or indirectly from any defect in the storage tank or component part s or from its use 4 Manufacturer shall not be liable under this warranty and this warranty shall be void and have no effect if the following events occur The storage tank or any of its component parts have been subject to misuse alteration neglect or accident or The storage tank has not been installed in accordance with the applicable local plumbing and or building code s and or regulations or The storage tank is not installed operated and maintained in accordance with the printed Manufacturers instructions or The storage tank or any part has been under water or The storage tank is exposed to highly corrosive atmospheric conditions or The storage tank is not continuously supplied with potable water or The storage tank replacement is requested for reasons of noise taste odor discoloration and or rust or The storage tank is not operated within the factory calibrated temperature limits or The s
39. Y LINES ARE USED THEY MUST BE INTERNALLY TINNED AND CERTIFIED FOR GAS SERVICE BEFORE ATTACHING THE GAS LINE BE SURE THAT ALL GAS PIPE IS CLEAN ON THE INSIDE TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS SUPPLY LINE ADIRT LEG SOMETIMES CALLED SEDIMENT TRAP OR DRIP LEG MUST BE INCORPORATED IN THE PIPING SEE FIG 21 THE DIRT LEG MUST BE READILY ACCESSIBLE AND NOT SUBJECT TO FREEZING CONDITIONS INSTALL IN ACCORDANCE WITH RECOMMENDATIONS OF SERVING GAS SUPPLIERS REFER TO THE LATEST VERSION OF THE NATIONAL FUEL GAS CODE To prevent damage care must be taken not to apply too much torque when attaching gas supply pipe to gas valve inlet Apply joint compounds pipe dope sparingly and only to the male threads of pipe joints Do not apply compounds to the first two threads Use compounds resistant to the action of liquefied petroleum gases BEFORE PLACING THE HEATER IN OPERATION CHECK FOR GAS LEAKAGE Use soap and water solution or other material acceptable for the purpose in locating the leaks DO NOT USE MATCHES CANDLES FLAME OR OTHER SOURCES OF IGNITION FOR THIS PURPOSE DISCONNECT THE HEATERAND ITS MANUAL GAS SHUTOFF VALVE FROM THE GAS SUPPLY PIPING SYSTEM DURING ANY SUPPLY PRESSURE TESTING EXCEEDING 1 2 PSIG GAS SUPPLY LINE MUST BE CAPPED WHEN DISCONNECTED FROM THE HEATER FOR TEST PRESSURES OF 1 2 PSIG OR LESS THE APPLIANCE NEED NOT BE DISCONNECTED BUT MUST BE ISOLATED FROM THE SUPPLY PRESSURE TEST BY CLOSING THE MANUAL G
40. age A WARN N G Jumping out control circuits or components can result in property damage personal injury or death e Service should only be performed by a qualified service AA WAR N N E agent using proper test equipment Altering the water heater controls and or wiring in any way Electrical Shock Hazard could result in permanent damage to the controls or water heater and is not covered under the limited warranty e Turn off power to the water heater sp before performing any service Altering the water heater controls and or wiring in any way could result in altering the ignition sequence allowing gas to Label all wires prior to disconnecting flow to the main burner before the hot surface igniter is at when performing service Wiring errors ignition temperature causing delayed ignition which can can cause improper and dangerous cause a fire or explosion operation Any bypass or alteration of the water Verify proper operation after servicing heater controls and or wiring will result Failure to follow these instructions can in voiding the appliance warranty result in personal injury or death GENERAL SAFETY INFORMATION A WARNING Read and understand this instruction manual and the safety messages herein before installing operating or servicing this water heater Failure to follow these instructions and safety messages could result in death or serious injury This manual must remain with the water heater Water te
41. ake with insulating blanket e Gas and carbon monoxide detectors are available e nstall water heater in accordance with oe the instruction manual Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Insulation blankets are available to the general public for external use on gas water heaters but are not necessary with these products The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters The water heaters covered by this manual meet or exceed the Energy Policy Act standards with respect to insulation and standby heat loss requirements making an insulation blanket unnecessary Should you choose to apply an insulation blanket to this heater you should follow these instructions See the Features and Components section of this manual for identification of components mentioned below Failure to follow these instructions can restrict the air flow required for proper combustion potentially resulting in fire asphyxiation serious personal injury or death e DO NOT apply insulation to the top of the water heater as this will interfere with safe operation of the exhaust inducer DO NOT cover the gas valve thermostat or the Temperature Pressure Relief Valve DO NOT allow insulation to come within 2 5 cm of the burners to prevent blockage of combustion air flow to the burners DO NOT allow insulation to come within 9 inch
42. ank cleanout plate and remove plate Remove lime scale or sediment using care not to damage the glass lining Inspect cleanout plate gasket if new gasket is required replace with part no 9004099215 Install cleanout plate Be sure to draw plate up tight by tightening screws securely 9 In some water areas the sediment might not be removed by this method and may result in the water heater making rumbling or boiling noises To dissolve and remove these more stubborn mineral deposits A O Smith UNeLIME Professional Delimer should be used DELIMING USING FLO JUG METHOD UN LIME in the 5 gallon size is recommended for deliming of all models Contact your local A O Smith dealer distributor or A O Smith Water Products Company Telephone 800 433 2545 Fax 800 433 2515 Website www hotwater com parts Prepare the Water Heater To delime the water heater using the Flo Jug method first prepare the heater for deliming Replace outer jacket cover plate MAWARNING Explosion Hazard e Flammable hydrogen gases may be present e Keep all ignition sources away from faucet when turning on hot water Do not smoke or have open flame or sparks in vicinity of heater Do not mix UNeLIME with other chemicals Do not allow contact with magnesium aluminum or galvanized metals A CAUTION Product contains phosphoric acid Keep out of reach of children Use rubber or neoprene gloves UNeLIME contains
43. art no 9005783205 The nipple collars on the heater will usually be damaged when removed New nipple collars will insure that the seal is such as to prevent leakage of flue products when properly installed NOTE Anode rod inspection may need to be made more frequently in areas subject to acid rain that obtains their water supply from surface water as the low pH will accelerate anode activity CAUTION Close cold water inlet valve serving heater and open nearby hot water faucet to relieve the pressure in the heater before attempting to remove anode s for inspection 27 DRAINING AND FLUSHING A DANGER e Burn harzard e Hot water discharge e Keep hands clear of drain valve discharge It is recommended that the water heater storage tank be drained and flushed every 6 months to reduce sediment buildup The water heater should be drained if being shut down during freezing temperatures TO DRAIN THE WATER HEATER STORAGE TANK Turn off the electrical supply to the water heater 2 Turn off the gas supply at the Main Gas Shutoff Valve if the water heater is going to be shut down for an extended period 3 Ensure the cold water inlet valve is open 4 Open a nearby hot water faucet and let the water run until the water is no longer hot 5 Close the cold water inlet valve to the water heater 6 Connecta hose to the water heater drain valve and terminate it to an adequate drain 7 Open the water heater drain valve and
44. ate time to burn relationship for normal adult skin If anyone using hot water provided by the water heater being installed fits into one of these groups or if there is a local code or state law requiring a certain water temperature at the point of use then special precautions must be taken In addition to using the lowest possible temperature setting that satisfies the demand of the application a Mixing Valve should be installed at the water heater see Figure 10 or at the hot water taps to further reduce system water temperature Mixing valves are available at plumbing supply stores Consult a Qualified Installer or Service Agency Follow mixing valve manufacturer s instructions for installation of the valves TABLE 6 Time to Produce 2nd amp 3rd Degree Burns on Adult Skin About 1 2 second Abouti 1 2seconds About 1 1 2 seconds Water Temperature 180 F 82 C 170 F 77 C 160 F 71 C 150 F 66 C 140 F 60 C 130 F 54 C 120 F 49 C HOT WATER 12 TO 15 30 38 cm TEMPERED WATER VALVE MIXING VALVE Do TO TANK INLET FIGURE 10 DISHWASHING MACHINES All dishwashing machines meeting the National Sanitation Foundation requirements are designed to operate with water flow pressures between 15 and 25 pounds per square inch 103 kPa and 173 kPa Flow pressures above 25 pounds per square inch 173 kPa or below 15 pounds per square inch 103 kPa will result in im
