American ABCG3, Installation, Operation And Maintenance Instructions

Page 1: ...R FUTURE REFERENCE P O Box 1597 500 Princeton Road Johnson City TN 37605 CAUTION TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY PLEASE READ THOROUGHLY BEFORE INSTALLING AND USING THIS APPLIANCE Thank you for buying this energy efficient water heater from American Water Heater Company We appreciate your confidence in our product PRINTED 0609 197935 001 ANSI NSF 5 ...

Page 2: ...7 75 70 cm NA NA 1 50 1 50 1 50 1 50 NA NA 1 50 1 50 1 50 1 50 750 Lbs 341 Kg 862 Lbs 391 Kg A BCG3 85T360 s 365 000 BTU Hr 107 kW Hr 85 Gal 322 L 79 50 202 cm 4 50 12 cm 70 25 178 cm 62 50 159 cm 22 50 57 cm 23 58 cm 3 4 3 4 63 00 160 cm 8 20 cm 27 75 70 cm 1 50 1 50 1 50 1 50 1 50 1 50 1 50 1 50 1 50 1 50 1 50 1 50 725 Lbs 329 Kg 833 Lbs 379 Kg A BCG3 100T390 s 390 000 BTU Hr 114 kW Hr 100 Gal 3...

Page 3: ...32 Electrical Servicing 32 Replacement Parts 32 Effikal Flue Damper Troubleshooting Guide 33 Operational Checklist 34 Limited Warranty 35 Page FOREWORD These designs comply with ANSI Z21 10 3 CSA 4 3 as an automatic circulating or automatic storage tank type water heater Heaters having an input of 305 000 89 Kwh 365 000 107 Kwh and 390 000 117 Kwh Btuh with a recovery rating of 277 3 gph 1049 Lph ...

Page 4: ...y explosive and heavier than air It collects first in the low areas making its odor difficult to detect at nose level If LP gas is present or even suspected do not attempt to find the cause yourself Go to a neighbor s house leaving your doors open to ventilate the house then call your gas supplier or service agent Keep area clear until a service call has been made At times you may not be able to s...

Page 5: ... elevation Correct orifice sizing and parts may be obtained from American Water Heater Company When ordering be sure to state the model number and the altitude of the location where the water heater is being installed Upon completion of derating of the heater adjustment to the gas pressure regulator may be required See CHECKING THE INPUT section in this manual for inlet and manifold pressure requi...

Page 6: ... a problem with the damper the Service Switch can be placed in the HOLD OPEN DAMPER position When the switch is placed in the HOLD OPEN DAMPER position the damper disc will rotate to the open position and the heater may be used until vent assembly is repaired or replaced DO NOT turn the damper disc manually damage will occur to the drive assembly if operated manually Refer to TESTING DAMPER OPERAT...

Page 7: ...gure 6 and Table 2 The following units are approved for installation with side rear and ceiling clearances as indicated below 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...

Page 8: ...ails of tank cleanout procedure AIR REQUIREMENTS REFER TO THE CURRENT EDITION OF THE NATIONAL FUEL GAS CODE ANSI Z223 1 NFPA 54 WARNING KEEPAPPLIANCEAREACLEARAND FREE OF COMBUSTIBLE MATERIALS GASOLINEAND OTHER FLAMMABLES VAPORS AND LIQUIDS DO NOT OBSTRUCT THE FLOW OF COMBUSTION OR VENTILATING AIR WARNING FOR SAFE OPERATION PROVIDE ADEQUATE AIR FOR COMBUSTION AND VENTILATION AN INSUFFICIENT SUPPLY ...

Page 9: ...ING 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 See table 3 TECHNICAL DATA VENTING This water heater must be vented in compliance with all local codes the current edition of the National Fuel Gas Code ANSI Z223 1 and with the ...

Page 10: ... 7 154 000 2 Ft 7 7 7 7 7 6 6 6 154 000 3 Ft 7 7 7 6 6 6 6 6 Numbers Combined Input of Heaters in Thousands of Btuh Manifold and Common Vent Diameter in inches 2 308 10 10 10 8 8 7 7 7 3 462 12 12 12 10 10 10 8 8 4 618 14 14 12 12 12 10 10 10 MODEL BCG380T1806_ BCG3100T1996_ BCG380T1996_ A BCG3100T2006_ Input 180 000 199 000 Btuh Total Vent Height Feet Draft Hood 6 6 8 10 15 20 30 50 100 Input Btu...

