American Water Heater ABCG3 User Manual
MODELS BCG3 & ABCG3 LOW NOx
COMMERCIAL GAS, GLASS-LINED, TANK-TYPE WATER HEATER
• INSTALLATION • OPERATION • MAINTENANCE • LIMITED WARRANTY
ANSI/NSF-5
Thank you for buying this energy efficient water heater from
American Water Heater Company. We appreciate your confidence
in our products.
CAUTION
TEXT PRINTED OR OUTLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ
THOROUGHLY BEFORE INSTALLING AND USING THIS
APPLIANCE.
American Water Heater
Product Service and Support
PO Box 1597, 500 Princeton Road
Johnson City, TN 37605
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER
AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PRINTED 0609 197934-001
1
ROUGH-IN-DIMENSIONS
TOP VIEW
FRONT VIEW
BACK VIEW
2
TABLE 1. ROUGH-IN-DIMENSIONS
Model BCG3 BCG3 BCG3 BCG3 (A)BCG3 (A)BCG3 (A)BCG3 (A)BCG3 (A)BCG3 (A)BCG3
Dim 70T120 80T150 100T180 100T199 100T200 100T250 100T275 85T310 85T366 85T390
5NOX 6NOX 6NOX 6NOX 6NOX 6NOX 6NOX 6NOX 6NOX 6NOX
Inches mm Inches mm Inches mm Inches mm Inches mm Inches mm Inches mm Inches mm Inches mm Inches mm
A 63 1800 68 1727 72 1829 72 1829 72 1829 72 1829 72 1829 73 1854 73 1854 73 1854
B 4 1/4 108 4 1/2 114 4 1/2 114 4 1/2 114 4 1/2 114 4 1/2 114 4 1/2 114 4 1/2 114 4 1/2 114 4 1/2 114
C 59 1/2 1511 62 1575 70 1778 70 1778 70 1778 70 1778 70 1778 72 1829 72 1829 72 1829
D 50 7/8 1292 53 5/8 1362 61 5/8 1565 61 5/8 1565 61 5/8 1565 61 5/8 1565 61 5/8 1565 62 1/ 2 1588 6 2 1/2 1588 62 1/2 1588
E 19 11/16 500 20 1/2 521 20 1/2 521 20 1/2 521 20 1/2 521 20 1/2 521 20 1/2 521 20 1/2 521 22 1/2 572 22 1/2 572
F 19 483 21 533 21 533 21 533 21 533 21 533 21 533 21 533 21 533 21 533
G 1/2NPT 1/2NPT 1/2NPT 1/2NPT 1/2NPT 1/2NPT 1/2NPT 1/2NPT 1/2NPT 1/2NPT
H 51 7/8 1318 54 5/8 1387 61 1549 61 1549 61 1549 61 1549 61 1549 63 1600 63 1600 63 1600
I 5 127 6 152 6 152 6 152 6 152 6 152 6 152 6 152 6 152 6 152
J 27 3/4 705 27 3/4 705 27 3/4 705 27 3/4 705 27 3/4 705 27 3/4 705 27 3/4 705 27 3/4 705 27 3/4 705 27 3/4 705
K 1 1/2NPT 1 1/2NPT 2NPT 2NPT 2NPT 2NPT 2NPT 1 1/2NPT 1 1/2NPT 1 1/2NPT
L 1 1/2NPT 1 1/2NPT 2NPT 2NPT 2NPT 2 NPT 2NPT 2 NPT 1 1/2NPT 1 1/2NPT
Appox.
Shipping 400 181 470 213 603 274 603 274 603 274 603 274 603 274 725 329 725 329 725 329
Weight lbs. K.g lbs. K.g lbs. K.g lbs. K.g lbs. K.g lbs. K.g lbs. K.g lbs. K.g lbs. K.g lbs. K.g
STD.
Approx.
Shipping - - - - - - - - 686 311 686 311 686 211 833 378 833 378 833 378
Weight lbs. Kg. lbs. Kg. lbs. Kg. lbs. Kg. lbs. Kg. lbs. Kg.