45. ater under this warranty the Owner will be furnished with a new storage tank of comparable capacity however the Owner will be charged for the additional value of the item s which Manufacturer has incorporated in the replacement storage tank A prior authorization number must be obtained from the Manufacturer before replacing the storage tank This warranty is limited to one replacement storage tank at the original installation site 2 Component Part If any component part other than the inner tank proves to Manufacturer s satisfaction to be defective in material or workmanship within one year after original installation the Manufacturer will furnish the Owner with a replacement for the defective part s This warranty is limited to one replacement component part for each original part 3 Return of Defective Storage Tank and Component Parts Manufacturer reserves the right to examine the alleged defect in the storage tank or component part s and it will be the Owner s obligation see paragraph D 5 to return the storage tank and or component part s to the Manufacturer a When returning a storage tank it must include ail component parts and the data plate label b When returning component part s they must be individually tagged and identified with the storage tank s product number model number serial number date of purchase and date of installation D WHAT THIS WARRANTY DOES NOT COVER 1 THE LIMITED WARRANTY STATED HEREIN IS IN LIEU OF AN
46. by the storage tank temperature control The sensing element is mounted in the hot water storage tank see Water Piping Diagram section A change in water temperature in the storage tank lower than the tank temperature control setting will cause the sensor to activate the circulating pump The pump then circulates the water through the heater where the thermostat senses the drop in water temperature and activates main burner operation of the appliance If the storage tank temperature control is out of calibration replace with new control SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE TEMPERATURE PRESSURE RELIEF VALVE TEST ADANGER e Burn hazard e Hot water discharge e Keep clear of Temperature Pressure Relief Valve discharge outlet It is recommended that the Temperature Pressure Relief Valve should be checked to ensure that it is in operating condition every 6 months 26 When checking the Temperature Pressure Relief Valve operation make sure that 1 no one is in front of or around the outlet of the Temperature Pressure Relief Valve discharge line and 2 that the water discharge will not cause any property damage as the water may be extremely hot Use care when operating valve as the valve may be hot To check the relief valve lift the lever at the end of the valve several times see Figure 26 The valve should seat properly and operate free
47. ccsesracose 17 2 aor lt 10 BW eo 59 s ws 20 vo KI KI KO KO DR a A BCG385T500 8P 147 322 207 44 196 171 53 3 171 20 70 1 50 1 50 1 50 1 50 1 50 1 50 368 389 TABLE 2 RECOVERY CAPACITIES based on 80 efficiency Input Rate Approximate Recovery Rating Capacities GPH and LPH at temperature rise indicated Model dd Tank Gap e DOE 120 130 1407F W Ge A BCG385T500 8N A BCG385T500 8N ao a CAME 6118 4588 3059 2622 2294 2039 1835 1668 1529 1412 1311 TABLE 3 GAS AND ELECTRICAL CHARACTERISTICS Gas Supply Pressure Model Gas Type Gas Manifold Pressure Volts Hz A BCG385T500 8P Natural 4 5 W C 1 12 kPa 14 W C 3 48 kPa 3 5 W C 0 87 kPa 120 60 A BCG385T500 8P Propane 11 W C 2 74 kPa 14 W C 3 48 kPa 10 W C 2 49 kPa 120 60 INSTALLATION CONSIDERATIONS LOCATING THE WATER HEATER CAUTION e All water heaters eventually leak e Do not install without adequate drainage When installing the heater consideration must be given to proper location Location selected should be as close to the stack or chimney as practicable with adequate air supply and as centralized with the piping system as possible AWARNING Fire or Explosion Hazard e Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance e Avoid all ignition sources if you smell gas e Do not expose water heater controls to ex
48. cessive gas pressure e Use only the gas shown on the water heater rating label Maintain required clearances to combustibles Keep ignition sources away from faucets after extended periods of non use A Read instruction manual before installing using or servicing water heater THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH AS GAS WATER HEATERS IN ROOMS GARAGES OR OTHER AREAS WHERE GASOLINE OTHER FLAMMABLE LIQUIDS OR ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED OPERATED OR REPAIRED FLAMMABLE VAPORS ARE HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE IGNITED BY THE HEATER S PILOT OR MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION SOME LOCAL CODES PERMIT OPERATION OF GAS APPLIANCES IN SUCH AREAS IF THEY ARE INSTALLED 18 OR MORE ABOVE THE FLOOR THIS MAY REDUCE THE RISK IF LOCATION IN SUCH AN AREA CANNOT BE AVOIDED DO NOT INSTALL THIS WATER HEATER DIRECTLY ON A CARPETED FLOOR AFIRE HAZARD MAY RESULT Instead the water heater must be placed on a metal or wood panel extending beyond the full width and depth by at least 3 inches in any direction If the heater is installed in a carpeted alcove the entire floor shall be covered by the panel Also see the DRAINING requirements in MAINTENANCE Section THE HEATER SHALL BE LOCATED OR PROTECTED SO IT IS NOT SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE FLAMMABLE ITEMS PRESSURIZED CONTAINERS OR ANY OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON OR
49. d ceiling clearances as indicated below TABLE 4 MINIMUM CLEARANCES TO COMBUSTIBLES IN INCHES mm MODEL BACK CEILING A BCG385T500 8N 5 D 5 20 A BCG385T500 8P 12 7 cm 12 7 cm 12 7 cm 50 8 cm TABLE 5 MINIMUM CLEARANCES TO NONCOMBUSTIBLE CONSTRUCTION D CEILING A BCG385T500 8N 12 A BCG385T500 8P 30 5 cm CEILING SS pou k 6 CLEARANCE ON REDUCING THIMBLE SEE RIGHT WALL FRONT VIEW NOTES INCLUDES 6 FROM VENTING AND FLUE BAFFLE SERVICE CLEARANCE ALL HORIZONTAL VENT PIPING SHALL HAVE A RISE OF 1 4 PER FOOT MINIMUM SEE VENTING REAR WALL TOP VIEW ILLUSTRATION OF MINIMUM COMBUSTIBLE CLEARANCES IN AN ALCOVE FIGURE 6 INSTALLATION ON COMBUSTIBLE FLOORING The A BCG385T500 8N A BCG385T500 8P is approved for installations on combustible flooring when installed with NSF Leg Kit number 9003425205 APPLIANCE LEG NUT FOR BOLT LEG EXTENSION FIGURE 7 1 Unit needs to be lifted in a way not to damage unit or laid on it s side to access the bottom of the legs 2 Slide leg extension under leg and the bolt up through the bottom hole located in the bottom of the leg Once in place screw nut down and secure Front of leg should line up with front of leg extension as shown in Figure 7 to make sure weight of unit is distributed through the leg extension INSULATION BLANKET AWARNING o o o of v e 960090 oye 9 e o not obstruct water heater air int
50. e container to the Drain Position see Figure 28 Deliming activity is indicated by foaming on the surface of the UNeLIME If there is deliming activity repeat steps 6 thru 8 Normally lime removal will be completed within one hour Severe build up of lime may take longer than an hour to complete descaling Note To check UNeLIME for continued use place some scale or white chalk in a glass with a small amount of UN LIME If the material is vigorously dissolved by the UNeLIME it can be reused if not the UNeLIME should be replaced POUR POSITION INSTALL 3 4 X 3 NIPPLE 3 4 X 4 NIPPLE OR DRAIN VALVE NIPPLE CLAMP NIPPLE CAP NOs 5 GALLON SS Fido ENT N WS REMOVE FOAMING DELIMING COVER INDICATES POSITION DELIMING ACTIVITY FLOW JUG CARTON GRADUATION DRAIN POSITION FIGURE 28 IGNITION MODULE SYSTEM Before calling your service agent the following checklist should be examined to eliminate obvious problems from those requiring replacement or servicing Check that main manual gas shutoff valve is fully open and that gas service has not been interrupted Check that after following the appliance OPERATING INSTRUCTIONS the Top Knob of the appliance gas valve is in ON position Check electrical supply to the appliance for possible blown or tripped fusing or power interruption Also check the 3 amp fuse on the front of the digital thermostat Fig
51. ed repair may result in a fire or explosion WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not use this appliance if any part has been under water Immediately call a Do not touch any electric switch do not use any telephone in your building qualified service technician to inspect the appliance and to replace any part of Immediately call your gas supplier from a neighbor s telephone Follow the the control system and any gas control which has been under water gas suppliers instructions GAS W STOP Read the safety information above on this label CONTROL KNOBS This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Set thermostat to lowest setting Turn off all electric power to the appliance Push in gas control knobs slightly and turn clockwise 4 to off Wait five 5 minutes to clear out any gas If you then smell gas Follow B in the safety information above on this label If you OCA eme y we l smell gas go on to next step VQ PS Turn gas control knobs counterclockwise __4 to ON Turn on all electric power to the appliance Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas
