American Water Heater 381T1546NOX Water Heater User Manual
Contents
1. UPPER PROBE LOWER PROBE THERMOSTAT 9 BLOWER 7 PRESSURE SWITCH IGNITION MODULE oT D V2 N W 51 GND PEL 12 az L L Bedae 7 RO BLOWER ON OFF SWITCH 120VAC HOT 120VAC NUETRAL EBM UGB FACTORY INSTALLED BY INSTALLER IF ANY OF THE ORIGINAL WIRE AS SUPPLIED MUST REPLACED USE ONLY 18 AWG 105 C 600V UL AWM STYLE 1015 WIRE EXCEPT GAS VALVE CABLE WHICH MUST USE 2 CONDUCTOR 18 AWG 80 C 300V UL CATAGORY QPTZ POWER LIMITED CIRCUIT CABLE Servicing should only be performed by a Qualified Service Technician COMMERCIAL GAS WATER HEATERS Visit the Information Central link of www americanwaterheater com for a listing of available Service Handbooks For additional information contact American Water Heaters PO Box 1597 500 Princeton Road Johnson City TN 37605 1 800 456 9805 www americanwaterheater com 2013 American Water Heater Company 325257 0002. 8 1 000 000 L1 14 14 12 12 10 10 9 9 14 Servicing should only be performed by a Qualified Service Technician OPERATION AND SERVICE SEQUENCE OF OPERATION 1 Switch power on to unit 2 Thermostat calls for heat 3 UGB Universal Gas Board sends PWM signal to blower to start the blower 4 Blower runs at high prepurge speed for 20 seconds 5 Combustion Blower initiates air flow through water heater closing the Prover Switch 6 After 30 seconds the Ignition Control provides power to the Spark Igniter and Gas Valve 7 Ignition Control maintains spark for up to 4 seconds and monitors Flame Sensor to determine if Burner is lit 8 If the Flame Sensor does not detect proper flame the Ignition Control shuts off the Gas Valve and allows the Blower to purge the unit At that time the Ignition Control restarts with step 6 It will try and ignite the main burners 2 more times If the unit does not light the Ignition Control will wait 15 minutes and then restart at step 6 This cycle will continue until the unit lights or the power is shut off to the unit 9 If the Flame Sensor detects proper flame the Ignition Control will energize the main gas valve output which will make the blower to run at a pre determined high speed until call for heat is removed from T stat 10 Once the unit is satisfied the Thermostat will shut off the Blower Gas Valve and lgnition Control and the unit will be in standby mode until ano
3. The indicator codes on the ignition module are as follows LED INDICATION FAULT MODE 2 Flashes Flame sensed without call for heat 3 Flashes Ignition Lockout Steady On Internal Control Failure The LED will flash on for 1 4 second then off for 1 4 second during a fault condition The pause between fault codes is 3 seconds INTERNAL CONTROL FAILURE If the ignition control detects an error in its software or hardware all outputs are turned off and the LED displays a steady ON condition If an internal control failure is indicated replace the ignition control TROUBLESHOOTING GUIDE FOR IGNITION CONTROL SYMPTOMS CAUSES 1 Control does not start a Miswired b No 24V AC power supply at TH W terminal c Bad control check LED for steady on or flashing code see above Table 2 Thermostat on no spark a Miswired b No 24V AC power supply at TH W terminal c Bad control check LED for steady on or flashing codes 3 Valve on no spark during TFI a Shorted electrode establish 1 8 inch gap b Check high voltage cable c Miswired 4 Spark on valve off a Valve coil open b Valve wire disconnected c Bad control check voltage at gas valve terminals PV1 and V2 5 Flame okay during TFI no flame sense after TFI a Poor ground at burner b Poor flame check flame current c Check flame rod position FLAME SENSOR CURRENT CHECK Flame current is the current that passes through the flame from the sensor to
4. and must communicate through a vertical or horizontal duct to the outdoors or spaces crawl or attic that freely communicate with the outdoors and must have a minimum free area of a 1 square inch per 3 000 BTU Hr 7cm per kW of the total input of all equipment located in the enclosure and b not less than the sum of the areas of all vent connectors in the confined space CONTAMINATED AIR 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 6 Servicing should only be performed by a Qualified Service Technician AIR REQUIREMENTS For safe operation an adequate supply of fresh u