Page 11: ...BCG365T3008_ Input 305 000 Btuh Total Vent Height Feet Draft Hood 8 6 8 10 15 20 30 50 100 Input Btuh Rise Vent Connector Diameter in inches 315 000 1 Ft 10 10 10 10 10 10 305 000 2 Ft 10 10 10 10 10 10 8 8 365 000 3 Ft 10 10 10 10 10 8 8 8 Number of Combined Input Heaters in Thousands of Btuh Manifold Common Vent Diameter 2 610 14 14 12 12 12 10 10 10 3 915 16 16 16 14 14 12 12 12 4 1220 18 18 16...

Page 12: ... THE WATER HEATER THE RELIEF VALVE S MUST NOT BE REMOVED OR PLUGGED ASME ratings cover pressure relief capacities ANSI ratings cover release rate with temperature actuation In addition to the appliance relief valve each remote storage tank which may be used in conjunction with this appliance shall also be installed with a properly sized rated and approved combination temperature ANSI and pressure ...

Page 13: ...IMPROPER OPERATION FIRE OR EXPLOSION IF COPPER SUPPLY LINES ARE USED THEY MUST BE INTERNALLY TINNED AND CERTIFIED FOR GAS SERVICE BEFOREATTACHING THE GAS LINE BE SURE THATALL GAS PIPE IS CLEAN ON THE INSIDE TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS SUPPLY LINE A DIRT LEG SOMETIMES CALLED SEDIMENT TRAP OR DRIP LEG MUST BE INCORPORATED IN THE PIPING SEE FIG 11 THE DIRT LEG MUST BE FIGURE 12 RE...

Page 14: ...OSE DISCONNECT THE HEATER AND ITS MANUAL GAS SHUT OFF VALVE FROM THE GAS SUPPLY PIPING SYSTEM DURING ANY SUPPLY PRESSURE TESTING EXCEEDING 1 2 PSIG 3 5 kPa GAS SUPPLY LINE MUST BE CAPPED WHEN DISCONNECTED FROM THE HEATER FOR TEST PRESSURES OF 1 2 PSIG 3 5 kPa OR LESS THE APPLIANCE NEED NOT BE DISCONNECTED BUT MUST BE ISOLATED FROM THE SUPPLY PRESSURE TEST BY CLOSING THE MANUAL GAS Shut off VALVE G...

Page 15: ...HOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES SEE WATER TEMPERATURE CONTROLWARNING ON PAGE 25 IF HIGHER PREHEATTEMPERATURESARE NECESSARYTO OBTAINADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES HORIZONTAL STORAGE TANK AND FORCED CIRCULATION ...

Page 16: ...E CLOSED ON DURING THERINSEOPERATIONANDOPEN OFF WHENDISHWASHER IS NOT OPERATING OR WHEN ON LONG STANDBY NOTE 2 INSTALL LINE TEMPERATURE CONTROL IN AN UNINSULATED TEE BEYOND THE DISHWASHING MACHINE TAKEOFF IN THE SANITIZING LOOP CONTROL SHOULD BE SET AT 185 F 85 C NOTE 3 ADJUST PLUG COCK SO THE SANITIZING LOOP FLOW RATE DOES NOT CAUSE UNNECESSARY TURBULENCE IN THE TANK TEMPERED WATER LOOP IF USED C...

Page 17: ... in the installation diagrams on the following pages are typical TWO TEMPERATURE TWO HEATERS ONE PRE HEATER ONE BOOSTER HEATER WITH OR WITHOUT BUILDING RECIRCULATION The discharge opening of the temperature and pressure relief valve must be piped to an open drain and should not be subject to freezing conditions DO NOT REDUCE BLOCK OR PLUG THE DISCHARGE OPENING OF THE VALVE CIRCULATING RETURN LINE ...

Page 18: ...TE 3 ADJUST PLUG COCK SO THE SANITIZING LOOP FLOW RATE DOES NOT CAUSE UNNECESSARY TURBULENCE IN THE TANK PIPE RELIEF VALVE TO OPEN DRAIN INSTALL IN ACCORDANCE WITH LOCAL CODES CIRCULATING RETURN LINE CONNECTIONS TEMPERED WATER LOOP IF USED CONNECT TO POINT R STOREDTEMPERATUREWATERLOOP IFUSED CONNECT TO COLD WATER INLET CAUTION IF BUILDING COLD WATER SUPPLY HAS A BACKFLOW PREVENTER CHECK VALVE OR W...

Page 19: ... WITH MIXING VALVE TWO PRE HEATERS WITH BOOSTER HEATER DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 25 IF HIGHER PREHEAT TEMPERATURESARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES INSET A ...