52. em ou ussm aq dund ay ojlluo2 pue 0 paJim eq pinoys o43u02 ounjeledwe yuej sy eDesn Jou ui AOB eus sapos eso IiSA AO0H YUN GUIDIAJSS 10 UMOUS Je SGAJBA 9 AJ9S ulojs s ay ui jueuodwoo Aue jo Buel euynsseJd paso9xa jou eys Gunjes Ajea Joeljo eunssaJd pue aunjeladua ay wesBeip Buidid pawajaid SALON NO TW y l l WOU AE COOL ANVL gt GSHSINI4 NOISNVdX3 Alddns 5 LVA CN p M arre NIV30 N3dO JILVIH NIVYd N3dO SIYUNLXIA OL d 9 L 3dld OL dl Jdid Wows NaNLJY 0 Q f YALVM LOH ig E S3YNM1XIW OL AILVM LOH Eed NIVMQ HOLIMS MO 13 4 31M S JOH NOO FYN VEAN ANVL SININ3YINO3Y IWNOILIGGV YOS 39V9 AYNLVYAdWAL dNNd ONILVINIOYAINO SAONVNIGHO ONV S30d09 TVOO 1 HLIM MO3HO S3OIA3Q YSHLO ANY NOILVYNSISANOO SNIdld UILSIDONS SMOHS ONIMVAC SIHL ONINHVM SAA 4338 3unssaud FATWA xo3H9 ON P 3ATVA 33 1138 C OIN3O93 ANVL ADVYOLS TVLNOZIHOH HLIM SLINN Z 3074 LLIN mi o V 40 eDesn 11y uUano6 eus sapos e20 Janamoy jIUN HUIDIAJAS 10 UMOUS Ie SBAJCA 8JIAJBS ulojs s ay ui Ju uoduuoo ue jo Gune eunsseJd pasoxa jou eys Dumas SAJeA Jer aJ eunsseJd pue ejnjeJeduig oui Z wesBeip Buidid pallajelg SALON ee O SS fi fi NANLIY H31VM H31S008 ANVL NOISNVAX3 P A1ddans Y31VWM A109 YSALVAH ISI EEIKEIS O Y431S009 dailsoog OL H3lVM NAU 24 Q31V3H 3Hd H31VM LOH CY HAT Yo E x gt SE ei O TS o O A CET SJA
53. enter the smaller common vent or chimney at a point above the large vent pipe MULTIPLE HEATER MANIFOLD Figure 13 and Table 7 should be used for horizontally manifolding two or more heaters VENT TOP ai D di COMMON VENT gt TOTAL VENT HEIGHT MANIFOLD VENT CONNECTORS TEE CAPPED MANIFOLD 7 CONNECTOR RISE HEATER FIGURE 13 FRESH AIR OPENINGS FOR CONFINED SPACES The following instructions shall be used to calculate the size number and placement of openings providing fresh air for combustion ventilation and dilution in confined spaces The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only DO NOT refer to these illustrations for the purpose of vent installation See Venting Installation on page 15 for complete venting installation instructions OUTDOOR AIR THROUGH TWO OPENINGS N AA EE EUM eg IN enm HH d FIGURE 14 The confined space shall be provided with two permanent openings one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm of the bottom of the enclosure The openings shall communicate directly with the outdoors See Figure 14 Each opening shall have a minimum free area of 1 square inch per 4 000 Btu hr 550 mm2 per kW of the aggregate input rating of all appliances installed in the enclosure Each opening shall not be less than 100 square inches 6
54. er temperature reach 203 F 95 C In the event of high limit switch operation the appliance cannot be restarted unless the water temperature is reduced to approximately 120 F 49 C The high limit reset button on the front of the control then needs to be depressed Continued manual resetting of high limit control preceded by higher than usual water temperature is evidence of high limit switch operation The following is a possible reason for high limit switch operation e A malfunction in the thermostatic controls would allow the gas valve to remain open causing water temperature to exceed the thermostat setting The water temperature would continue to rise until high limit switch operation Contact your dealer or service agent if continued high limit switch operation occurs LED LIGHTS RESET BUTTON FUSE DIGITAL THERMOSTAT FIGURE 2 ELECTRONIC IGNITION CONTROL Each heater is equipped with an ignition module The solid state ignition control Figure 3 ignites the main burner by utilizing a silicon nitride igniter The silicon nitride igniter shuts off during the heating cycle and the main burner flame is sensed through a remote flame sensor integral to the silicon nitride igniter assembly The ignition control will try to ignite the main burner three times before lockout Then it waits one hour before trying again to ignite the main burners This is a continuous cycle IGNITION CONTROL BOARD FIGURE 3 E
55. es 23 cm of floor within 2 inches 5 cm of bottom cover to prevent blockage of combustion air flow to the burners DO NOT cover the instruction manual Keep it on the side of the water heater or nearby for future reference DO obtain new warning and instruction labels from the manufacturer for placement on the blanket directly over the existing labels DO inspect the insulation blanket frequently to make certain it does not sag thereby obstructing combustion air flow HARD WATER Where hard water conditions exist water softening or the threshold type of water treatment is recommended This will protect the dishwashers coffee urns water heaters water piping and other equipment See the Maintenance Section in this manual for sediment and lime scale removal procedures CIRCULATION PUMPS A circulating pump is used when a system requires a circulating loop or there is a storage tank used in conjunction with the water heater See Water Piping Diagrams in this manual for installation location of circulating pumps See the Circulation Pump Wiring Diagrams Figure 8 Figure 9 in this manual for electrical hookup information Install in accordance with the current edition of the National Electrical Code NFPA 70 or the Canadian Electrical Code CSA C22 1 All bronze circulators are recommended for used with commercial water heaters Some circulating pumps are manufactured with sealed bearings and do not require further lubr
56. f flame from burner ports GV AWA YX FIGURE 24 If the preceding burner characteristics are not evident check for accumulation of lint scale or other foreign debris that restricts or blocks the air openings to the burner or heater NOTE 1 2 3 Remove main burners from unit Check that burner venturi and ports are free of foreign debris Clean burners with bristle brush and or vacuum cleaner DO NOT distort burner ports or pilot location Reinstall burners in unit Make sure front and rear of burners are installed correctly in burner support brackets Also check for good flow of combustion and ventilating air to the unit Maintain a clear area around the heater at all times GAS VALVES Figure 25 shows the type of combination manual gas control valve and regulator used on these heaters If the gas valve becomes defective repairs should not be attempted A new valve should be installed in place of the defective one SEALING CAP FIGURE 25 CHECKING THE INPUT For appliance installation locations with elevations above 2000 feet refer to HIGH ALTITUDE INSTALLATIONS section of this manual for input reduction procedure 1 Attach a pressure gauge or a manometer to the manifold pressure tap on the gas valve and refer to Table 3 page 8 for correct manifold pressure Use this formula to clock the meter Be sure that other gas consuming appliances are not operating duri
57. gs must be reduced at the rate of 4 for each 1000 feet 305m above sea level For example if a heater is rated at 78 000 Btuh 22 9 Kwh at sea level to rate the heater at 4000 feet 1219m you subtract 4 once for each thousand feet x 04 4 input reduction x 78 000 original rating from the original rating Therefore to calculate the input rating at 4 000 feet 1219m 4 x 04 x 78 000 12 480 Btuh 3 7 Kwh 78 000 22 9 Kwh 12 480 3 7 Kwh 65 520 Btuh 19 2 Kwh At 6000 feet 1829m the correct input rating should be 59 280 Btuh 17 4 Kwh NATURAL GAS INSTALLATIONS The natural gas fired version of the water heater covered by this manual is certified for use without modification for altitudes up to 10 100 feet For installations above 10 100 feet call the technical support phone number listed on the back cover of this manual for further technical assistance Call the local gas or utility company to verify Btu per cubic foot content before calling for technical assistance and have that information available Note The actual firing rate of the water heater must not exceed the input rating on the water heater s rating label under any circumstances Note Due to the input rating reduction at high altitudes the output rating of the appliance is also reduced and should be compensated for in the sizing of the equipment for applications INSTALLATION REQUIREMENTS WATER TEMPERATURE CONTROL AND MIXING VALVES A DANGER G