5. injury NE or loss of life FLAMMABLE BEFORE OPERATING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES This appliance does not have a pilot It is equipped with If you cannot reach your gas supplier call the fire an ignition device which automatically lights the burner department Do not try to light the burner by hand C Use only your hand to push the control buttons Never use BEFORE OPERATING smell all aroung the area for gas tools Ithe contol buttons push indon try to repair them call a qualified service technician Force or Be sure to smell next to the floor because some gas is heavier than air and will settison the floor attempted repair may result in a fire or explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has been under water Do not try to light any appliance Immediately contact a qualified installer or service agency to replace a flooded water heater Do not attempt to repair Do not touch any electric switch the unit It must be replaced do not use any phone in your building immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions OPERATING INSTRUCTIONS 1 STOP Read the safety information 8 Set the thermostat to the desired setting above ON Iis label CAUTION Hotter water increases the risk 2 Set the ON OFF switch on the control box to of scald injury Consult the instruction
6. monitored to assure the system continues to operate properly When the thermostat is satisfied and the demand for heat ends the gas valve and UGB speed signals are de energized immediately FAILURE TO LIGHT LOCKOUT MULTI TRIAL CONTROL Should the burner fail to light or if flame is not detected during the first trial for ignition period the gas valve is de energized The control then goes through an interpurge delay before another ignition attempt The control will attempt two additional ignition trials before going into lockout and the valve relay will be de energized immediately This ignition control has an automatic reset If the thermostat is still calling for heat after 15 minutes the control will automatically reset and attempt to ignite the burner FLAME FAILURE RECYCLE MODE This control has the recycle after loss of flame function upon loss of an established burner flame the gas valve is de energized and the control proceeds to interpurge before attempting to relight the burner The ignition control will allow three tries for ignition including inter purges If the burner relights normal operation resumes If the burner does not relight the control will go into lockout as described in failure to light 26 Servicing should only be performed by a Qualified Service Technician FAULT CONDITIONS The water heater is equipped with an ignition control that incorporates a diagnostic system to assist in troubleshooting the appliance
7. or rough operation If a drop of more than 1 5 W C 0 37 kPa in supply gas pressure occurs when the main burner ignites ensure the supply gas lines and regulator s are properly sized and installed 4 Servicing should only be performed by a Qualified Service Technician AIR SUPPLY Stoichiometric or theoretical complete combustion requires 10 cubic feet of air per 1 000 BTU of gas supplied The National Fuel Gas Code also recommends an additional 2 5 cubic feet of excess air For information on minimum make up air opening sizes for various building installations refer to the National Fuel Gas Code NFPA 54 ANSI Z223 1 1 000 BTU 2 5 CUBIC FEET EXCESS AIR INSUFFICIENT MAKE UP AIR NEGATIVE AIR PRESSURE AND DOWNDRAFTS Downdraft Caused by Kitchen Vent Hood Alack of combustion and ventilation air can create a negative ambient air pressure in the installed space The vent system on one or more gas fired appliances can experience down drafts due to the outdoor air pressure being greater than the ambient air pressure in the installed space Where multiple gas fired appliances are installed one or more gas fired appliances can pull air through the vent system s of other appliances installed nearby One common example is in a restaurant installation where exhaust vent equipment was not considered in sizing make up requirements This condition may result in air being back drafted by the restaurant exhaust equ
8. the OFF position l manual before changing temperature 3 Set the thermostat to the lowest setting 9 If the appliance will not operate follow the 4 This appliance is equipped with a device which instructions TO TURN OFF GAS TO automatically lights the burner DO NOT TRY TO LIGHT THE BUNER BY HAND ANEA 5 Wait five 5 minutes to clear out any gas WARNING TURN OFF ALL ELECTRIC If you then smell gas STOP Follow B in the safety information above on this label If POWER BEFORE SERVICING you don t smell gas go to the next step 6 Turn on all electrical power to the appliance 7 Set the ON OFF switch on the control box to the ON position TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to the lowest setting 3 Turn off all electrical power to the appliance 2 Set the ON OFF switch on the control box to if service is to be performed the OFF position Servicing should only be performed by a Qualified Service Technician TROUBLESHOOTING COMPLAINT CAUSE Upper and or lower temperature probe out of calibration Insufficient hot water Thermostat set too low See WATER TEMPERATURE CONTROL WARNING on page Upper and or lower 12 of Instruction Manual temperature probe out of calibration Main manual gas shutoff valve partially closed Heater too small for demand Heater recovery is slower Water temperature too hot Thermostat set too high Sedime