ASME
TABLE 2. RECOVERY CAPACITIES, based on 80% efficiency
TANK APPROX U.S Gallons/Hr. and Litres/Hr at TEMPERATURE RISE INDICATED
Model Btuh K W U.S.Gal. Litres % C ° 22C° 28C° 33C° 39C° 44C° 50C° 56C° 61C° 67C° 72C° 78 C°
BCG3 70 120,000 71 80 GPH 288 239 192 164 144 128 115 105 96 89 82
T1205NOX 35 269 LPH 1089 871 726 622 545 484 436 396 363 335 311
BCG3 80 154,000 81 80 GPH 369 295 246 211 185 184 148 134 123 114 106
T1506NOX 45 307 LPH 1398 1118 932 79 699 621 559 508 466 430 399
BCG3 100 180,000 100 80 GPH 432 345 288 247 218 192 173 157 144 133 123
T1806NOX 53 307 LPH 1634 1307 1089 934 817 726 654 594 545 503 487
BCG3 100 199,000 100 80 GPH 477 382 318 273 239 212 191 174 159 147 136
T1996NOX 58 307 LPH 1806 1445 1204 1032 903 803 723 657 602 556 516
ABCG3 100199,000 100 80 GPH 477 382 318 273 239 212 191 174 159 147 136
T2006NOX 58 379 LPH 1806 14 45 1204 1032 903 803 723 657 602 556 516
ABCG3 100 250,000 100 80 GPH 600 480 400 343 300 266 240 218 200 184 171
T2506NOX 73 379 LPH 2269 18 15 1513 1297 1135 1009 908 825 756 698 648
ABCG3 100 275,000 100 80 GPH 659 528 440 377 330 293 264 240 220 203 188
T2756NOX 81 379 LPH 2496 19 97 1664 1426 1248 1109 999 908 832 768 713
ABCG3 85 310,000 85 80 GPH 743 595 496 425 372 330 297 270 248 229 212
T3106NOX 91 322 LPH 2814 2251 1876 1808 1407 1251 1126 1023 938 866 804
ABCG3 85 366,000 85 80 GPH 878 702 585 502 439 390 351 319 293 270 251
T3666NOX 107 322 LPH 3322 2658 2215 1898 1661 1477 1329 1208 1107 1022 949
ABCG3 85 390,000 85 80 GPH 935 748 624 534 468 416 374 340 312 288 267
T3906NOX 114 322 LPH 3540 2832 2360 2023 1770 1573 1416 1287 1180 1089 1011
CAPACITY EFF. F ° 40F° 50F° 60F° 70F° 80F° 90F° 100F° 110F° 120F° 130F° 140F°
TABLE 3. GAS AND ELECTRICAL CHARACTERISTICS
Model Type of Gas Inches vs. W.C. kPa Volts/Hz Amperes
All Models Natural 3.5 0.87 120/60 < 5
Manifold Pressure
3
TABLE OF CONTENTS
ROUGH-IN-DIMENSIONS -------------------------------- 2-3
FOREWORD ------------------------------------------------- 3
GENERAL SAFETY INFORMATION -------------------- 5
Precautions --------------------------------------------------- 5
Grounding Instructions ------------------------------------ 5
Chemical Vapor Corrosion ------------------------------- 5
Improper Combustion ------------------------------------- 5
Extended non-use Periods ------------------------------- 5
Insulation Blankets ----------------------------------------- 5
High Altitude Installation ---------------------------------- 6
FEATURES---------------------------------------------------- 6
High Limit Switch ------------------------------------------- 6
Electronic Ignition Control -------------------------------- 6
Exhaust Inducer (Blower Assy.) ------------------------- 7
Circulating Pump ------------------------------------------- 7
Dishwashing Machine Requirement ------------------ 7
INSTALLATION INSTRUCTIONS ------------------------ 7
Required Ability ---------------------------------------------- 7
Uncrating ------------------------------------------------------ 7
Locating The Heater --------------------------------------- 7-8
Levelling ------------------------------------------------------- 8
Clearances --------------------------------------------------- 8
Hard Water ---------------------------------------------------- 8
Air Requirements ------------------------------------------- 8-9
Venting --------------------------------------------------------- 9
Multiple Heater Manifold ---------------------------------- 9
Technical Data Venting ------------------------------------ 10-11
Water Line Connections ---------------------------------- 12
Water (Potable) Heating and Space Heating -------- 12
Thermometers (Not Supplied) -------------------------- 1 2
Relief Valve --------------------------------------------------- 1 2
INSTALLATION DIAGRAMS-TOP
INLET/OUTLET USAGE ----------------------------------- 1 3
General -------------------------------------------------------- 13
Code Restrictions ------------------------------------------ 13
INSTALLATION DIAGRAMS ------------------------------- 14-20
Heater Wiring ------------------------------------------------ 21
Page Page
Gas Piping ---------------------------------------------------- 2 2
Purging -------------------------------------------------------- 22
Gas Pressure Regulator ---------------------------------- 22-23