58. heater Check for sooted flue passage Heater is over fired EE Check for obstructed vent line and call a service agent Check backdraft or lack of draft backdraft or Check backdraft or lack of draft of draft Possible gas leaks Shut off gas supply to heater and call gas company at once probe out of calibration Heater recovery is slower Call service agent Sediment accumulation on Rumbling bottom of tank Air chambers in piping have Pounding become waterlogged Combustion noises Gas odors 33 WATER PIPING DIAGRAMS Jo 3u02 eJnjeJeduje yuej ay uey JaeyBly d saalbap jas eq pinous jJe SOW EY Bunesedo s Jo1e9u Jajem sy s yue aBeJo s ou pue s 1ajesy Jajem ou UBEMjeq dwnd y jo1Juo9 pue o polim aq p nous o1Ju05 eJnjeJeduje yuej ey eGesn say uJeAoD eus Sapos e20 J19SASMOH PUN GBUIDIAJSS 10 UMOUS 9 8 SSAJLA 8JIAJBS ul9 s s ou ui jueuoduuoo Aue jo Huljes eunsseJd p ox jou peys Huas aAjen Jer oJ eunsseJd pue aunjeladua ay weJbeip Buidid paa19JoJg SALON QNO TY e pou Y00714 XNVL N Q3HSINIJ NOISNVdX3 Alddns M H31VM 07109 ae P LI NOLLO3NNOO H31VM 1102 LIV y SE UN gt NaLV3H S3uni1XId WOUJ NUNLSY YIIVM LOH ea oman 5 v S d L NIV N3dO K OL d81 Adid e STUNLXIA 4 YILVM LOH NIVSC HOLIMS MO 13 41M S TOULNOD SYNLVYAdWAL ANVL SINAWSYINOAY WNOILIGGV HOJ FOV 3MnivM3dWal Z dWNa DNILVINIOYIO SSA
59. iations found in this Instruction Manual include e ANSI American National Standards Institute e ASME American Society of Mechanical Engineers e GAMA Gas Appliance Manufacturer s Association NEC National Electrical Code NFPA National Fire Protection Association e UL Underwriters Laboratory e CSA Canadian Standards Association QUALIFICATIONS QUALIFIED INSTALLER OR SERVICE AGENCY Installation and service of this water heater requires ability equivalent to that of a Qualified Agency as defined by ANSI below in the field involved Installation skills such as plumbing air supply venting gas supply and electrical supply are required in addition to electrical testing skills when performing service ANSI 2223 1 2006 Sec 3 3 83 Qualified Agency Any individual firm corporation or company that either in person or through a representative is engaged in and is responsible for a the installation testing or replacement of gas piping or b the connection installation testing repair or servicing of appliances and equipment that is experienced in such work that is familiar with all precautions required and that has complied with all the requirements of the authority having jurisdiction If you are not qualified as defined by ANSI above and licensed or certified as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the procedures described in this manual
60. ication Some circulating pumps must be periodically oiled Refer to the pump manufacturer s instructions for lubrication requirements CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK OR BUILDING RECIRCULATION FIELD SUPPLIED TEMPERATURE CONTROL INSTALLED IN THE STORAGE TANK OR CIRCULATING LOOP RETURN LINE NOTE USE SEPARATE 120 VAC POWER SUPPLY FOR PUMP CIRCUIT DO NOT SHARE POWER WITH APPLIANCE AS THIS MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION L1 HOT 120 VAC POWER L2 NEUTRAL FIGURE 8 CIRCULATING PUMP WIRING DIAGRAM DISHWASHER LOOP WITH TOGGLE SWITCH DISHWASHER TOGGLE SWITCH FIELD SUPPLIED TEMPERATURE CONTROL INSTALLED IN THE CIRCULATING LOOP RETURN LINE NOTE USE SEPARATE 120 VAC POWER SUPPLY FOR PUMP CIRCUIT DO NOT SHARE POWER WITH APPLIANCE AS THIS MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION L1 HOT 120 VAC POWER L2 NEUTRAL FIGURE 9 HIGH ALTITUDE INSTALLATIONS 4 WARNING e Under no circumstances should the input exceed the rate shown on the water heater s rating label e Overfiring could result in fire or explosion e Gas and carbon monoxide detectors are available 11 4AWARNING e Under no circumstances should the input exceed the rate shown on the water heater s rating label e Overfiring could result in damage to the water heater and sooting e Gas and carbon monoxide detectors are avai
61. ided AIR INHOT WATER FAUCETS HYDROGEN GAS Hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable and explosive To prevent the possibility of injury under these conditions we recommend the hot water faucet located farthest away be opened for several minutes before any electrical appliances which are connected to the hot water 31 system are used such as a dishwasher or washing machine If hydrogen gas is present there will probably be an unusual sound similar to air escaping through the pipe as the hot water faucet is opened There must be no smoking or open flame near the faucet at the time it is open HIGH WATER TEMPERATURE SHUT OFF SYSTEM This water heater is equipped with an automatic reset type high limit Energy Cutoff sensor The high limit switch interrupts the main burner gas flow should the water temperature reach 203 F 95 C The high limit will automatically reset when the water temperature drops below 120 F 49 C After cooling the tank temperature turn off the water heater for at least 10 seconds by using the switch on front of the control box Turn on the water heater If this fails to correct the problem contact your plumber or service representative SEQUENCE OF OPERATION FLOW CHART Description of this flow chart can be found in the SEQUENCE OF OPERATION section found on page 23
62. ies Supply gas regulators shall have inlet and outlet connections not less than the minimum supply gas line size for the water heater they serve as shown in Table 9 The Maxitrol 325 7L or equivalent is recommended POWER SUPPLY The water heaters covered in this manual require a 120 VAC 19 single phase 60Hz 15 amp power supply and must also be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 or the Canadian Electrical Code CSA C22 1 Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at fixtures Water heated to a temperature which will satisfy clothes washing dish washing and other sanitizing needs can scald and cause permanent injury upon contact Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the water heater s temperature setting by up to 20 F 11 C Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm and the physically mentally disabled Table 6 shows the approxim
63. in inside the building Shall not have any valve or other obstruction between the relief valve and the drain A DANGER e Burn hazard e Hot water discharge e Keep clear of Temperature Pressure Relief Valve discharge outlet The Temperature Pressure Relief Valve must be manually operated at least twice a year Caution should be taken to ensure that 1 no one is in front of or around the outlet of the Temperature Pressure Relief Valve discharge line and 2 the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions in this manual and replace the Temperature Pressure Relief Valve with a properly rated sized new one NOTE The purpose of a Temperature Pressure Relief Valve is to prevent excessive temperatures and pressures in the storage tank The T amp P valve is not intended for the constant relief of thermal expansion A properly sized thermal expansion tank must be installed on all closed systems to control thermal expansion see Closed Water Systems and Thermal Expansion on page 13 14 If you do not understand these instructions or have any questions regarding the Temperature Pressure Relief Valve call the toll free number listed on the back cover of this manual for tech
64. lable Aa So 2 9d Oy 9 239099 b bo Ioa od Qu Doo V7 Bd 9 S Pod p Yo g d v Kee H a5 De Ze ae ag P vo pta Q Cod yo je a 9 eo o p Bon o 9 o ga 9 ogo o o v v D o a oo 90 DA GAY Us Bg gt D o i i b Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual PROPANE INSTALLATIONS INSTALLATIONS ABOVE 2000 FEET 610 METERS REQUIRE REPLACEMENT OF BURNER ORIFICES IN ACCORDANCE WITH CURRENTEDITION OF THENATIONALFUELGAS CODE ANSI Z223 1 FOR CANADIAN INSTALLATIONS CONSULT CANADIAN INSTALLATIONS CODE CAN CSAB149 1 FAILURE TO REPLACE ORIFICES WILL RESULT IN IMPROPER AND INEFFICIENT OPERATION OF THE APPLIANCE RESULTING IN THE PRODUCTION OF INCREASED LEVELS OF CARBON MONOXIDE GAS IN EXCESS OF SAFE LIMITS WHICH COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH You should contact your gas supplier for any specific changes which may be required in your area As elevation above sea level is increased there is less oxygen per cubic foot of air Therefore the heater input rate should be reduced at high altitudes for satisfactory operation with the reduced oxygen supply Failure to make this reduction would result in an over firing of the heater causing sooting poor combustion and or unsatisfactory heater performance Ratings specified by manufacturers for most appliances apply for elevations up to 2000 feet 610m For elevations above 2000 feet 610 ratin
65. lame Sensor does not detect a strong enough flame the Ignition Control Board shuts off the Gas Valve and allows the Exhaust Inducer to purge the unit for 20 seconds At that time the Ignition Control Board restarts with step 7 It will try and ignite the main burners 2 more times If the unit does not light the Ignition Control Board will wait one hour and then restart at step 3 This cycle will continue until the unit lights or the power is shutoff to the unit 13 Ifthe Flame Sensor detects a strong flame the Ignition Control Board will allow the unit to operate until the thermostat is satisfied 14 Once the unit is satisfied the Ignition Control Board will shut off the Gas Valve and the unit will be in standby mode until another call for heat is initiated by the thermostat See the flow chart on page 32 for more information LIGHTING amp OPERATION LABEL A This appliance does not have a pilot It is equipped with an ignition device which O If you cannot reach your gas supplier call the fire department automatically lights the burner Do not try to light the burner by hand C Use only your hand to push in or turn the gas control knob Never use tools If BEFORE OPERATING smell all around the appliance area for gas Be sure to smell ttis Eno not hi ican hand dentine irit Call lified next to the floor because some gas is heavier than air and will settle on the floor PRO MOU PU EUCH IP RING ee service technician Force or attempt
