Instruction manual | American Water Heater (A)BCG3 85T500

Instruction Manual
commercial gas water heaters
MODELS (A)BCG3 85T500-8N &
(A)BCG3 85T500-8P
SERIES 120/121
INSTALLATION - OPERATION - SERVICE
- MAINTENANCE - LIMITED WARRANTY
P.O. Box 1597
Johnson City, TN 37605
ASME CRN
Low Lead Content
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not
touch any electrical switch; do
not use any phone in your building.
• Immediately
call your gas supplier
from a neighbor’s phone. Follow the
gas supplier’s instructions.
• If you cannot
reach your gas supplier,
call the fire department.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
Thank you for buying this energy efficient water heater.
We appreciate your confidence in our products.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
place these instructions adjacent to heater and notify owner to keep for future reference.
PRINTED 0211
318296-001
Table Of Contents
Safe Installation, Use and Service........................................ 3
Outdoor Air Through Two Vertical Ducts......................................... 17
APPROVALS......................................................................................... 3
Air From Other Indoor Spaces........................................................ 17
General Safety Information..................................................... 4
Technical Data Venting................................................................... 18
Precautions....................................................................................... 5
water heater installation....................................................... 19
Grounding Instructions..................................................................... 5
Water Line Connections................................................................. 19
Hydrogen Gas Flammable................................................................ 5
T&P Valve Discharge Pipe.............................................................. 19
Introduction................................................................................... 6
Installation Diagrams - Top Inlet/Outlet Usage............................... 20
Abbreviations Used.......................................................................... 6
Code Restrictions........................................................................... 20
Qualifications.................................................................................... 6
Heater Wiring.................................................................................. 21
features and components........................................................ 7
Gas Piping...................................................................................... 22
The Eliminator (self-cleaning system).............................................. 7
Purging........................................................................................... 22
High Limit Switch.............................................................................. 7
Gas Pressure Regulator................................................................. 22
Electronic Ignition Control................................................................. 7
OPERATION........................................................................................ 23
Exhaust Inducer (blower assy.)........................................................ 7
General........................................................................................... 23
Uncrating.......................................................................................... 7
Filling.............................................................................................. 23
installation considerations.................................................... 8
SEQUENCE OF OPERATION............................................................ 23
Rough In Dimensions....................................................................... 8
Lighting & Operation Label............................................................. 24
Recovery Capacities......................................................................... 8
Check Venting................................................................................ 25
Gas and Electrical Characteristics.................................................... 8
Check the Igniter Assembly............................................................ 25
Locating the Water Heater................................................................ 9
Igniter Assembly............................................................................. 25
Clearances....................................................................................... 9
Main Burner.................................................................................... 25
Installation On Combustible Flooring.............................................. 10
Gas Valves...................................................................................... 25
Insulation Blanket........................................................................... 10
Checking the Input.......................................................................... 26
Hard Water..................................................................................... 10
mAINTENANCE.................................................................................. 26
Circulation Pumps.......................................................................... 10
Venting System............................................................................... 26
High Altitude Installations............................................................... 11
Remote Storage Tank Temperature Control................................... 26
Propane Installations...................................................................... 11
Temperature-Pressure Relief Valve Test........................................ 26
Natural Gas Installations................................................................ 11
Hot Water Odor............................................................................... 27
Installation Requirements..................................................... 12
Anode Rod Inspection.................................................................... 27
Gas Pressure Requirements.......................................................... 12
Draining and Flushing..................................................................... 27
Supply Gas Regulator.................................................................... 12
Recommended Procedure for Periodic Removal of Lime Deposits
Power Supply................................................................................. 12
from Tank Type Commercial Water Heaters................................... 28
Water Temperature Control and Mixing Valves.............................. 12
Deliming Solvents........................................................................... 28
Dishwashing Machines................................................................... 13
Tank Cleanout Procedure............................................................... 28
Closed Water Systems................................................................... 13
Deliming Using Flo-Jug Method..................................................... 28
Thermal Expansion......................................................................... 13
Ignition Module System.................................................................. 30
Temperature-Pressure Relief Valve................................................ 13
System Diagnostics........................................................................ 30
Contaminated Air............................................................................ 14
SERVICE............................................................................................. 30
Air Requirements............................................................................ 14
Electrical Servicing......................................................................... 30
Unconfined Space.......................................................................... 15
Confined Space.............................................................................. 15
for your information................................................................ 30
Vent Adapter................................................................................... 15
Start Up Conditions........................................................................ 30
vENTING INSTALLATION.................................................................. 15
Operational Conditions................................................................... 30
Venting............................................................................................ 15
Sequence of Operation Flow Chart................................................ 32
Multiple Heater Manifold................................................................. 16
operational checklist.............................................................. 33
Fresh Air Openings For Confined Spaces...................................... 16
water Piping Diagrams............................................................... 34
Outdoor Air Through Two Openings............................................... 16
Manifold Kits................................................................................. 49
Outdoor Air Through One Opening................................................. 16
COMMERCIAL STORAGE TANK warranty.................................. 50
Outdoor Air Through Two Horizontal Ducts.................................... 16
notes................................................................................................ 51
2
Safe Installation, Use and Service
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and
how to avoid the risk of injury.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances
known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of
potential exposure to such substances.