OPERATION -------------------------------------------------- 23
General -------------------------------------------------------- 23
Filling ----------------------------------------------------------- 23
SEQUENCE OF OPERATION ---------------------------- 24
Lighting and Operation ------------------------------------ 25
Water Temperature Control ------------------------------ 26
Checking Venting ------------------------------------------- 26
PREVENTIVE MAINTENANCE --------------------------- 26
Check The Ignitor Assembly ----------------------------- 26
Ignitor Assembly --------------------------------------------- 26-27
Main Burner --------------------------------------------------- 27
Gas Valves ---------------------------------------------------- 27
Checking The Input ----------------------------------------- 27-28
Venting System ---------------------------------------------- 28
Remote Storage Tank Temperature Control --------- 28
Relief Valve --------------------------------------------------- 28
Hot Water Odor ---------------------------------------------- 2 8
Anode Rod Inspection ------------------------------------- 28
Flushing ------------------------------------------------------- 2 8
Draining ------------------------------------------------------- 28
Recommended Procedure For Periodic
Removal of Lime Deposits From Tank Type
Commercial Water Heaters ------------------------------ 29
Tank Cleanout Procedures ------------------------------- 29
Ignition Module System ----------------------------------- 29-30
System Diagnostics ---------------------------------------- 30
SERVICE ------------------------------------------------------ 30
Electrical Servicing ----------------------------------------- 30
Sequence of Operation Flow Chart -------------------- 3 1
Operational Checklist -------------------------------------- 32
Limited Warranty -------------------------------------------- 33
NOTES --------------------------------------------------------- 34-35
FOREWORD
These designs comply with ANSI Z21.10.3 as an automatic
circulating or automatic storage tank type water heater.
Heaters having an input of 310,000, 366,000, 390,000 Btuh with
a recovery rating of 277.3 gph or more also comply with ANSI
Z21.10.3 as an automatic instantaneous type heater.
Detailed installation diagrams are found in this manual. These
diagrams will serve to provide the installer with a reference for
the materials and methods of piping necessary. It is highly
essential that all water, gas piping and wiring be installed as
shown on the diagrams.
Particular attention should be given to the installation of
thermometers at the locations indicated on the diagrams as
these are necessary for checking the proper functioning of the
heater.
The heater is designed to operate on natural gas only. If you
have obtained this heater for use on propane-STOP. Do not
install this water heater. Immediately call your supplier to correct
the situation.
These heaters may be installed on combustible floors.
In addition to these instructions, the equipment shall be installed
in accordance with those installation regulations in force in the
local area where the installation is to be made. These shall be
carefully followed in all cases. Authorities having jurisdiction
should be consulted before installations are made.
The installation must conform to these instructions and the local
code authority having jurisdiction. In the absence of local codes,
the installation must comply with the current editions of the
National Fuel Gas Code, ANSI Z223.1/NFPA 54 and the National
Electrical Code, NFPA 70, documents are available from the
National Fire Protection Association, 1 Batterymarch Park, Quincy,
MA 02269.
4
GENERAL SAFETY
INFORMATION
OPERATION OF THESE FANS CAN PRODUCE A NEGATIVE
DRAFT IN THE AREA OF THE WATER HEATER PREVENTING
THE PRODUCTS OF COMBUSTION FROM EXHAUSTING
THROUGH THE CHIMNEY OR VENT PIPE.
PRECAUTIONS
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN
UNDER WATER. Immediately call a qualified service technician
to inspect the appliance and to replace any part of the control
system and any gas control which has been under water.
IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO NOT
OPERATE HEATER UNTIL ALL CORRECTIVE STEPS HAVE
BEEN MADE BY A QUALIFIED SERVICEMAN.