9. the gas supply and electricity to water heater Servicing should only be performed by a Qualified Service Technician SPARK IGNITER FLAME SENSOR SIGHT GLASS The spark igniter and the flame sense rod are shown below Also shown is the burner sight glass These features are typical for all models Sightglass Burner Flame Sensor Spark Igniter SPARK IGNITER FLAME SENSOR CONTROL TIMING SPARK IGNITER This water heater is equipped with a spark igniter Do not damage the ceramic insulator Inspect the igniter ceramic insulator for any cracks The spark gap between the spark rod and grounding rod is 1 8 FLAME SENSOR This water heater is equipped with a flame sensor The flame sensor senses flame by passing a small electric current through the flame This type of flame sensing is also known as flame rectification The Ignition Control is looking for a minimum current of 0 7 micro amperes for the water heater to operate CONTROL TIMING 3 Servicing should only be performed by a Qualified Service Technician 11 VENTING INSTALLATION VENTING CATEGORY AND MATERIALS BCL VENTING Category Non condensing negative pressure in vent below atmospheric Type venting Must be installed Conventional Vent uses room air for combustion and discharges flue gases to the outdoor atmosphere through one pipe MINIMUM CLEARANCES This water heater is approved for installation on combustible flooring in an alcove with minimu
10. E VOLTS HZ MINIMUM MAXIMUM Models 3 5 WC 0 87 kPa 14 0 WC 3 48 kPa 120 60 All models require a minimum gas supply pressure of 3 5 W C The minimum supply pressure is measured while gas is flowing dynamic pressure The supply pressure dynamic should never fall below 3 5 W C 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 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 GAS PRESSURE REQUIREMENTS Main line gas pressure to the water heater for natural gas should be between a maximum of 14 w c 3 48 kPa static pressure and a minimum of 3 5 w c 0 87 kPa dynamic pressure for Natural Gas A supply gas pressure regulator service regulator must be installed on the gas supply line if the static pressure exceeds 14 w c and it should be installed no closer than 3 feet 1 meter but no farther than 8 feet 2 4 meters of equivalent length from the water heater s inlet gas connection 1 Check gas line pressure with a manometer 2 Cycle the burner on and off several times to check its operation 3 Check the operation of the limit a
11. LOW CHART exe Rx Eu RR RR RR Rm Rl CN REOR Rn 16 LIGHTING AND OPERATING LABEL rhe RR nc OR Enn m ye Rc eee 14 TROUBLESHOOTING c peio sariani p d o dei et De OEE Rn E fed 18 CONTROLS OVERVIEW CONTROL BOX ASSEMBLY hk REOR e RC Ra 19 PRESSURE SWITCHES ALL MODELS enam mm hk RR RR y yen yy Re 19 HIGH LIMIT SWITCH DIGITAL THERMOSTAT iu a utra ea n tec nn Ren SR nri rc el 20 CONTINUITY CHECK OF HIGH LIMIT ECO RERO rc eX ci dC d eae e 22 UPPER TEMPERATURE PROBE CONTINUITY CHECK tiki ai ur cata i RR e ud RD Re 23 LOWER TEMPERATURE PROBE CONTINUITY xxu etm eR o ee 24 IGNITION CONTROL RR dice eie eee Y pe een aea ER Roma d e e Por eager e 25 STARTUP FLAME RECOVERY SAFETY poti noe d DURS mant ero eR 26 UGB BEOWER SPEED CONTROL Rode t CR il len e cna Res 28 WIRING DIAGRAM is nur CR et iore Ceo t RC Re eee De etica ce n Pelee e a c d 29 Servicing should only be performed by a Qualified Service Technician 1 INTRODUCTION The service handbook is designed to aid in servicing and troubleshooting American Water Heaters BCL commercial water heaters in the field No duplication or reproduction of this book may be made without the express written authorization of American Water Heaters The following text and illustrations will provide you with a step by step procedure to verify proper
12. Service Handbook COMMERCIAL GAS WATER HEATERS FOR MODELS BCL 381T1206NOX 381T1546NOX 395T1806NOX american 395T1996NOX 395T2506NOX WATER HEATERS ULTRA LOW NOx SERIES 104 PO Box 1597 500 Princeton Road INSTALLATION CONSIDERATIONS PRE SERVICE CHECKS Johnson City TN 37605 CONSTRUCTION OPERATION amp SERVICE TROUBLESHOOTING SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN PRINTED IN THE U S A 0113 325257 000 TABLE OF CONTENTS INTRODUCTION ss ac RE Re e t em n ESS RC APES E uc eO Aa i 2 Ur Bae peo C 2 TOOLS REQUIRED a ER e eek weld ca 3 INSTALLATION CONSIDERATIONS ias a ac acie e ood e eue gad 4 GAS AND ELECTRICAL CHARACTERISTICS ec scx atic geh e RR RR n o Rh n we 4 GAS PRESSURE REQUIREMENTS 4x ec ns ice iC CHER XC ES E ah caa 4 FEATURESAND COMPONENT S ws 4 ia ORS ee Ge cid iC e ROC t d ee 8 BLOWER AND BURNER ASSEMBLY fis 22 acr aranea Re naka wo CX CE E Noreen Ks 9 SPARK IGNITER FLAME SENSOR SIGHT GLASS ccc cece ite wea et eee yh wee eee eee 11 VENTING PREX 12 VENTING TABLES TECHNICAL VENTING DATA s iara soca tee whew RC 14 OPERATONAND SERVICE 426 4584 ond Red hae ei ee ee Rees oe e D 89 58 093 15 SEQUENCE OF OPERATION F
