American Water Heater 381T1206NOX, 381T1546NOX, 395T1806NOX, 395T1996NOX, 395T2506NOX User Manual

PO Box 1597, 500 Princeton Road

Johnson City, TN 37605

Service Handbook

COMMERCIAL GAS WATER HEATERS

FOR MODELS: BCL

381T1206NOX, 381T1546NOX, 395T1806NOX,

395T1996NOX, 395T2506NOX

ULTRA LOW NOx SERIES 104

INSTALLATION CONSIDERATIONS - PRE SERVICE CHECKS -

CONSTRUCTION - OPERATION & 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 ......................................................................2

QUALIFICATIONS .....................................................................2

TOOLS REQUIRED ....................................................................3

INSTALLATION CONSIDERATIONS .......................................................4

GAS AND ELECTRICAL CHARACTERISTICS ...............................................4

GAS PRESSURE – REQUIREMENTS .....................................................4

FEATURES AND COMPONENTS .........................................................8

BLOWER AND BURNER ASSEMBLY ......................................................9

SPARK IGNITER, FLAME SENSOR, SIGHT GLASS .........................................11

VENTING ...........................................................................12

VENTING TABLES

OPERATION AND SERVICE ............................................................15

SEQUENCE OF OPERATION – FLOW CHART .............................................16

LIGHTING AND OPERATING LABEL .....................................................17

TROUBLESHOOTING .................................................................18

CONTROLS OVERVIEW - CONTROL BOX ASSEMBLY ......................................19

PRESSURE SWITCHES – ALL MODELS ..................................................19

HIGH LIMIT SWITCH/ DIGITAL THERMOSTAT .............................................20

CONTINUITY CHECK OF HIGH LIMIT (ECO)...............................................22

UPPER TEMPERATURE PROBE CONTINUITY CHECK ......................................23

LOWER TEMPERATURE PROBE CONTINUITY CHECK .....................................24

IGNITION CONTROL..................................................................25

START UP/ FLAME RECOVERY/ SAFETY LOCKOUT........................................26

UGB – BLOWER SPEED CONTROL .....................................................28

WIRING DIAGRAM ...................................................................29

– TECHNICAL VENTING DATA ..........................................14

Servicing should only be performed by a Qualied Service Technician

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 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 1-800-4569805, by email at help@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 representative 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 stripped 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.

Servicing should only be performed by a Qualied Service Technician

TOOLS REQUIRED

• Electrical multimeter capable of measuring continuity/ ohms, ac & dc volts, amperes, microamperes, millivolts, and frequency (hz)

• UEi 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.

• UEi model EM200 or equivalent

• Water pressure gauge w/lazy hand and hose bibb connection

• Thermometer

• 1-1/16 Inch socket with extension for anode replacement

• Phillips head screwdriver

• Set of numbered drill bits

• Standard screwdrivers

• 3/8, 7/16, 1/2 and 9/16 inch open end wrenches

DIGITAL MANOMETER DIGITAL MULTIMETER

Servicing should only be performed by a Qualied Service Technician

WATER PRESSURE

TEST GAUGE W/LAZY

HAND AND HOSE BIBB

CONNECTION

INSTALLATION CONSIDERATIONS

GAS AND ELECTRICAL CHARACTERISTICS

MODELS GAS TYPE

All Models Natural 3.5" WC (0.87 kPa) 14.0" WC (3.48 kPa) 120/60 < 5

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 SUPPLY PRESSURE

VOLTS/HZ AMPERES

MINIMUM MAXIMUM

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 and 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/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.

Servicing should only be performed by a Qualied 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.

INSUFFICIENT MAKE-UP AIR, NEGATIVE AIR PRESSURE AND DOWNDRAFTS:

Downdraft Caused by Kitchen Vent Hood

A lack 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 equipment 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 Qualied Service Technician

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.

Additionally, when the water heater is installed in a 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 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

per kW) of the total input of all equipment located in the enclosure and b) not less than the sum of the

(7cm 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).

Servicing should only be performed by a Qualied Service Technician

AIR REQUIREMENTS:

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 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 (leakage). 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.

POWER SUPPLY:

The water heaters covered in this manual require a 120 VAC, 1Ø (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.

Servicing should only be performed by a Qualied Service Technician

FEATURES AND COMPONENTS

Exhaust/Vent

Outlet Tube

Upper Thermostat Probe/ECO

Inlet Tube

T & P Relief Valve

The Eliminator

Lower Thermostat Probe

Drain Valve

Control Box Assembly

Gas Control

Valve

Clean Out Cover

Servicing should only be performed by a Qualied Service Technician

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