1. EXTERNAL FIRE.
2. DAMAGE.
3. FIRING WITHOUT WATER.
4. SOOTING
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.
The venting of the water heater should be inspected by a qualified
service technician at the time of installation and periodically
thereafter to ensure a down-draft condition does not exist.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND
VENTILATING AIR. ADEQUATE AIR FOR COMBUSTION AND
VENTILATION MUST BE PROVIDED FOR SAFE OPERATION.
EXTENDED NON-USE PERIODS
WARNING
HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER
SYSTEM SERVED BY THIS HEATER 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,
it is recommended that the hot water faucet be opened for several
minutes at the kitchen sink 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.
INSULATION BLANKETS
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 9.
CHEMICAL VAPOR CORROSION
WARNING
CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY
OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN
CHEMICAL VAPORS. SUCH CORROSION MAY RESULT IN
FAILURE AND RISK OF ASPHYXIATION.
Spray can propellants, cleaning solvents, refrigerator and air
conditioning refrigerants, swimming pool chemicals, calcium and
sodium chloride (water softener salt), waxes, and process
chemicals and typical compounds which are potentially corrosive.
Do not store products of this sort near the heater. Also, air which
is brought in contact with a the heater should not contain any of
these chemicals. If necessary, uncontaminated air should be
obtained from remote or outside sources. The limited warranty is
voided when failure of water heater is due to a corrosive
atmosphere. (Refer to the limited warranty for complete terms
and conditions.
IMPROPER COMBUSTION
Insulation blankets available to the general public for external
use on gas water heaters are not approved for use on your
American water heater. The purpose of an insulation blanket is
to reduce the standby heat loss encountered with storage tank
water heaters. Your American water heater meets or exceeds
the ASHRAE/IES 90.1-2004 standards with respect to insulation
and standby loss requirement making an insulation blanket
unnecessary.
WARNING
Should you choose to apply an insulation blanket to this heater,
you should follow these instructions. Failure to follow these
instructions can result in fire, asphyxiation , serious personal injury
or death.
Do not apply insulation to the top of the water heater, as this
•
will interfere with safe operation of exhaust inducer.
• Do not cover gas valve on the temperature & pressure relief
valve.
• Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
Do not allow insulation to come within 2” (5cm) of the burner,
•
to prevent blockage of combustion air flow to the burners.
• Do not allow insulation to come within 9” (23cm) of the floor,
(within 2” (5cm) of bottom cover) to prevent blockage of
combustion air flow to the burners.
WARNING
ATTIC AND/OR EXHAUST FANS OPERATING ON THE
PREMISES WITH A WATER HEATER CAN RESULT IN CARBON
MONOXIDE POISONING AND DEATH.
• Do inspect the insulation blanket frequently to make sure it
does not sag, thereby obstructing combustion air flow.
• Do obtain new labels from American for placement on the
blanket directly over the existing labels.
5
HIGH ALTITUDE INSTALLATIONS
WARNING
INSTALLATIONS ABOVE 2000 FEET (610 METERS) REQUIRE
REPLACEMENT OF THE BURNER ORIFICE IN ACCORDANCE
WITH THE NATIONAL FUEL GAS CODE (ANSI Z223.1). FAILURE
TO REPLACE THE ORIFICE 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
overfiring of the heater causing sooting, poor combustion and/or
unsatisfactory heater performance.
REQUIREMENTS
Ratings specified by manufacturers for most appliances apply for
elevations up to 2000 feet. For elevations above 2000 feet, ratings
must be reduced at the rate of 4% for each 1000 feet above sea
level. For example, if a heater is rated at 120,000 Btuh at sea level,
to rate the heater at 4000 feet, you subtract 4 (once for each thousand
feet) x.04 (4% input reduction) x 120,000 Btuh (original rating) from
the original rating. Therefore, to calculate the input rating at 4,000
feet: 4 x .04 x 120,000 =19,200 Btuh, 120,000 - 19,200 = 100,800
Btuh. At 6000 feet the correct input rating should be 91,200 Btuh.
The input reduction is primarily achieved by reducing the size of the
main burner orifices. To do this, the main burner orifices require
replacement with orifices sized for the particular installation
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 requirements.
Note: The inlet tube may have 1, 3 or 7 cross tubes. - FIGURE 1
For proper function, the Eliminator must be oriented correctly.