13. arge pressure when the water system pressure is zero If drain valve cannot be closed tightly replace Repair or in case of suspected tank leakage be certain to confirm before replacing heater Shut off gas supply to heater and close cold water inlet valve to heater Shut off gas supply to heater and call gas company at once Servicing should only be performed by a Qualified Service Technician CONTROLS OVERVIEW CONTROL BOX ASSEMBLY ON OFF Switch Blower Prover Switch Digital Thermostat Ignition Control PRESSURE SWITCHES ALL MODELS All BCL 120 thru 250 models are provided with one blower prover switch with 0 38 w c setpoint The blower prover switch is provided on the heater to verify that the fan is operating It is a positive pressure switch whose electrical contacts are normally open The blower prover switch electrical contacts will close on a rise in pressure as the blower increases the pressure in the burner This switch is connected to the blower outlet pressure tap by a piece of silicone tubing This tubing must be connected in order for the switch to close the electrical contacts Servicing should only be performed by a Qualified Service Technician 19 HIGH LIMIT SWITCH DIGITAL THERMOSTAT The digital thermostat contains the high limit energy cut out switch The high limit switch interrupts burner gas flow should the water temperature reach 203 F 95 C In the event of high li
14. d skirt ring flange surfaces to remove any portions of the old skirt ring flange gasket Servicing should only be performed by a Qualified Service Technician 9 10 11 14 15 16 17 18 19 20 21 22 Support the blower and burner assembly in a vertical position with the burner extending downward Remove the 3 brass locknuts holding the blower adapter to the flange plate Separate the blower from the flange plate Clean the flange plate surfaces removing any portions of the old burner gasket 12 13 Remove the burner from the flange plate Insert the new burner into the flange plate and align the notch in the burner flange with the tab in the flange plate Install the new burner gasket over the three studs extending from the flange plate Install the blower assembly on the flange plate with the 3 brass locknuts Torque the nuts to 60 in lb Install the new skirt ring flange gasket on the flange plate Install the blower and burner assembly into the combustion chamber and engage the 4 studs through the mounting holes slots in the flange plate Install 4 flat washers and 4 brass locknuts on the studs and torque to 16 ft lb Reconnect the gas line Reconnect the spark ignition cable and ground wire plus the flame sensor wire at their connection points on the flange plate Reconnect the blower s power supply PWM control and pressure sensing tubing Check that all gas connections and fasteners are tight Turn on
15. e This type of failure is not covered under the 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 CONTAMINATED AIR 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 POWER SUPPLY The water heaters covered in this manual require a 120 18 single phase 60Hz 15 amp power supply and must als
16. formed by a Qualified Service Technician CONTINUITY CHECK OF HIGH LIMIT ECO CONDITIONS e Power On No Hot Water Red digital thermostat Call for Heat LED On Turn Power OFF Continuity check of ECO energy cut out high limit Black to Black wires of upper probe Power is off Continuity is indicated Opens 203 closes at 193 If water is below 193 F ZERO 0 0 Resistance continuity is correct Continuity is not present Replace ECO sensor if water temperature is below 193 meter reads 0 L Water is less than 120 F Reset status LED should be on Replace digital thermostat if control will not manually reset 22 Servicing should only be performed by a Qualified Service Technician UPPER TEMPERATURE PROBE CONTINUITY CHECK CONDITIONS Power On Water below temperature set point digital thermostat Reset Status LED OFF Call for Heat LED Off OHMS RESISTANCE TABLE Upper Temperature Probe continuity check Red wire to red wire Turn supply power Off for this test Test indicates no continuity Replace probe Continuity is indicated Probe should be okay also verify Ohms resistance for water temperature Reading will be approximate Servicing should only be performed by a Qualified Service Technician 23 LOWER TEMPERATURE PROBE CONTINUITY CHECK CONDITIONS Main burner ignited e Stored water is below temperature setti