66. lime released from water is in direct proportion to water temperature and usage see chart The higher the water temperature or water usage the more lime deposits are dropped out of the water This is the lime scale which forms in pipes heaters and on cooking utensils Lime accumulation not only reduces the life of equipment but also reduces efficiency of the heater and increases fuel consumption The usage of water softening equipment greatly reduces the hardness of the water However this equipment does not always remove all of the hardness lime For this reason it is recommended that a regular schedule for deliming be maintained The time between cleaning will vary from weeks to months depending upon water conditions and usage The depth of lime buildup should be measured periodically Heaters equipped with cleanouts will have about 2 of lime buildup when the level of lime has reached the bottom of the cleanout opening A schedule for deliming should then be set up based on the amount of time it would take for a 1 buildup of lime It is recommended that the water heater initially be inspected after 6 months Example 1 The initial inspection after 6 months shows 1 2 of lime accumulation Therefore the heater should be delimed once a year Example 2 The initial inspection after 6 months shows 2 of lime accumulation Therefore the heater should be delimed every 3 months POUNDS OF LIME DEPOSITED VS TEMPERATURE AND WAT
67. ly If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater and drain the water heater according to the Draining and Flushing instructions on page 27 Replace the Temperature Pressure Relief Valve with a properly rated sized new one see Temperature Pressure Relief Valve on pages 13 14 for instructions on replacement TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE FIGURE 26 If the Temperature Pressure Relief Valve on the water heater weeps or discharges periodically this may be due to thermal expansion NOTE Excessive water pressure is the most common cause of Temperature Pressure Relief Valve leakage Excessive water system pressure is most often caused by thermal expansion in a closed system See Closed Water Systems and Thermal Expansion on page 13 The Temperature Pressure Relief Valve is not intended for the constant relief of thermal expansion Temperature Pressure Relief Valve leakage due to pressure build up in a closed system that does not have a thermal expansion tank installed is not covered under the limited warranty Thermal expansion tanks must be installed on all closed water systems DO NOT PLUG THE TEMPERATURE PRESSURE RELIEF VALVE OPENING THIS CAN CAUSE PROPERTY DAMAGE SERIOUS INJURY OR DEATH MAWARNING Explosion Hazard e Temperature Pressure Relief Valve must comply with ANSI Z21 22 CSA
68. me cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be not less than 3 inches OUTDOOR AIR THROUGH TWO VERTICAL DUCTS The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only DO NOT refer to these illustrations for the purpose of vent installation See Venting Installation on page 15 for complete venting installation instructions FIGURE 17 The confined space shall be provided with two permanent vertical ducts one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm of the bottom of the enclosure The vertical ducts shall communicate directly with the outdoors See Figure 17 Each duct opening shall have a minimum free area of 1 square inch per 4 000 Btu hr 550 mm per kW of the aggregate input rating of all appliances installed in the enclosure When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be not less than 3 inches AIR FROM OTHER INDOOR SPACES Sa pe Ve uen ee E lt SE RE ael ebe Se m x s en tede ag ee EE FIGURE 18 The confined space shall be provided with two permanent openings one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm of the bott
69. mperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury A DANGER Feel water before bathing or showering Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at fixtures AWARNING Explosion Hazard e Overheated water can cause water tank explosion e Properly sized temperature and pressure relief valve must be installed in the opening provided CAUTION Improper installation use and service may result in property damage Do not operate water heater if flood damaged Inspect and anode rods regularly replace if damaged Install in location with drainage Fill tank with water before operation Properly sized thermal expansion tanks are required on all closed water systems Refer to this manual for installation and service Verify the power to the water heater is turned off before performing any service procedures GENERAL SAFETY INFORMATION PRECAUTIONS DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER Immediately call a qualified service agency to inspect the appliance and to make a determination on what steps should be taken next If the unit is exposed to the following do not operate heater until all corrective steps have been made by a qualified service agency
70. n a nearby hot water faucet to permit the air in the system to escape 3 Fully open the cold water inlet pipe valve allowing the heater and piping to be filled 4 Close the hot water faucet as water starts to flow 5 The heater is ready to be operated THE GAS VALVE MUST HAVE BEEN IN THE OFF POSITION FOR AT LEAST 5 MINUTES This waiting period is an important safety step Its purpose is to permit gas that may have accumulated in the combustion chamber to clear IF YOU DETECT GAS ODOR AT THE END OF THIS PERIOD DO NOT PROCEED WITH LIGHTING RECOGNIZE THAT GAS ODOR EVEN IF IT SEEMS WEAK MAY INDICATE PRESENCE OF ACCUMULATED GAS SOMEPLACE IN THE AREA WITH RISK OF FIRE OR EXPLOSION SEE THE FRONT PAGE FOR STEPS TO BE TAKEN All gas and water lines must be leak tested and open Read SEQUENCE OF OPERATION section of this manual prior to lighting and operating this appliance With above conditions satisfied start the unit in accordance with the instructions on the operating label attached to the heater For your convenience a copy of the instructions are shown on page 24 Each heater is equipped with an ignition control board The controller will try three times to light the main burner before going into lockout After the controller tries three times it will wait one hour before trying to light the unit again This cycle will continue until the main burners are ignited or the unit is shut down ADJUSTMENTS ON INITIAL STARTUP SOME ADJUST
71. nces demand If the discharge pipe is not connected to a drain or other suitable means the water flow may cause property damage T amp P Valve Discharge Pipe Requirements Shall not be smaller in size than the outlet pipe size of the valve or have any reducing couplings or other restrictions Shall not be plugged or blocked Shall not be exposed to freezing temperatures Shall be of material listed for hot water distribution Shall be installed so as to allow complete drainage of both the Temperature Pressure Relief Valve and the discharge pipe Must terminate a maximum of six inches above a floor drain or external to the building In cold climates it is recommended that the discharge pipe be terminated at an adequate drain inside the building Shall not have any valve or other obstruction between the relief valve and the drain The type size and location of the relief valves must be in accordance with local codes The locations of the relief valves shown in the installation diagrams are typical See pages 34 48 The heater has a factory installed high temperature limit switch and temperature and pressure relief valve Cold water lines to heater should be installed as shown in order to minimize gravity circulation of hot water to building cold water lines A listed temperature and pressure relief valve of adequate capacity is installed on the heater The locations shown in the installation diagrams on pages 34 48 are typical