There is a marked range on the pipe nipple that must be aligned
with the top of the inlet spud (check for label on the appliance)
to assure proper operation. Please check to confirm that the
marked range is in alignment with the top of the spud. A pipe
union is supplied with the Eliminator to help eliminate the
possibility of changing the orientation by accidentally
overtightening the inlet supply. Improper orientation of the
Eliminator may cause temperature buildup issues or spells of
colder than usual water temperatures.
HIGH LIMIT SWITCH
The digital thermostat (Fig. 2) contains the high limit (energy
cutoff) sensor. The high limit switch interrupts main burner gas
flow should the water 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:
• 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.
Also due to the input rating reduction required at high altitudes, the
output rating of the appliance is also reduced and should be
compensated for in the sizing of the equipment for application.
FEATURES
THE ELIMINATOR (SELF-CLEANING SYSTEM)
These units include The Eliminator (Self-Cleaning System) installed
in the front water inlet, see Figure 2. 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.
DIGITAL THERMOSTAT
FIGURE 2
ELECTRONIC IGNITION CONTROL
Each heater is equipped with a ignition module. The solid sate
ignition control (Fig. 3), ignites the main burner by utilizing a
silicone nitride ignitor. The silicone nitride ignitor shuts off during
the heating cycle and the main burner flame is sensed through
a remote flame sensor integral to the silicone nitride ignitor
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.
6
IGNITION CONTROL BOARD - FIGURE 3
EXHAUST 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
CIRCULATING PUMP
A circulating pump is used when a system requires a circulating
loop or there is a storage tank used in conjunction with the
heater. Refer to the piping diagrams in this manual for electrical
hookup information and install in accordance with the current
version of the National Electrical Code ANSI/NFPA No. 70.
Only all bronze circulating pumps are used with commercial
water heaters.
Although circulating pumps are oiled and operated by the
manufacturer some circulating pumps must be oiled again
before operating. Please refer to manufacturer’s instructions.
DISHWASHING MACHINE REQUIREMENT
These appliances meet the National Sanitation Foundation
Standard for sanitary installations when used with the following
leg kit, Part No. 6570-7.
INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES
ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN
THE FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, GAS
SUPPLY AND ELECTRICAL WORK ARE REQUIRED.
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT
IN SERIOUS PERSONAL INJURY OR DEATH.
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.
LOCATING THE HEATER
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.
WARNING
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
BE AVOIDED.
DO NOT INSTALL THIS WATER HEATER DIRECTLY ON A
CARPETED FLOOR. A FIRE HAZARD MAY RESULT.
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 SHOULD BE LOCATED OR PROTECTED SO IT IS
NOT SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE.
CANNOT
Instead the
All dishwashing machines meeting the National Sanitation
Foundation requirements are designed to operate with water flow
pressures between 15 and 25 psi. Flow pressures above 25 psi, or
below 15 psi, will result in improperly sanitized dishes. Where
pressures are high, a water pressure reducing or flow regulating
control valve should be used in 180
and should be adjusted to deliver water between these limits.
The National Sanitation Foundation also recommends
circulation of 180
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
dishwashing machine. Adjust flow by means of the plug cock in
the circulating line.
0
F water. Where this is done, the circulation
0
F line to the dishwashing machine,
0
F water at the point of take-off to the
INSTALLATION INSTRUCTIONS
REQUIRED ABILITY
WARNING
FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY
OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST
NEVER BE PLACED ON OR 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, A SUITABLE
METAL DRAIN PAN SHOULD BE INSTALLED UNDER THE
HEATER.
7
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.
LEVELING
If the unit is not level, insert the bolts which were used in crating
into the legs to correct this condition.
CLEARANCES
These heaters are approved for installation on combustible
flooring (with Leg Kit 9003425205) in an alcove when the
minimum clearance from any combustion construction are
followed as indicated in figure 5 and Table 4.
In all installations the minimum combustible clearances from
vent piping shall be 6" (152mm). Vent piping passing through a
combustible wall or ceiling must be a continuous run (no joints)
and retain the 6" (152mm) clearance unless an approved
reducing thimble is used.