17. gher than any portion of a building within a horizontal distance of 10 feet for vents of 12 inches in diameter or less 10 or Less Roof Surface gt Within 10 Horizontally i Chimney Chimney _ Y 10 Feet or Less 10 or Less Height Above Any Servicing should only be performed by a Qualified Service Technician VENTING TABLES TECHNICAL VENTING DATA TYPE B GAS VENT Multiple Gas Fired Tank Type Heaters VENESAE COMMON VENT When venting multiple tank type heaters MANIFOLD mE using Type B vent pipe follow the installation a en diagram and tables below which give sizing TEE CAPPED and data based upon NFPA 54 ANSI 2223 1 VENT CONNECTOR RISE VENT CONNECTORS HEATER Model BCL381T1206NOX Input 120 000 Btu hr Total Vent Height Feet Vent connector size 6 inches _ Z 6 8 10 15 20 30 50 100 InputBtuhr Rise Vent Connector Diameter Inches 32000 1ft j 6 6e 5 5 5 5 5 5 Number of 120 Heaters combines pus 10 Manifold and Common Vent Diameter Inches Thousands of Btu hr 240 000 J 7 7 j 6 6 6 6 J 6 6 360 000 Jpjeas8 7 7 6 6 6 4 480000 1 9 jo es 7 j v 6 Model BCL381T1546NOX Vent connector size 6 inches 1 1 6 j 10 15 20 30 50 100 input Btuyhr Rise Vent Connector Diameter Inches 1 155400 1t 6 6 J o o
18. ground The minimum flame current necessary to keep the system from lockout is 0 7 micro amps To measure flame current connect analog DC microammeter to the FC FC terminals on the Ignition Control Meter should read 0 7 microamps or higher If the meter reads below O on scale meter leads are reversed disconnect power and reconnect meter leads for proper polarity Servicing should only be performed by a Qualified Service Technician 27 UGB BLOWER SPEED CONTROL The BCL 120 thru 250 A models are equipped with a UGB PWM output control board for blower speed control When the UGB J5 6 is energized by T stat Call for heat the UGB will provide 90 duty cycle PWM signal to the blower for 20 seconds prepurge then provide a PWM control signal per SW2 dipswitch setting for igntion speed After the flame is confirmed and the UGB J5 3 is energized by the main gas control of the igntion module the UGB will provide a high blower speed control per SWA dipswitch setting For the detailed SW2 and SWA dipswitch settings of different BCL models see the dipswitch table listed in this page SWA SW2 jS3NHUH e ELTE USEbFOR sso 8 1 8 BCLSBIMSANOX 3038802 6 A BCLS9STI0NNOX 3 8 BCLSOST2SONOX PIN CONNECTIONS 24VAC N ENABLE HIGH FIRE PIN NUMBER DESCRIPTION 24VAC H J5 28 Servicing should only be performed by a Qualified Service Technician WIRING DIAGRAM
19. installation operation and troubleshooting procedures Additional quick reference data is included to assist you in servicing these products The information contained in this handbook is designed to answer commonly faced situations encountered in the operation of this product line and is not meant to be all inclusive If you are experiencing a problem not covered in this handbook please contact American Water Heaters Technical Information at 1 800 456 9805 by email at helo americanwaterheater com or your local American Water Heaters representative for further assistance Our website at www americanwaterheater com is also a resource for installation and service information This handbook is intended for use by licensed plumbing professionals and reference should be made to the installation manual accompanying the product This handbook contains supplemental information to the product s installation and operation manual QUALIFICATIONS Qualified Service Technician or Qualified 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 Z223 1 Sec 3 3 85 Qualified Agency Any individual firm corporation or company that either in person or through a representati
20. ipment through the heater causing the draft proving switch to open and or erratic heater shutdown Down drafts can cause flue gases to spill into the installed space Servicing should only be performed by a Qualified Service Technician 5 MAKE UP AIR DIRECT COMMUNICATION WITH OUTDOORS A fresh supply of make up air for combustion can be supplied to the water heater through make up air ducts which directly communicate with the outdoors Not Direct Vent Two openings are required one within 12 inches 30 cm of the top of the enclosure and one within 12 inches 30 cm of the bottom of the enclosure Each opening must have a free area of not less than 1 square inch per 4 000 BTU Hr of the total input of all appliances within the enclosure The lower opening primarily provides combustion air The upper opening provides vent dilution air and acts as a relief opening for flue gases should the vent become obstructed or a downdraft condition occur 1 SQUARE INCH PER 4 000 BTUH FOR EACH OPENING e Additionally when the water heater is installed in confined space and communicating with the outdoor air one permanent opening beginning within 12 inches 30 cm of the top of the enclosure must be permitted where the equipment has clearances of at least 1 inch 2 5 cm from the sides and back and 6 inches 16 cm from the front of the appliance The opening must directly communicate with the outdoors