72. ng this interval 3600 T x H Btuh T Time in seconds to burn one cubic foot of gas H Btu s per cubic foot of gas Btuh Actual heater input Example Using BCG385T500 8N heater T 7 56 seconds H 1050 Btu Btuh 3600 7 56 X 1050 500 000 Btuh Compare with the BCG385T500 8N model and rating Should it be necessary to adjust the gas pressure to the burners to obtain the full input rate the steps below should be followed 3 Remove the regulator adjustment sealing cap fig 25 and adjust the pressure by turning the adjusting screw with a screwdriver CN Clockwise to increase gas pressure and input rate Counterclockwise to decrease gas pressure and input rate 4 Clock the meter as in step 2 above 5 Repeat steps 3 and 4 until the specified input rate is achieved 6 Turn the gas control knob to PILOT Remove the pressure gauge and replace the sealing cap and the threaded plug in the pressure tap opening UNDER NO CIRCUMSTANCES SHOULD THE GAS INPUT EXCEED THE INPUT SHOWN ON THE HEATER MODEL AND RATING PLATE OVERFIRING COULD RESULT IN DAMAGE OR SOOTING OF THE HEATER MAINTENANCE 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 retard free draft REMOTE STORAGE TANK TEMPERATURE CONTROL The water temperature in the remote storage tank if used is controlled
73. nical assistance CONTAMINATED AIR AWARNING e Install water heater in accordance with the Instruction Manual and NFPA 54 or CAN CSA B 149 1 e To avoid injury combustion and ventilation air must be taken from outdoors e Do not place chemical vapor emitting i h products near water heater Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Corrosion of the flue ways and vent system may occur if air for combustion contains certain chemical vapors Such corrosion may result in failure and risk of asphyxiation Combustion air that is contaminated can greatly diminish the life span of the water heater and water heater components such as hot surface igniters and burners Propellants of aerosol sprays beauty shop supplies water softener chemicals and chemicals used in dry cleaning processes that are present in the combustion ventilation or ambient air can cause such damage Do not store products of this sort near the water heater Air which is brought in contact with the water heater should not contain any of these chemicals If necessary uncontaminated air should be obtained from remote or outdoor sources The limited warranty is voided when failure of water heater is due to a corrosive atmosphere See limited warranty for complete terms and conditions AIR REQUIREMENTS AWARNING n 9 GEI 2d Sein 7960 gt Ki e Install water heater in accordance with the Inst
74. njeledwej yue ay eDesn 1194 UJAO eys sapos e20 Janamoy jiun Bursiales JOJ UMOUS Be SOEN BOIAIOS ulejs s au ui jueuodwoo Aue jo Hues eunsseJd posoxe jou eus Gunes AeA jala eynssaJd pue ounjejedwaj ay wesBeip Buidid pallajald SALON Cl oi TW NOISNVdX3 3 E nd Alddns i aFLVM 0109 Ki ul 9 z q102 LV lt NIVHO N3dO E Ol d91 Jdid NyN L38 e YALVSH La YALVM LOH 0 N e NIVHO N3dO NIVHO N3dO NIVHO Nado L xw Ol 48 1 Jdid Ol d91 Jdid OL d91 3dld TE SAYNLXI4 OL O1 d91 3dld Y31VM LOH Nivaa E HO LIMS MO T3 YLVM JOMINOO FANIVHFAWALYANYL SLNAWSYINOAY IWNOILIGGV HO 39V9 JAYNIVAIJJNIL dNNd 9NLLVTIOYOMIO o S3ONVNIGSO ANY S3I0d09 TVOO 1 HLIM MO3HO S3OIA3q YSHLO ANY NOILVYNSISANOO SNIdld UJILSIDONS SMOHS SNIMV8SG SIHL ONINSHVM JAYA 43138 38NSSAYA 3NIVAMD3HD ON SR Y 3ATVA 4317138 ANIWA TIV8 LHOd TINA C dJHnssasd Y JANIVAIdWIL Yo MNVL JOVYOLS TVILLYIJA HLIM SLINA v INTA LLININ IN393 47 i Ph MNVL NOISNVdX3 E AIddns Hd3lVM DON JoJ3u02 eunjejeduje yue ay uey JeyBiy 4 seslbap jas eq pinous je souou Gunelado s ajesy Jajem 9u L s 4ue1 e8e101s ou pue s 1a esy Jejem ou ussm aq duund oun o 1U00 pue 0 paJlM eq pjnous o43u02 ounjeledwe yuej sy eDesn 11y UJAO eus sapos eso Janamoy YUN HUIDIAJOS 10 UMOUS Je SGSAJBA DINOS ulojs s ay ui jueuodwoo Aue jo Gune euynsseJd pasoxa jou jeys Buas anea Jelj
75. o eunsseJd pue ounjeladwaej ay wesBeip Guidid peJ19jeJgd SALON CN ei st iO N l AAA AA AA 2443480013 O3HSINI3 Y NIVYG N3dO OL d 1 3dld Ha NOILVOOT ALVNYALIV q gt e d NHAL3H GEIKEIS SY f 3JFILVIH Nu YSLVM LOH 4 N NIV30O N3dO SI34N1XIW SE NIV30O N3dO NIV30O N3dO NIVHC N3dO Ol d 81 3dld YSLVM LOH OL d 81 3dld Ol d81 3dld Ol d81 3dld NIVHO HOLIMS MO 13 41M u TOULNOO SYNLWYAdWAL ANVL SINAWSYINOAY WNOILIGGV HOJ FJOYO 3H nlVH3dWN3L dINNad SNI LV WO SAONVNIGHO ANY Sd3GOO9 TVOO 1 HLIM MOSHO S3OIA3G YSHLO ANY NOILVHOO9IJNOO ONI did JAYA SOU SA 3A VA 33l 138 JansSSJAJ 3ATVA 33 1138 C OIN393 UILSITDONS SMOHS SNIMV8SG SIHL ONINSVM MNVL JOVYUOLS TVLNOZINOH HLIM SLINA v 3N14 1LINW too M 48 MANIFOLD KITS TWO UNIT MANIFOLD KIT PART NO 9003426205 a gt VACUUM RELIEF e VALVE INSTALL PER LOCAL CODES 1 1 2 INLET A AND OUTLET MANIFOLD CONNECTIONS e 50 127cm m _ 60 5 8 154 cm SS cui MODEL DIMENSION A A BCG385T500 8P I THREE UNIT MANIFOLD KIT PART NO 9003427205 2 1 2 INLET AND OUTLET i MANIFOLD CONNECTIONS A IM ka Ss _ yon y ene seal 91 3 4 233 cm FOUR UNIT MANIFOLD KIT SCHEER PART NO 9003428205 NEN erie Sonam ca 2 1 2 INLET AND OUTLET I MANIFOLD i CONNECTIONS lt
76. om of the enclosure See Figure 18 Each opening shall communicate directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an Unconfined Space Each opening shall have a minimum free area of 1 square inch per 1 000 Btu hr 2200 mm per kW of the aggregate input rating of all appliances installed in the enclosure Each opening shall not be less than 100 square inches 645 cm TABLE 7 TECHNICAL DATA VENTING VENT CAP W COMMON VENT TYPE B GAS VENT MANIFOLD En Multiple Gas Fired Tank Type Heaters HEIGHT When venting multiple tank type heaters using Type B vent TEE CAPPED pipe follow the installation diagram figure 13 and tables WENT EGHNECTORS below which give sizing and data based upon NFPA 54 ANSI VENT CONNECTOR RISE Z223 2006 HEATER Model 500 Input 500 000 btu hr A Total Vent Height Feet eee ME A SP A ES A E Vent Connector Diameter Inches ew 3R T D L s Dr ooo ere m 8 8 7 CECR asm wo s 9 8 7 AA Multiple Fan Assisted Water Heaters Total Vent Height Feet Number of 500 Combined 6 sa J n 155 2 30 5 10 Heaters Input btu hr Manifold and Common Vent Diameter Inches Combination of Multiple Fan Assisted and Natural Draft Water Heaters eva _ Heaters Input btu hr Manifold and Common Vent Diameter mwen 3 fo e pow pow p
77. onform to all local code authority having jurisdiction AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF ELECTRICAL SHOCK OR POSSIBLE ELECTROCUTION If any of the original wire as supplied with the appliance must be replaced use only type 105 C thermoplastic or equivalent and 250 C type F must be used for the flame sensor and igniter leads The controls of this water heater are polarity sensitive Be certain to properly wire the hot and neutral connections o BLOWER PROVER PRESSURE SWITCH TO EARTH Ii CO I GROUND 1a 1 1b HOT 120 VAC NEUTRAL m m EARTH GROUND IGNITER FLAME SENSOR 120 VAC CIRCUIT FACTORY INSTALLED a an an an n a BY INSTALLER BK BLACK BR BROWN WIRING DIAGRAM WHEN EQUIPPED WITH R RED WHITE RODGERS IGNITION BOARD DIGITAL Y YELLOW THERMOSTAT AND CONTROLS G GREEN IF ANY OF THE ORIGINAL WIRE AS SUPPLIED BL BLUE MUST BE REPLACED USE ONLY TYPE 105 C W WHITE THERMOPLASTIC OR EQUIVALENT USE 250 C TYPE F FOR FLAME SENSOR AND IGNITER LEADS FIGURE 20 21 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 9 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 Note Fittings such as elbows tees and line regulators will add
78. ontact ELECTRICAL SERVICING LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING FOR YOUR INFORMATION START UP CONDITIONS SMOKE ODOR It is not uncommon to experience a small amount of smoke and odor during the initial start up This is due to burning off of oil from metal parts and will disappear in a short while STRANGE SOUNDS Possible noises due to expansion and contraction of some metal parts during periods of heat up and cool down do not necessarily represent harmful or dangerous conditions Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal See Condensation in this manual CONDENSATION Whenever the water heater is filled with cold water some condensate will form while the burner is on A water heater may appear to be leaking when in fact the water is condensation This usually happens when a Anew water heater is filled with cold water for the first time b Burning gas produces water vapor in water heaters particularly high efficiency models where flue temperatures are lower Large amounts of hot water are used in a short time and the refill water in the tank is very cold 30 Moisture from the products of combustion condense on the cooler tank surfaces and form drops of water which may fall onto the bu
79. opane Installations 11 Natural Gas Installations usina is 11 INSTALLATION REQUIREMENTS 12 Gas Pressure Requirements 12 Supply Gas Regulator 12 Power le EE 12 Water Temperature Control and Mixing Valves 12 Dishwashing Machines a ko a ka 13 Closed Water Systems 13 Thermal Expansion a 13 Temperature Pressure Relief Valve 13 So A e o FU O 14 pia 0 nn 14 UNCONTINECO Wee 15 Confined Spate AAA o o RA 15 Vent MCAD OL M RE m repa kek asasin 15 VENTING INSTALLATION 2 scalacecccacscdaacnsctactazeeassacetoeedsatancsinceanteonctias 15 YO CAN DA Cf t pat osi cr 15 Multiple Heater Manifold 16 Fresh Air Openings For Confined Spaces ea0nnenannnenennnnnenna 16 Outdoor Air Through Two Openings 16 Outdoor Air Through One Opening 16 Outdoor Air Through Two Horizontal Ducts 16 Outdoor Air Through Two Vertical Duce 17 Air From Other