A service clearance of 24" (610mm) 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 and ceiling
clearances as indicated below:
CLEARANCES TO NONCOMBUSTION CONSTRUCTION
MODEL ”A” ”B” ”C” ”D”
RIGHT LEFT BACK CEILING
SIDE SIDE
BCG370T1205NOX 0 0 0 12” (305mm)
BCG380T1506NOX 0 0 0 12” (305mm)
BCG3100T1806NOX 0 0 0 12” (305mm)
BCG3100T1996NOX 0 0 0 12” (305mm)
(A)BCG3100T2006NOX 0 0 0 12” (305mm)
(A)BCG3100T2506NOX 0 0 0 12” (305mm)
(A)BCG3100T2756NOX 0 0 0 12” (305mm)
(A)BCG385T3106NOX 6” 6” 6” 12” (305mm)
(152mm) (152mm) (152mm)
(A)BCG385T3666NOX 0 0 0 12” (305mm)
(A)BCG385T3906NOX 0 0 0 12” (305mm)
TABLE 5
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 MAINTENANCE section for details of tank cleanout procedure.
AIR REQUIREMENTS
REFER TO THE CURRENT EDITION OF THE "NATIONAL FUEL
GAS CODE" ANSI Z223.1/NFPA 54.
MINIMUM CLEARANCES TO COMBUSTIBLES IN INCHES (mm)
MODEL ”A” ”B” ”C” ”D”
RIGHT LEFT BACK CEILING
SIDE SIDE
BCG370T1205NOX 2” (51mm) 2” (51mm) 2” (51mm) 12” (305mm)
BCG380T1506NOX 2” (51mm) 2” (51mm) 2” (51mm) 12” (305mm)
BCG3100T1806NOX 2” (51mm) 2” (51mm) 2” (51mm) 12” (305mm)
BCG3100T1996NOX 2” (51mm) 2” (51mm) 2” (51mm) 12” (305mm)
(A)BCG3100T2006NOX 2” (51mm) 2” (51mm) 2” (51mm) 12” (305mm)
(A)BCG3100T2506NOX 2” (51mm) 2” (51mm) 2” (51mm) 12” (305mm)
(A)BCG3100T2756NOX 2” (51mm) 2” (51mm) 2” (51mm) 12” (305mm)
(A)BCG385T3106NOX 3” (76mm) 3” (76mm) 3” (76mm) 12” (305mm)
(A)BCG385T3666NOX 6” (152mm) 6” (152mm) 6” (152mm) 12” (305mm)
(A)BCG385T3906NOX 3” (76mm) 3” (76mm) 3” (76mm) 12” (305mm)
TABLE 4
KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE
MATERIALS, GASOLINE AND 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 OF
AIR WILL CAUSE RECIRCULATION OF COMBUSTION PRODUCTS
RESULTING IN AIR CONTAMINATION THAT MAY BE HAZARDOUS
TO LIFE. SUCH A CONDITION OFTEN WILL RESULT IN A YELLOW,
LUMINOUS BURNER FLAME, CAUSING CARBONING OR SOOTING
OF THE COMBUSTION CHAMBER, BURNERS AND FLUE TUBES
AND CREATES A RISK OF ASPHYXIATION.
ILLUSTRATION OF MINIMUM COMBUSTIBLE CLEARANCES IN AN ALCOVE - FIGURE 5
8
Where an exhaust fan is supplied in the same room with a
heater, sufficient openings for air must be provided in the
walls.
UNDERSIZED OPENINGS WILL CAUSE AIR TO BE
DRAWN INTO THE ROOM THROUGH THE CHIMNEY,
CAUSING POOR COMBUSTION. SOOTING MAY RESULT IN
SERIOUS DAMAGE TO THE HEATER AND RISK OF FIRE OR
EXPLOSION.
UNCONFINED SPACE
In buildings of conventional frame, brick, or stone construction,
unconfined spaces may provide adequate air for combustion,
ventilation and draft hood dilution.
If the unconfined space is within a building of tight construction
(buildings using the following construction: weather stripping,
heavy insulation, caulking, vapor barrier, etc.), air for combustion,
ventilation and draft hood dilution must be obtained from outdoors.
The installation instructions for confined spaces in tightly
constructed buildings must be followed to ensure adequate air
supply.
CONFINED SPACE
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 pages
10 and 11.