Page 20: ...R OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES PIPE RELIEF VALVE TO OPEN DRAIN WHEN USING AN AMERICAN T 140 200 350 OR 400 STORAGE TANK USE LOWER 3 4 OPENING FOR TANK TEMPERATURE CONTROL IF BUILDING CIRCULATING LOOP IS USED CONNECT TO AN OPENING NEAR THE BOTTOM OF THE TANK CAUTION IF BUILDING COLD WATER SUPPLY HAS A BACKFLOW PREVENTER CHECK VALVE OR WATER METER WITH CHECK VALV...

Page 21: ...URAL PROPANE 1050 2500 21 1 SEC 50 3 SEC 199 000 NATURAL PROPANE 1050 2500 19 0 SEC 47 4 SEC 250 000 NATURAL PROPANE 1050 2500 15 1 SEC 35 3 SEC 251 000 NATURAL PROPANE 1050 2500 15 06 SEC 35 1 SEC 275 000 NATURAL PROPANE 1050 2500 13 75 SEC 32 2 SEC 305 000 NATURAL PROPANE 1050 2500 12 4 SEC 29 5 SEC 365 000 NATURAL PROPANE 1050 2500 10 4 SEC 24 7 SEC 390 000 NATURAL PROPANE 1050 2500 9 5 SEC 22 ...

Page 22: ...OAVOIDRISKOF FIRE OR EXPLOSION PURGE DISCHARGE MUST NOT ENTER CONFINEDAREAS OR SPACES WHERE IGNITION CAN OCCUR THEAREAMUSTBE WELLVENTILATEDANDALLSOURCES OF IGNITION MUST BE INACTIVATED OR REMOVED WARNING 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 cha...

Page 23: ...23 FOR NATURAL GAS MODELS FOR YOUR SAFETY READ BEFORE OPERATING OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING ...

Page 24: ...24 FOR PROPANE GAS MODELS FOR YOUR SAFETY READ BEFORE OPERATING OPERATING INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE ...

Page 25: ...mbing authority The water temperature is controlled by a thermostat Fig 3 which has two sensing elements One sensor is located near the top of the tank and the other is near the center The thermostat is set in the lowest position before the heater leaves the factory The thermostat temperature dial Fig 3 is accessible by removing the control cover The dial is adjustable and may be set for 120 F 49 ...

Page 26: ... MAINTENANCE CHECK THE PILOT At least once a year check the pilot burner fig 15 and the main burner fig 16 for proper operation Refer to the following pilot and main burner sections PILOT BURNER For access to pilot unfasten two screws to burner cover and remove Locate the burner with pilot and remove screw holding burner to manifold Unfasten pilot tubing from valve and slide out burner and pilot S...

Page 27: ... a pressure gauge or a manometer to the gauge port and refer to Table 5 for correct manifold pressure 2 Use this formula to clock the meter Be sure that other gas consuming appliances are not operating during this interval 3600 X H Btuh T 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 BTRC 199 heater T 15 8 seconds H 1050 Btu Bt...

Page 28: ...he heater and replacement of the factory installed magnesium anodes with aluminum anodes may correct the condition Occasionally water softener companies recommend removal of heater anodes for odor reasons CAUTION Unauthorized removal of the anode s will void the warranty For further information contact your dealer ANODE ROD INSPECTION The heater tank is equipped with anode rods to provide corrosio...

Page 29: ... that main manual gas shut off 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 Is the water temperature in tank below the thermostat dial setting on the applian...

Page 30: ...s 4 Blown fuse or circuit breaker 5 Disconnect switch off 6 Harness not plugged into appliance receptacle A FLUE DAMPER OPEN OR OPENING Unit is calling for heat and damper disc should be in vertical position VOLTAGE ACROSS 4 1 All Times that High Limit is closed 4 2 Calling for Heat Open or Opening 4 3 During Combustion Damper Open B FLUE DAMPER CLOSED Unit is not calling for heat and damper disc ...

Page 31: ...slower Call service agent Check gas input If incorrect adjust gas pressure or replace main burner orifice Draft hood not installed or Call service agent Install draft hood or baffles as one or more flue baffles furnished with unit Water temperature too hot Thermostat set too high Set thermostat to a lower setting Heater makes sounds sizzling Condensation on outside of tank normal Rumbling Sediment...

Page 32: ...tive method of controlling thermal expansion is also installed at the heater s and operational at all times The relief valve installed on the heater is not an acceptable method 4 SERVICE AND REPAIR EXPENSES Under the limited warranty the warrantor will provide only a replacement water heater or part thereof The owner is responsible for all other costs Such costs may include but are not limited to ...

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Page 36: ...36 P O Box 1597 500 Princeton Road Johnson City TN 37605 ...