80. ot install water heater on e Do not expose water heater controls to excessive gas carpeted floor ressure j e Do not operate water heater if Use only the gas shown on the water heater rating label flood damaged Maintain required clearances to combustibles Keep ignition sources away from faucets after extended periods of non use AWARN d e Read instruction manual before Use joint compound or Teflon tape installing using or servicing compatible with propane gas water heater Leak test before placing the water heater in operation Disconnect gas piping and main gas shutoff valve before leak AWARNING gas sh Install sediment trap in Breathing Hazard Carbon Monoxide Gas accordance with NFPA 54 e Do not obstruct water heater air intake with insulating blanket e Gas and carbon monoxide detectors AWARN N G are available Fire and Explosion Hazard e Install water heater in accordance with WK the instruction manual e Do not use water heater with any gas ther than th hown on the ratin Breathing carbon monoxide can cause brain damage or pw IS death Always read and understand instruction manual a e Excessive gas pressure to gas valve can cause serious injury or death CAUTION e Turn off gas lines during installation e Contact a qualified installer or service Property Damage Hazard agency for installation and service e All water heaters eventually leak e Do not install without adequate drain
81. ow e 9 w 18 WATER HEATER INSTALLATION WATER LINE CONNECTIONS This manual provides detailed installation diagrams see pages 34 48 of this manual for typical methods of application for the water heater s WATER POTABLE HEATING AND SPACE HEATING 1 All piping components connected to this unit for space heating applications shall be suitable for use with potable water 2 Toxic chemicals such as those used for boiler treatment shall NEVER be introduced into this system 3 This unit may NEVER be connected to any existing heating system or component s previously used with a non potable water heating appliance 4 When the system requires water for space heating at temperatures higher than required for domestic water purposes a tempering valve must be installed Please refer to installation diagrams on pages 34 48 of this manual for suggested piping arrangements THERMOMETERS NOT SUPPLIED Thermometers should be obtained and field installed as shown in the installation diagrams Thermometers are installed in the system as a means of detecting the temperature of the outlet water supply WATER PIPING DIAGRAMS This manual provides detailed water piping diagrams for typical methods of application for the water heaters see Water Piping Diagrams beginning on page 34 The water heater may be installed by itself or with a separate storage tank on both single and two temperature systems When used wi
82. permits required for installation of a new storage tank or replacement part s and d All costs necessary or incidental in returning the defective storage tank or component part s to a location designated by the manufacturer 6 The terms of this Limited Warranty cannot be modified by any person whether or not he she claims to represent or act on behalf of the Manufacturer E HOW STATE LAW MAY RELATE TO THIS WARRANTY Some States do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you Similarly some States do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you Further this warranty gives you specific legal rights and you may also have other rights which may vary from State to State F HOW THE ORIGINAL OWNER CAN MAKE A WARRANTY CLAIM 1 The Owner should submit the warranty claim directly to Manufacturer s Service Department at the address or phone number listed below and Manufacturer will arrange for the handling of the claim and if valid will give the Owner an authorization number which must appear on any document presented for warranty exchange 2 Whenever any inquiry or request is made be sure to include the storage tank s product number model number serial number date of purchase date of installation maintenance records and location of installation gt lt rub ro O O EE FOR TECHNI
83. phosphoric acid In case of external contact flush with cool water If irritation persists get medical attention If swallowed give 1 or 2 glasses of water or milk and call physician Get immediate medical attention for contact with eyes Keep out of reach of children NOTE THE USE OF RUBBER OR NEOPRENE GLOVES IS RECOMMENDED ESPECIALLY IF YOU HAVE ANY OPEN SORES OR CUTS TO AVOID UNNECESSARY IRRITATION OR DISCOMFORT 1 Turn off fuel and or power supply to heater Also turn off power to any electrical device or equipment which is attached or part of the system Open hot water side of faucet closest to heater and allow water to run until it is cool enough to handle safely Close cold water inlet valve to heater Connect hose to drain valve at bottom of heater and start draining heater into suitable floor drain area Remove relief valve while heater is draining NOTE Do not replace relief valve until deliming is completed Relief valve opening will also act as a vent in case of possible contact between the delimer and the anode rod s which may produce flammable hydrogen air mixtures If relief valve appears to be limed up place it in a clean glass or plastic container adequate in size so that you can pour enough UNeLIME into the container to cover the valve and allow space for foaming When foaming stops run fresh cool water into the container and rinse the relief valve for a few minutes If heater does no
84. properly sanitized dishes Where pressures are high a water pressure reducing or flow regulating control valve should be used in the 180 F 82 C line to the dishwashing machine and should be adjusted to deliver water pressure between these limits The National Sanitation Foundation also recommends circulation of 180 F 82 C water Where this is done the circulation should be very gentle so that it does not cause any unnecessary turbulence inside the water heater The circulation should be just enough to provide 180 F 82 C water at the point of take off to the dishwashing machine Adjust flow by throttling a full port ball valve installed in the circulating line on the outlet side of the pump Never throttle flow on the suction side of a pump See Water Piping Diagrams in this manual CLOSED WATER SYSTEMS Water supply systems may because of code requirements or such conditions as high line pressure among others have installed devices such as pressure reducing valves check valves and back flow preventers Devices such as these cause the water system to be a closed system THERMAL EXPANSION As water is heated it expands thermal expansion In a closed system the volume of water will grow when it is heated As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the
85. ressures of more than 14 0 W C 3 48 kPa Aservice regulator is necessary if higher gas pressures are encountered The manifold gas pressure specified in Table 10 refers to the gas pressure measured at the pressure tap of the automatic gas valve when the burners are firing TABLE 10 MANIFOLD GAS PRESSURE IN INCHES OF WATER COLUMN ALL MODELS TYPE OF GAS NATURAL PROPANE 3 5 0 87 kPa 10 0 2 49 kPa OPERATION IMPORTANT A qualified person must perform the initial firing of the heater At this time the user should not hesitate to ask the individual any questions which they may have in regard to the operation and maintenance of the unit An Operational Checklist is included on page 33 of this manual By using this checklist the user may be able to make minor Operational adjustments and avoid unnecessary service calls However the user should not attempt repairs which are not listed under the USER column GENERAL NEVER OPERATE THE HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER AND A TEMPERATURE AND PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE OPENING OF THE HEATER SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE Before proceeding with the operation of the unit make sure the water heater and system are filled with water and all air is expelled FILLING 1 Close the heater drain valve by turning handle clockwise 2 Ope
86. rner or other hot surfaces to produce a sizzling or frying noise OPERATIONAL CONDITIONS SMELLY WATER The water heater has at least one anode rod for corrosion protection of the tank Certain water conditions will cause a reaction between this rod and the water The most common complaint associated with the anode rod is one of a rotten egg smell in the hot water The smell is a result of four factors which must all be present for the odor to develop a Aconcentration of sulfate in the supply water b Little or no dissolved oxygen in the water c A sulfate reducing bacteria which has accumulated within the water heater this harmless bacteria is nontoxic to humans d Anexcess of active hydrogen in the tank This is caused by the corrosion protective action of the anode Smelly water may be eliminated or reduced in some water heater models by replacing the anode s with one of less active material and then chlorinating the water heater tank and all water lines Contact the local water heater supplier or service agency for further information regarding anode replacement and this chlorination treatment If the smelly water persists after the anode replacement and chlorination treatment we can only suggest that chlorination or aeration of the water supply be considered to eliminate the water problem Do not remove the anode leaving the tank unprotected By doing so all warranty on the water heater tank is vo