This water heater must be vented in compliance with all local
codes, the current edition of the National Fuel Gas Code (ANSIZ223.1) and with the Category I Venting Tables.
If any part of the vent system are 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.
When drawing combustion and dilution air from inside a
conventionally constructed building to a confined space,
such a space shall be provided with two permanent
openings, ONE IN OR WITHIN 12 INCHES (30.5cm) OF
THE ENCLOSURE TOP AND ONE IN OR WITHIN 12 INCHES
(30.5cm) OF THE ENCLOSURE BOTTOM. Each opening
shall have a free area of at least one square inch per 1000
Btuh (2,225mm
the enclosure, but not less than 100 square inches (645
square cm).
If the confined space is within a building of tight construction,
air for combustion, ventilation, and drafthood dilution must be
obtained from outdoors. When directly communicating with
the outdoors or communicating with the outdoors through
vertical ducts, two permanent openings, located in the above
manner, shall be provided. Each opening shall have a free
area of not less than one square inch per 4000 Btuh
(8,900mm2/Kw)of the total input of all appliances in the
enclosure. If horizontal ducts are used, each opening shall
have a free area of not less than one square inch per 2000
Btuh (4,450mm2/Kw)of the total input of all appliances in the
enclosure.
2
/Kw) of the total input of all appliances in
VENTING
WARNING
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.
FIGURE 6
• 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 enter
the smaller common vent or chimney at a point above the
large vent pipe.
MULTIPLE HEATER MANIFOLD
Figure 7 and tables on pages 10 and 11 should be used for
horizontally manifolding two or more heaters.
FIGURE 7
9
TABLE 6. TECHNICAL DATA VENTING
TYPE B GAS VENT
Multiple Gas Fired Tank-Type Heaters
When venting multiple tank type heaters using Type B
vent pipe, follow the installation diagram (figure 4) and
tables below which give sizing and data based upon
NFPA 54/ANSI Z223. 1992.
MODEL BCG370T1205NOX
Input: 120,000 Btu/hr Total Vent Height (Feet)
Vent Connector Size: 5 inches 6 8 10 15 20 30 50 100
Input Btu/hr Rise Vent Connector Diameter (Inches)
120,000 1 Ft. 6 6 5 5 5 5 5 5
120,000 2 Ft. 5 5 5 5 5 5 5 5
120,000 3 Ft. 5 5 5 5 5 5 5 5
Number of Combined Input
BCG370T1205NOX in Thousands of Btu/hr Manifold and Common Vent Diameter (Inches)
2 240,000 7 7 6 6 6 6 6 6
3 360,000 8 8 7 7 7 6 6 6
4 480,000 9 9 9 8 8 7 7 6
MODEL BCG380T1506NOX
Input: 154,000 Btu/hr Total Vent Height (Feet)
Vent Connector Size: 6 inches 6 8 10 15 20 30 50 100
Input Btu/hr Rise Vent Connector Diameter (Inches)
154,000 1 Ft. 6 6 6 6 6 6 6 6
154,000 2 Ft. 6 6 6 6 6 6 6 6
154,000 3 Ft. 6 6 6 6 6 6 6 6
Number of Combined Input
BCG380T1506NOX in Thousands of Btu/hr Manifold and Common Vent Diameter (Inches)
2 308,000 7 7 6 6 6 6 6 6
3 462,000 8 8 7 7 7 6 6 6
4 616,000 9 9 9 8 8 7 7 6
MODEL BCG3100T1806NOX, BCG3100T1996NOX, & (A)BCG3100T2006NOX
