American Water Heater BCG3-100T250-6NOX, BCG3-80T150-6NOX, BCG3-85T390-6NOX User Manual
MODELS BCG3 & ABCG3 LOW NOx
COMMERCIAL GAS, GLASS-LINED, TANK-TYPE WATER HEATER
• INSTALLATION • OPERATION • MAINTENANCE • LIMITED WARRANTY
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 0707 197934-000
1
ROUGH-IN-DIMENSIONS
FRONT VIEW
TABLE 1. ROUGH-IN-DIMENSIONS
TOP
OUTLET
1 1/2” NPT
F
TOP VIEW
TOP
INLET
1 1/2” NPT
BACK VIEW
TABLE 2. RECOVERY CAPACITIES, based on 80% efficiency
TABLE 3. GAS AND ELECTRICAL CHARACTERISTICS
2
TABLE OF CONTENTS
ROUGH-IN-DIMENSIONS -------------------------------- 2
FOREWORD ------------------------------------------------- 3
GENERAL SAFETY INFORMATION ------------------- 4
Precautions --------------------------------------------------- 4
Grounding Instructions ------------------------------------- 4
Chemical Vapor Corrosion -------------------------------- 4
Improper Combustion -------------------------------------- 4
Extended non-use Periods -------------------------------- 4
Insulation Blankets ------------------------------------------ 4
High Altitude Installation ----------------------------------- 5
FEATURES --------------------------------------------------- 5
High Limit Switch -------------------------------------------- 5
Electronic Ignition Control --------------------------------- 5
Exhaust Inducer (Blower Assy.) -------------------------- 5-6
Circulating Pump -------------------------------------------- 6
Dishwashing Machine Requirement -------------------- 6
INSTALLATION INSTRUCTIONS ----------------------- 6
Required Ability ---------------------------------------------- 6
Uncrating ------------------------------------------------------ 6
Locating The Heater ---------------------------------------- 6-7
Levelling ------------------------------------------------------- 7
Clearances ---------------------------------------------------- 7
Hard Water ---------------------------------------------------- 7
Air Requirements -------------------------------------------- 7-8
Venting --------------------------------------------------------- 8
Multiple Heater Manifold ----------------------------------- 8
Technical Data Venting------------------------------------- 9
Water Line Connections ----------------------------------- 10
Water (Potable) Heating and Space Heating -------- 10
Thermometers (Not Supplied) --------------------------- 10
Relief Valve --------------------------------------------------- 10
INSTALLATION DIAGRAMS-TOP
INLET/OUTLET USAGE ----------------------------------- 11
General -------------------------------------------------------- 11
Code Restrictions ------------------------------------------- 11
INSTALLATION DIAGRAMS ------------------------------ 12-17
Heater Wiring ------------------------------------------------- 18
Page Page
Gas Piping ---------------------------------------------------- 19
Purging --------------------------------------------------------- 19
Gas Pressure Regulator ----------------------------------- 19-20
OPERATION -------------------------------------------------- 20
General -------------------------------------------------------- 20
Filling ----------------------------------------------------------- 20
SEQUENCE OF OPERATION --------------------------- 21
Lighting and Operation ------------------------------------- 22
Water Temperature Control ------------------------------- 23
Checking Venting-------------------------------------------- 23
PREVENTIVE MAINTENANCE -------------------------- 23
Check The Ignitor Assembly ------------------------------ 23
Ignitor Assembly --------------------------------------------- 23-24
Main Burner --------------------------------------------------- 24
Gas Valves ---------------------------------------------------- 24
Checking The Input ----------------------------------------- 24
Venting System ---------------------------------------------- 25
Remote Storage Tank Temperature Control ---------- 25
Relief Valve --------------------------------------------------- 25
Hot Water Odor ---------------------------------------------- 25
Anode Rod Inspection ------------------------------------- 25
Flushing -------------------------------------------------------- 25
Draining -------------------------------------------------------- 25
Recommended Procedure For Periodic
Removal of Lime Deposits From Tank Type
Commercial Water Heaters ------------------------------- 26
Tank Cleanout Procedures -------------------------------- 26-27
Ignition Module System ------------------------------------ 27
System Diagnostics ----------------------------------------- 27
SERVICE ------------------------------------------------------ 27
Electrical Servicing ------------------------------------------ 27
Sequence of Operation Flow Chart --------------------- 28
Operational Checklist -------------------------------------- 29
NOTES --------------------------------------------------------- 30
Limited Warranty -------------------------------------------- 31
FOREWORD
These designs comply with ANSI Z21.10.3 as an automatic
circulating or automatic storage tank type water heater.