21. is a 24 VAC ignition control The microprocessor circuit design provides precise repeatable timing and operating sequences The on board diagnostics with LED output make troubleshooting easy and ensures safe and efficient operation WIRING TERMINALS 1 Wi O igh Speed Control Signal MES Go System Ground Remote Flame Sensor po High Voltage Output PV1 MV 1 v2 GND 51 HV Servicing should only be performed by a Qualified Service Technician 25 START UP FLAME SAFETY LOCKOUT START UP HEAT MODE When a call for heat is received from the thermostat supplying 24 volts to to UGB J5 6 the UGB will enable blower run at prepurge speed which will cause the blower prover switch closing and allow 24vac power from the T stat to TH W terminal of the control module The control will reset perform a self check routine flash the diagnostic LED once in the first two seconds and a pre purge delay begins 20 seconds after high speed prepurge UGB will send a ignition low speed PWM to blower for preparing the ignition sequence Following the 30 seconds pre purge period the gas valve is energized and sparks commence for the trial for ignition period When flame is detected during the trial for ignition the sparking process is terminated and the UGB high speed signal is energized after a 5 second dwell period and the heater will run at the rated fire rate The thermostat and burner flame are constantly
22. m clearance from combustion construction as indicated in below Figure and Table 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 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 Temperature pressure relief valves baffles digital thermostats cleanout openings or drain valves The units are approved for installation with side rear and ceiling clearances as indicated below MINIMUM CLEARANCES TO COMBUSTIBLE OR NON COMBUSTIBLE CONSTRUCTION MODELS A RIGHTSIDE B LEFT SIDE C BACK D CEILING 0 BCL 120 154 180 00 1227 199 250 CEILING REAR WALL h 6 CLEARANCE ON REDUCING THIMBLE SEE RIGHT WALL ILLUSTRATION OF MINIMUM COMBUSTIBLE CLEARANCES IN AN ALCOVE 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 12 Servicing should only be performed by a Qualified Service Technician EXTERIOR CLEARANCES The illustration below shows the required clearances for venting units using natural draft venting The vent must extend at least 3 feet above the highest point where it passes through a roof of a building and at least 2 feet hi
23. mit switch operation the water heater cannot be restarted unless the water temperature is reduced to approximately 120 F 49 C The manual 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 Contact your dealer or qualified service technician if continued high limit switch operation occurs Manual Reset Temperature To 120V Adjustment supply Dial E2 Display Fuse LED Label To Lower E4 Temperature Probe Display LED s To Upper E3 Temperature Probe 20 Servicing should only be performed by a Qualified Service Technician DISPLAY LIGHTS DIGITAL THERMOSTAT Power OPEN ECO a a Status du Reset Status 5 Call for Heat PUSH RESET LED INDICATION ACTION STATUS Calling for heat Normal status No action required e Check for excessively hot water 203 F or e The ECO Energy Cut Out has higher e opened e Check the resistance of the temperature probes and continuity of the high limit ECO No power Check the breaker Tank is at a set temperature 2 F No action required e Push the manual reset button Tank has cooled below 120 F Preceded by ECO indication e Check the resistance of the temperature e probes and continuity of the high limit ECO Servicing should only be per
24. ncontaminated 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 of the Instruction Manual 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 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 leakag