This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This
appliance can cause low level exposure to some of the substances listed in the Act.
APPROVALS
ASME CRN
Low Lead Content
California AB1953
3
General Safety Information
Fire or Explosion Hazard
Fire Hazard
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
For continued protection against
risk of fire:
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas
pressure.
Do not install water heater on
carpeted floor.
Do not operate water heater if
flood damaged.
Use only the gas shown on the water heater rating label.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended
periods of non-use.
Fire and Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Use joint compound or Teflon tape
compatible with propane gas.
Leak test before placing the
water heater in operation.
Disconnect gas piping and main
gas shutoff valve before leak
testing.
Install sediment trap in
accordance with NFPA 54.
Breathing Hazard - Carbon Monoxide Gas
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Fire and Explosion Hazard
Install water heater in accordance with
the instruction manual.
Do not use water heater with any gas
other than the gas shown on the rating
label.
Excessive gas pressure to gas valve can
cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
CAUTION
Property Damage Hazard
• All water heaters eventually leak.
• Do not install without adequate drainage.
Jumping out control circuits or components can
result in property damage, personal injury or death.
•
•
Electrical Shock Hazard
•
Turn off power to the water heater
before performing any service.
•
Label all wires prior to disconnecting
when performing service. Wiring errors
can cause improper and dangerous
operation.
•
•
Verify proper operation after servicing.
•
Service should only be performed by a qualified service
agent using proper test equipment.
Altering the water heater controls and/or wiring in any way
could result in permanent damage to the controls or water
heater and is not covered under the limited warranty.
Altering the water heater controls and/or wiring in any way
could result in altering the ignition sequence allowing gas to
flow to the main burner before the hot surface igniter is at
ignition temperature causing delayed ignition which can
cause a fire or explosion.
Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the appliance warranty.
Failure to follow these instructions can
result in personal injury or death.
4
General Safety Information
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Explosion Hazard
Overheated water can cause
water tank explosion.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
This manual must remain with the
water heater.
CAUTION
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Improper installation, use and service may result
in property damage.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
•
•
•
•
•
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Do not operate water heater if flood damaged.
Inspect and anode rods regularly, replace if damaged.
Install in location with drainage.
Fill tank with water before operation.
Properly sized thermal expansion tanks are required on all
closed water systems.
Refer to this manual for installation and service.
Verify the power to the water heater is turned off before performing any service procedures.
General Safety Information
Precautions
Hydrogen Gas Flammable
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN
UNDER WATER. Immediately call a qualified service agency to
inspect the appliance and to make a determination on what steps
should be taken next.
Explosion Hazard
If the unit is exposed to the following, do not operate heater
until all corrective steps have been made by a qualified
service agency.
Flammable hydrogen gases
may be present.
1. External fire.
Keep all ignition sources away
from faucet when turning on
hot water.
2. Damage.
3. Firing without water.
Hydrogen gas can be produced in a hot water system served
by this appliance 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 a hot water faucet served by this appliance be
opened for several minutes 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.
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.
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 20.
5
Introduction
Thank You for purchasing this water heater. Properly installed
and maintained, it should give you years of trouble free service.
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.
Abbreviations Used
Abbreviations found in this Instruction Manual include :
ANSI Z223.1 2006 Sec. 3.3.83: “Qualified Agency” - “Any
individual, firm, corporation or company that either in person
or through a representative is engaged in and is responsible
for (a) the installation, testing or replacement of gas piping
or (b) 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.”
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• GAMA - Gas Appliance Manufacturer’s Association
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• UL - Underwriters Laboratory
• CSA - Canadian Standards Association
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.
Qualifications
Qualified Installer or Service Agency
Installation and service of this water heater requires ability
equivalent to that of a Qualified Agency (as defined by ANSI
6
features and components
The Eliminator (self-cleaning system)
Electronic Ignition Control
These units include The Eliminator (Self-Cleaning System)
installed in the front water inlet, See Figure 1. The Eliminator inlet
tube can only be used in the front water inlet connection. Do not
install the Eliminator inlet tube in either the top or back inlet water
connection. 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.
Each heater is equipped with an ignition module. The solid state
ignition control (Figure 3), ignites the main burner by utilizing a
silicon nitride igniter. The silicon nitride igniter shuts off during
the heating cycle and the main burner flame is sensed through
a remote flame sensor integral to the silicon nitride igniter
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.
Note: The Eliminator may have 1, 3 or 7 cross tubes.
FIGURE 1
High Limit Switch
IGNITION CONTROL BOARD
FIGURE 3
The digital thermostat (Figure 2) contains the high limit (energy
cutoff) switch. The high limit switch interrupts main burner gas flow
should the water temperature reach 203°F (95°C).