Heater model having an input of 390,000 Btuh also complies 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.
3
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 A.O.
Smith water heater. The purpose of an insulation blanket is to
reduce the standby heat loss encountered with storage tank water
heaters. Your A.O. Smith water heater meets or exceeds the
ASHRAE/IES 90.1-1999 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 A.O. Smith for placement on the
blanket directly over the existing labels.
4
HIGH ALTITUDE INSTALLATIONS
WARNING
INSTALLATIONS ABOVE 2000 FEET (610 METERS) REQUIRE
REPLACEMENT OF THE BURNER ORIFICE IN ACCORDANCE
WITH SECTION 11.1.2 OF 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
A.O. Smith Water Products Company. When ordering, be sure
to state the model number and the altitude of the location where
the water heater is being installed.
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.
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.
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.
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
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.
IGNITION CONTROL BOARD
FIGURE 3
EXHAUST INDUCER (BLOWER ASSY.)
All BCG low NOx 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.
5
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
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.
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 latest version of
the National Electrical Code ANSI/NFPA No. 70.
Only all bronze circulators are used with commercial water
heaters.
Although circulators are oiled and operated by the manufacturer
some circulators 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.
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
machine, and should be adjusted to deliver water between these
limits.
The National Sanitation Foundation also recommends circulation
of 1800F 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 1800F water at the point of take-off to the dishwashing
machine. Adjust flow by means of the plug cock in the circulating
line.
0
F line to the dishwashing
INSTALLATION INSTRUCTIONS
REQUIRED ABILITY
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
CANNOT BE AVOIDED.
DO NOT INSTALL THIS WATER HEATER DIRECTLY ON A
CARPETED FLOOR. A FIRE HAZARD MAY RESULT.
the water heater must be placed on a metal or wood panel
extending beyond the full width and depth by at least 3 inches in
any direction. If the heater is installed in a carpeted alcove, the
entire floor shall be covered by the panel. Also, see the DRAINING
requirements in MAINTENANCE Section.
THE HEATER SHALL BE LOCATED OR PROTECTED SO IT IS
NOT SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE.
Instead
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.
INSTALLATION OR SERVICE OF THIS WATER HEATER
REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED
TRADESMAN IN THE FIELD INVOLVED. PLUMBING, AIR
WHEN SUCH LOCATIONS CANNOT BE AVOIDED, A SUITABLE
DRAIN PAN SHOULD BE INSTALLED UNDER THE HEATER.
Such pans should be fabricated with sides at least 2" deep, with
6
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 TO NONCOMBUSTION CONSTRUCTION
MODEL ”A” ”B” ”C” ”D”
RIGHT LEFT BACK CEILING
SIDE SIDE
BCG3-80T150-6NOX 0 0 0 12” (305mm)
BCG3-100T250-6NOX 0 0 0 12” (305mm)
BCG3-85T390-6NOX 0 0 0 12” (305mm)
CLEARANCES
These heaters are approved for installation on combustible flooring
(with Leg Kit #6570-7) 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:
MINIMUM CLEARANCES TO COMBUSTIBLES IN INCHES (mm)
MODEL ”A” ”B” ”C” ”D”
RIGHT LEFT BACK CEILING
SIDE SIDE
BCG3-80T150-6NOX 2” (51mm) 2” (51mm) 2” (51mm) 12” (305)
BCG3-100T250-6NOX 2” (51mm) 2” (51mm) 2” (51mm) 12” (305)
BCG3-85T390-6NOX 3” (76mm) 3” (76mm) 3” (76mm) 12” (305)
TABLE 4
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.
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,
ILLUSTRATION OF MINIMUM COMBUSTIBLE CLEARANCES IN AN ALCOVE - FIGURE 5
7
BURNERS AND FLUE TUBES AND CREATES A RISK OF
ASPHYXIATION.