25. nd operating controls 4 Check the vent system seams and joints and ensure that there is no discharge of flue products into the room 5 Check the input rate Supply gas pressure shall be measured while the water heater is not firing static pressure and while the water heater is firing at full capacity dynamic pressure If the supply gas pressure to the water heater is not between the required minimum and maximum values given in table above adjust the supply gas regulator as necessary Adjust the supply gas regulator s per the regulator manufacturer s instructions to achieve the required static and dynamic supply gas pressure MULTIPLE APPLIANCE INSTALLATIONS In multiple water heater installations or in installations where the installed water heater s share a common gas supply main with other gas fired appliances the supply gas pressures shall be measured at each water heater with all gas fired appliances connected to a common main firing at full capacity In multiple water heater installations the supply gas line regulators shall be adjusted to provide gas pressure to each water heater within the minimum and maximum supply pressure requirements listed in table above with all gas fired appliances connected to a common gas main firing at full capacity Note A pressure drop of more than 1 5 W C 0 37 kPa when the main burner ignites is an indication of an inadequate supply of gas and can lead to ignition failure rough starts and
26. ng more than 5 F Tank Average Power Off Plug disconnected from digital thermostat receptacle E4 OHMS RESISTANCE TABLE Lower Temperature Probe continuity check Red wire to red wire Turn supply power Off for this test Test indicates no continuity Replace probe Continuity is indicated Probe should be okay also verify Ohms resistance for water temperature Reading will be approximate 24 Servicing should only be performed by a Qualified Service Technician IGNITION CONTROL Each heater is equipped with an ignition control The solid state ignition control ignites the burner by utilizing spark igniter The spark igniter shuts off during the heating cycle and the burner flame is sensed through a remote flame sensor The ignition control will try to ignite the burner three times before lockout The control waits 15 minutes before trying again to ignite the burner This is a continuous cycle NS u wy us 3 14 PEE m INDICA FE TOR NUMBER 5 6 0906 229 ON MODE CONTROL FAULT IGNITION SYSTEM 2FLASHES FLAME NO CALL FO RE PURGE 30 SEC IGNITION 4 SEC SFLASHES IGNITION LOCKOUT INTERPURGE 30 SEC I INPUT 24 VAC 50 60 Hz 300 mA PILOT VALVE 24 VAC 2 0 A max s MAIN VALVE 24 2 0 A max A AMBIENT 40 F to 160 F ANSI Z21 20 CAN CSA C22 2 No 199 M89 LUTION HI VOLTAGE DISCONNECT WIRING BEFORE SERVICING This
27. nt accumulation on bottom of tank Ticking or metallic sounds Expansion and contraction normal Pounding or water hammer Air chambers in piping have become waterlogged Thermal expansion tank damaged improperly charged or improperly sized Drain valve not closed tightly If leakage source cannot be corrected or identified call qualified agency Rumbling Water leaks Gas odors Possible gas leaks 18 REMEDY USER QUALIFIED AGENCY Set thermostat dial to a higher temperature Call qualified agency Check continuity and resistance Ohms of upper and lower temperature probes Replace probes if out of specification Set thermostat dial to a higher temperature Call qualified agency Check continuity and resistance Ohms of upper and lower temperature probes Replace probes if out of specification Open main manual gas shutoff valve to fullest extent Space usage to give heater time to restore water temperature Call qualified agency Check gas input If incorrect check for inlet air blockage and or flue gas exhaust blockage Set thermostat to a lower setting Drain a quantity of water Delime heater through drain valve If rumbling persists call qualified agency Drain piping system and Follow the manufacturer s refill Heater must be off instructions for proper charging of while this is being done the thermal expansion tank Check thermal expansion tank ch
28. o o 6 6 S 15400 2ft 6 6 jo 6 o 6 6 j 6 154900 t 4 e de de e e leel 6e 6 Number of 154 Heaters Combined input in Manifold and Common Vent Diameter Inches Thousands of Btu hr 308 000 o 7 462 000 8 7T r Y 4 616 000 9 9 9 7 16 Model BCL395T1806NOX 1996NOX Input 180 000 and 199 000 Btu hr Total Vent Height Feet Vent connector size 6 inches 6 8 10 15 20 30 50 100 Eo Input Btu hr Rise Vent Connector Diameter Inches 6 6 6 6 po 199 000 smt 16 Je 6 6 J 6 6 6 6 Number of Heaters Manifold and Common Vent Diameter Inches Thousands of Btu hr 3600 J esa y 7 7 J 6 6 39800 J Jea eas v 7 7 J 6 6 59700 tt J 7 7 I te te et 7960002 2 10 0 9 9 8 Model A BCL39512506NOX Vent connector size 6inches 20 30 50 100 InputBtuhr amp VentConnectorDiameter Inches D 1 29000 X 32 1t 8 7 v 7 J 6 6 e o O 299000 aan aaa e f e f e f ei il 25000 7 7 7 7 6 6 6 J 6 po Number of 250 Heaters Combined Input in Manifold and Common Vent Diameter Inches Thousands of Btu hr 500 000 L 1 1 9 9 9 7 7 750 000 2 0 10 10 9 8