Input: 180,000, 190,000 and 199,000 Btu/hr Total Vent Height (Feet)
Vent Connector Size: 6 inches 6 8 10 15 20 30 50 100
Input Btuh/hr Rise Vent Connector Diameter (Inches)
180,000 1 Ft. 7 7 6 6 6 6 6 6
190,000 1 Ft. 7 7 7 6 6 6 6 6
199,000 1 Ft. 7 7 7 6 6 6 6 6
180,000 2 Ft. 6 6 6 6 6 6 6 6
190,000 2 Ft. 7 6 6 6 6 6 6 6
199,000 2 Ft. 7 7 6 6 6 6 6 6
180,000 3 Ft. 6 6 6 6 6 6 6 6
190,000 3 Ft. 6 6 6 6 6 6 6 6
199,000 3 Ft. 6 6 6 6 6 6 6 6
Number of Combined Input
(A)BCG3 Heaters in Thousands of Btu/hr Manifold & Common Vent Diameter (Inches)
360,000 7 7 6 6 6 6 6 6
2 380,000 7 7 7 6 6 6 6 6
398,000 6 7 7 6 6 6 6 6
540,000 7 6 6 6 6 6 6 6
3 570,000 7 6 6 6 6 6 6 6
597,000 6 7 6 6 6 6 6 6
720,000 6 6 6 6 6 6 6 6
4 760,000 6 6 6 6 6 6 6 6
796,000 6 6 6 6 6 6 6 6
10
TABLE 6. TECHNICAL DATA VENTING (Continued)
MODEL (A)BCG3100T2506NOX
Input: 250,000 Btu/hr Total Vent Height (Feet)
Vent Connector Size: 6 inches 6 8 10 15 20 30 50 100
Input Btuh/hr Rise Vent Connector Diameter (Inches)
250,000 1 Ft 8 8 7 7 7 6 6 6
250,000 2 Ft 7 7 7 7 6 6 6 6
250,000 3 Ft 7 7 7 7 6 6 6 6
Number of Combined Input
(A)BCG3100T2506NOX Heaters in Thousands of Btu/hr Manifold and Common Vent Diameter (Inches)
2 500,000 9 9 9 8 8 7 7 7
3 750,000 12 12 10 10 10 9 8 8
4 1,000,000 14 14 12 12 10 10 9 9
MODEL (A)BCG3100T2756NOX
Input: 275,000 Btu/hr Total Vent Height (Feet)
Vent Connector Size: 6 inches 6 8 10 15 20 30 50 100
Input Btu/hr Rise Vent Connector Diameter (Inches)
275,000 1 Ft 8 8 7 7 6 6 6 6
275,000 2 Ft. 8 8 7 7 6 6 6 6
275,000 3 Ft 7 7 7 7 6 6 6 6
Number of Combined Input
(A)BCG3100T2756NOX Heaters in Thousands of Btu/hr Manifold and Common Vent Diameter (Inches)
2 550,000 10 9 9 8 8 8 7 7
3 825,000 12 12 12 10 9 9 8 8
4 1,100,000 14 14 14 12 12 10 9 9
MODEL (A)BCG385T3106NOX
Input: 310,000 Btu/hr Total Vent Height (Feet)
Vent Connector Size: 6 inches 6 8 10 15 20 30 50 100
Input Btu/hr Rise Vent Connector Diameter (Inches)
310,000 1 Ft. 9 8 8 8 7 7 6 6
310,000 2 Ft. 8 8 8 7 7 7 6 6
310,000 3 Ft. 8 8 8 7 7 7 6 6
Number of Combined Input
(A)BCG385T3106NOX Heaters in Thousands of Btu/hr Manifold & Common Vent Diameter
2 620,000 10 10 9 9 8 8 7 7
3 930,000 14 12 12 12 10 9 9 8
4 1,240,000 14 14 14 12 12 12 10 9
MODEL (A)BCG385T3666NOX & (A)BCG385T3906NOX
Input: 366,000, 399,000 Btu/hr Total Vent Height (Feet)
Vent Connector Size: 6 inches 6 8 10 15 20 30 50 100
Input Btu/hr Rise Vent Connector Diameter (Inches)
366,000 1 Ft 9 9 9 8 8 8 8 8
399,000 1 Ft 10 9 9 9 8 8 8 8
366,000 2 Ft 9 9 8 8 8 8 8 8
399,000 2 Ft 9 9 9 8 8 8 8 8
366,000 3 Ft 9 8 8 8 8 8 8 8
399,000 3 Ft 9 9 8 8 8 8 8 8
Number of Combined Input
(A)BCG3 Heaters in Thousands of Btu/hr Manifold & Common Vent Diameter (Inches)
2 732,000 12 10 10 9 9 9 8 8
798,000 12 12 10 10 9 9 8 8
3 1,098,000 14 14 14 12 12 10 9 9
1,197,000 14 14 14 12 12 10 10 9
4 1,464,000 16 16 14 14 14 12 12 1 0
1,596,000 16 16 16 14 14 12 12 1 0
11
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