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.
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
9 and 10.
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.
CONFINED SPACE
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 (2,225mm2/Kw) of the
total input of all appliances in 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.
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 9 and 10 should be used for
horizontally manifolding two or more heaters.
FIGURE 7
8
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 BCG3-80T150-6NOX
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
Heaters 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 BCG3-100T250-6NOX
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 Combined Input
of 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 BCG3-85T390-6NOX
Input: 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
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 10
1,596,000 16 16 16 14 14 12 12 10
9
WATER LINE CONNECTIONS
SYSTEM CONNECTIONS
This manual provides detailed installation diagrams (see pages
13-19 of this manual) for typical methods of application for the
water heater(s).
The water heater may be installed by itself, or with a separate
storage tank, on both single and two-temperature systems. When
used with a separate storage tank, the circulation may be either
by gravity or by means of a circulating pump. When a circulating
pump is used it is important to note that the flow rate should be
slow so that there will be a minimum of turbulence inside the
heater.
If a water heater is installed in a closed water system, provisions
for the thermal expansion in the Hot Water System must be
provided. Contact the water supplier or local plumbing inspector
on how to control this situation.
WATER (POTABLE) HEATING AND SPACE
HEATING (See pages 13-19)
1. All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
2. Toxic chemicals, such as those used for boiler treatment, shall
NEVER be introduced into this system.
The system installation must conform to these instructions and to
the local code authority having jurisdiction. Good practice requires
that all heavy piping be supported.
THERMOMETERS (Not Supplied)
Thermometers should be obtained and field installed as shown in
the installation diagrams.
Thermometers are installed in the system as a means of detecting
the temperature of the outlet water supply.
RELIEF VALVE
This water heater is equipped with a combination temperaturepressure relief valve that complies with the standard for relief
valves for hot water supply system, ANSI Z21.22. FOR SAFE
OPERATION OF THE WATER HEATER, THE RELIEF VALVE(S)
MUST NOT BE REMOVED OR PLUGGED.
ASME ratings cover pressure relief capacities. CSA 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 (ASME) relief valve(s).
3. This unit may NEVER be connected to any existing heating
system or component(s) previously used with a non-potable
water heating appliance.
4. When the system requires water for space heating at
temperatures higher than required for domestic water
purposes, a tempering valve must be installed. Please refer
to installation diagrams on pages 16 and 18 of this manual for
suggested piping arrangements.
CAUTION
A closed system will exist if a check valve (without bypass),
pressure reducing valve (without bypass), or a water meter (without
bypass) is installed in the cold water line between the water heater
and street main (or well).
Excessive pressure may develop in such closed systems,
causing premature tank failure or intermittent relief valve
operation.
a similar device may be required in the inlet supply line between
the appliance and the meter or valve to compensate for the
thermal expansion of the water.
This is not a warranty failure. An expansion tank or
WARNING
THE PURPOSE OF RELIEF VALVE IS TO AVOID EXCESSIVE
PRESSURE OR TEMPERATURE INTO THE STEAM RANGE,
WHICH MAY CAUSE SCALDING AT FIXTURES, TANK
EXPLOSION, SYSTEM OR HEATER DAMAGE. NO VALVE IS
TO BE PLACED BETWEEN THE RELIEF VALVE AND TANK.
Your local code authority may have other specific relief valve
requirements.
A DRAIN LINE MUST BE CONNECTED TO THE RELIEF VALVE
TO DIRECT DISCHARGE TO A SAFE LOCATION TO AVOID
SCALDING OR WATER DAMAGE. THIS LINE MUST NOT BE
REDUCED FROM THE SIZE OF THE VALVE OUTLET AND MUST
NOT CONTAIN VALVES, RESTRICTIONS NOR SHOULD IT BE
LOCATED IN FREEZING AREAS. DO NOT THREAD OR CAP
THE END OF THIS LINE. RESTRICTED OR BLOCKED
DISCHARGE WILL DEFEAT THE PURPOSE OF THE VALVE
AND IS UNSAFE. DISCHARGE LINE SHALL BE INSTALLED
TO ALLOW COMPLETE DRAINAGE OF BOTH THE VALVE AND
LINE.
See SERVICE INFORMATION section for procedure and
precautions.
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