29. o 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 Servicing should only be performed by a Qualified Service Technician 7 FEATURES AND COMPONENTS Exhaust Vent Inlet Tube Outlet Tube Upper Thermostat Probe ECO The Eliminator Clean Out Cover Lower Thermostat Probe Drain Valve Control Box Assembly Gas Control Valve 8 Servicing should only be performed by a Qualified Service Technician BLOWER AND BURNER ASSEMBLY Blower Silicone Blower Flange Gasket Burner Gasket Flange Gas Control Plate Valve Brass Locknuts 3 Flame Burner Sensor Spark Igniter 0 Skirt Ring Flange Gasket BURNER REPLACEMENT 1 Turn off the gas supply and electricity to the water heater and remove the blower cover 2 Disconnect the spark ignition cable and ground wire plus the flame sensor wire at their connection points on the flange plate 3 Disconnect the hose tubes power supply and PWM Pulse Width Modulation control to the blower 4 Disconnect the gas line near the gas valve 5 Remove the 4 brass locknuts and 4 flat washers holding the flange plate to the skirt ring flange 6 Pull the blower and burner assembly out of the combustion chamber Take care not to damage the spark igniter or flame sensor during the removal process 7 Clean the flange plate an
30. ped before being crimped in a wire connector ensure wires are crimped tightly in their connectors ensure connection pins in sockets and plugs are not damaged or worn ensure plugs and sockets are mating properly and providing good contact Failure to perform this critical step or failing to perform this step thoroughly often results in needless down time unnecessary parts replacement and customer dissatisfaction 2 Servicing should only be performed by a Qualified Service Technician TOOLS REQUIRED Electrical multimeter capable of measuring continuity ohms ac amp dc volts amperes microamperes millivolts and frequency hz e Model DL289 or equivalent Digital manometer 60 w c resolution 0 01 increments Note A digital manometer is required for testing pressure switches and can replace a gas pressure gauge draft gauge or slack tube manometer for checking gas pressure e model EM200 or equivalent e Water pressure gauge w lazy hand and hose bibb connection Thermometer e 1 1 16 Inch socket with extension for anode replacement Phillips head screwdriver Set of numbered drill bits e Standard screwdrivers e 3 8 7 16 1 2 and 9 16 inch open end wrenches WATER PRESSURE TEST GAUGE W LAZY HAND AND HOSE BIBB DIGITAL MANOMETER DIGITAL MULTIMETER CONNECTION Servicing should only be performed by a Qualified Service Technician INSTALLATION CONSIDERATIONS GAS AND ELECTRICAL CHARACTERISTICS MODELS GAS TYPE
31. ther call for heat is initiated by the thermostat Servicing should only be performed by a Qualified Service Technician 15 SEQUENCE OF OPERATION FLOW CHART Switch power on to unit Thermostat calls for heat UGB sends PWM signal to Blower to start the blower at high purge speed Blower engages Prover Switch 20 seconds later blower runs at low ignition speed Y After 30 seconds Ignition Control provides power to Spark Igniter and opens Gas Valve Ignition Control maintains spark for up to 4 seconds and monitors Flame Sensor to determine if Burner is lit Wait 15 minutes Blower runs at low speed Does Burner light Is this the third Gas Valve oft ignition trial Ignition Control changes Blower from low speed to high speed after 5 seconds Ignition Control monitors flame signal YES Is this the third loss Gas Valve off gt of flame signal Loss of flame signal Thermostat is satisfied Blower off Blower Prover opens Ignition Control off Gas Valve closes 16 Servicing should only be performed by a Qualified Service Technician LIGHTING AND OPERATING LABEL FOR YOUR SAFETY READ BEFORE OPERATING LN WARNING if you do not follow these instructions exactly a fire or Ae losion may result causing property damage personal
32. ve is engaged in and is responsible for 1 the installation testing or replacement of gas piping or 2 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 Service of this water heater requires ability equivalent to that of a Qualified Service Technician in the field involved Installation skills such as plumbing air supply venting gas supply electrical supply are required in addition to electrical testing skills Some products may require combustion testing equipment and certification If you do not possess these skills or do not have the proper tools you should not attempt to service this water heater SERVICE WARNING 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 If you do not understand the instructions given in this manual do not attempt to perform any procedures outlined in this manual SERVICE REMINDER When performing any troubleshooting step outlined in this manual always consider the wiring and connectors between components Perform a close visual inspection of all wiring and connectors to and from a given component before replacement Ensure wires were strip
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