87. rs anes 28 Deliming Solvents E 28 Tank Cleanout Procedure 28 Deliming Using Flo Jug Method 28 Ignition Module SY 30 System DIAONO e 30 A ie 30 Electrical SerVIGCin0g_ u uuu uuu ana kontake santan Ans e KANA A AAS DANI EE 30 FOR YOUR INFORMATION eebe 30 0 A Ee 30 Operational COndll AS ista asta eeh 30 Sequence of Operation Flow Chart 32 OPERATIONAL CHECKLIST ctussuszm2tc urtart eod etu Roda teo tetro es be pe tates 33 WATER PIPING DIAGRAMS aa a saras 34 MANIFOLD KITS c N 49 COMMERCIAL STORAGE TANK WARRANTY 50 le 51 SAFE INSTALLATION USE AND SERVICE The proper installation use and servicing of this water heater is extremely important to your safety and the safety of others Many safety related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard Read and obey all safety messages and instructions throughout this manual It is very important that the meaning of each safety message is understood by you and others who install use or service this water heater This is the safety alert symbol It is used to alert yo
88. ruction Manual and NFPA 54 or CAN CSA B149 1 e To avoid injury combustion and ventilation air must be taken from outdoors e Do not place chemical vapor emitting products near water heater Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual For safe operation an adequate supply of fresh uncontaminated air for combustion and ventilation must be provided An insufficient supply of air can cause recirculation of combustion products resulting in contamination that may be hazardous to life Such a condition often will result in a yellow luminous burner flame causing sooting of the combustion chamber burners and flue tubes and creates a risk of asphyxiation Do not install the water heater in a confined space unless an adequate supply of air for combustion and ventilation is brought in to that space using the methods described in the Confined Space section that follows Never obstruct the flow of ventilation air If you have any doubts or questions at all call your gas supplier Failure to provide the proper amount of combustion air can result in a fire or explosion and cause property damage serious bodily injury or death UNCONFINED SPACE An Unconfined Space is one whose volume IS NOT LESS THAN 50 cubic feet per 1 000 Btu hr 4 8 cubic meters per kW of the total input rating of all appliances installed in the space Rooms communicating directly with the space in which the
89. s been determined that each water heater connected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use If improper venting is observed during any of the above tests the venting system must be corrected FAILURE TO CORRECT BACK DRAFTS MAY CAUSE AIR CONTAMINATION AND UNSAFE CONDITIONS If the back draft cannot be corrected by the normal method or if a suitable draft cannot be obtained a blower type flue gas exhauster must be employed to assure proper venting and correct combustion CHECK THE IGNITER ASSEMBLY At least once a year check the igniter assembly Figure 23 and the main burner Figure 24 for proper operation Refer to the following igniter assembly and main burner sections IGNITER ASSEMBLY For access to igniter assembly unfasten two screws to burner cover and remove Locate the burner with the igniter assembly and remove screw holding burner to manifold Slide burner out to access igniter assembly Servicing of the igniter assembly includes keeping the igniter free of lint scale or any other foreign debris 25 FIGURE 23 MAIN BURNER The main burner figure 24 should display the following characteristics Cause rapid ignition and carry across entire burner Give reasonably quiet operation during ignition burning and extinction Cause no excessive lifting o
90. t drain completely after a reasonable length of time turn off the main water supply valve to stop water from entering the tank due to a by pass problem or defective cold water inlet valve Also check for clogged drain valve opening Heater must be completely drained before introducing UN LIME Remove the cleanout cover and place a clean plastic bucket next to the cleanout opening Partially open the cold water inlet valve to allow time to accomplish the following and then close the valve While the water is being run through the tank insert a stiff wire copper tube flattened at one end or an opened wire coat hanger through the cleanout opening and scrape out any loose deposits of scale or sediment This is an economical way to avoid unnecessary usage of the deliming solution Repeat the opening and closing of the cold water inlet valve as necessary but be sure the heater is completely drained when ready to introduce the UN LIME Upon completion reinstall the cleanout cover and use a new cleanout cover gasket part number 9004099215 Remove the drain valve Install the long plastic male adapter insert fitting into the drain valve opening of heater after applying Teflon tape or paste to threads Tighten firmly by hand and use wrench or adjustable pliers to check for secure connection Do not over tighten to avoid damage to threads and fittings 29 Prepare the Up N Down Transfer Kit The next step is the preparation of the
91. th a separate storage tank the circulation may be either by gravity or by means of a circulating pump When a circulating pump is used it is important to note that the flow rate should be slow so that there will be a minimum of turbulence inside the heater Adjust flow by throttling a full port ball valve installed in the circulating line on the outlet side of the pump Never throttle flow on the suction side of a pump T amp P VALVE DISCHARGE PIPE AWARNING e Temperature Pressure Relief Valve must comply with ANSI Z21 22 CSA 4 4 and ASME code e Properly sized temperature pressure relief valve must be installed in opening provided e Can result in overheating and excessive tank pressure e Can cause serious injury or death This water heater is provided with a properly rated sized and certified combination temperature pressure T amp P relief valve by the manufacturer See Temperature Pressure Relief Valve on pages 13 14 for information on replacement and other requirements CAUTION e Temperature Pressure Relief Valve discharge pipe must terminate at adequate drain Install a discharge pipe between the T amp P valve discharge opening and a suitable floor drain Do not connect discharge piping directly to the drain unless a 6 15 2 cm air gap is provided To prevent bodily injury hazard to life or property damage the relief valve must be allowed to discharge water in adequate quantities should circumsta
92. torage tank is supplied or operated with desalinated deionized water or The storage tank is removed from its original installation location or The storage tank is installed outdoors this storage tank is intended only for indoor installation or The storage tank or any of its component parts fail due to lime and or sediment build up or m The storage tank does not have installed a temperature and pressure relief valve certified to ANSI Z21 22 and approved by the American Society of Mechanical Engineers or n The storage tank or any of its component parts fail because of fire floods lightening or any other act of God or o The storage tank is installed in a closed system without adequate provision for thermal expansion 5 Except when specifically prohibited by the applicable state law the Owner and not the Manufacturer shall be liable for and shall pay for all charges for labor or other expenses incurred in the removal repair or replacement of the water heater or any component part s claimed to be defective or any expense incurred to remedy any defect in the product Such charges may include but are not necessarily limited to a All freight shipping handling and delivery costs of forwarding a storage tank or replacement part s to the owner b All costs necessary or incidental in removing the defective storage tank or component part s and installing a new storage tank or component part s c Any material required to complete and or
93. u to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently e a mem WARNING indicates a potentially hazardous situation which if not avoided could result in injury or death CAUTION Indicates a potentially hazardous TU CAUTION used without the safety alert EE property damage All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances listed in the Act APPROVALS MS S A UL ASM E CRN Low Lead Content WATER QUALITY California AB1953 GENERAL SAFETY INFORMATION A WARNING A WARNING Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance For continued protection against risk of fire Avoid all ignition sources if you smell gas e Do n

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