Exhaust Inducer (blower assy.)
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.
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.
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:
The exhaust inducer is equipped with a gravity controlled damper
to reduce the amount of heat loss through the flue, improving
efficiency.
• 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.
EXHAUST INDUCER
FIGURE 4
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.
DIGITAL THERMOSTAT
FIGURE 2
7
installation considerations
Rough In Dimensions
Recovery Capacities
Gas and Electrical Characteristics
FRONT VIEW
BACK VIEW
TOP
OUTLET
1 1/2” NPT
TOP
INLET
1 1/2” NPT
F
TOP VIEW
FIGURE 5
TABLE 1. ROUGH-IN-DIMENSIONS
Model
(A)BCG385T500-8N/
(A)BCG385T500-8P
(A)BCG385T500-8N/
(A)BCG385T500-8P
Input Rate
Btu/Hr
Kw/Hr
Approximate
Tank Cap
G/L
500,000
85
147
322
Connections
Inlet (NPT)
Outlet (NPT)
Dimensions in Inches/cm
A
B
C
D
E
F
81.50 17.50 77.25 67.50 27.13 21.00
207
44
196
171
69
53
Gas
Inlet
G
H
Vent
Dia
I
1.00
67.50
8.00
3
171
20
J
Top
27.75 1.50
70
1.50
Approx. Ship Weight
Front Back
Top
Front Back
Std.
Lbs/
Kgs.
ASME
Lbs/
Kgs.
1.50
1.50
1.50
1.50
1.50
812
857
1.50
1.50
1.50
1.50
1.50
368
389
TABLE 2. RECOVERY CAPACITIES, based on 80% efficiency
Model
(A)BCG385T500-8N/
(A)BCG385T500-8P
(A)BCG385T500-8N/
(A)BCG385T500-8P
Recovery Rating Capacities (GPH and LPH) at temperature rise indicated
Input Rate
Btu/Hr
Kw/Hr
Approximate
Tank Cap
G/L
30°F
17°C
40°F
22°C
50°F
28°C
60°F
33°C
70°F
39°C
80°F
44°C
90°F
50°C
100°F
56°C
110°F
61°C
120°F
67°C
130°F
72°C
140°F
78°C
500,000
85
1616
1212
970
808
693
606
539
485
441
404
373
346
147
322
6118
4588
3671
3059
2622
2294
2039
1835
1668
1529
1412
1311
TABLE 3. GAS AND ELECTRICAL CHARACTERISTICS
Model
(A)BCG385T500-8N/
(A)BCG385T500-8P
(A)BCG385T500-8N/
(A)BCG385T500-8P
Gas Type
Minumum
Gas Supply Pressure
Maximum
Gas Manifold Pressure
Volts / Hz
Amperes
Natural
4.5" W.C. (1.12 kPa)
14" W.C. (3.48 kPa)
3.5" W.C. (0.87 kPa)
120/60
<5
Propane
11" W.C. (2.74 kPa)
14" W.C. (3.48 kPa)
10" W.C. (2.49 kPa)
120/60
<5
8
Installation Considerations
Locating the Water Heater
IS NOT SUBJECT TO PHYSICAL DAMAGE BY A MOVING
VEHICLE.
CAUTION
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.
Property Damage Hazard
• All water heaters eventually leak.
• Do not install without adequate drainage.
THE HEATER MUST NOT BE LOCATED IN AN AREA WHERE
IT WILL BE SUBJECT TO FREEZING.
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.
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.
Fire or Explosion Hazard
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
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.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Clearances
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas
pressure.
This water heater is approved for installation on combustible
flooring (with NSF Leg Kit #9003425205) in an alcove when the
minimum clearance from any combustible construction is as
indicated in Figure 6 and Table 4.
In all installations the minimum combustible clearances from
vent piping shall be 6” (15.2 cm). Vent piping passing through a
combustible wall or ceiling must be a continuous run (no joints)
and retain the 6” (15.2 cm) clearance unless an approved reducing
thimble is used.
A service clearance of 24” (61 cm) should be maintained from
serviceable parts, such as 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:
Use only the gas shown on the water heater rating label.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended
periods of non-use.
Read instruction manual before
installing, using or servicing
water heater.
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.
TABLE 4
MINIMUM CLEARANCES TO COMBUSTIBLES IN INCHES (mm)
MODEL
(A)BCG385T500-8N/
(A)BCG385T500-8P
"A"
"B"
RIGHT
LEFT
SIDE
SIDE
5"
(12.7 cm)
5"
(12.7 cm)
"C"
"D"
BACK
CEILING
5"
(12.7 cm)
20"
(50.8 cm)
TABLE 5
DO NOT INSTALL THIS WATER HEATER DIRECTLY ON A
CARPETED FLOOR. A FIRE HAZARD MAY RESULT. Instead 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.
MINIMUM CLEARANCES TO NONCOMBUSTIBLE CONSTRUCTION
MODEL
(A)BCG385T500-8N/
(A)BCG385T500-8P
THE HEATER SHALL BE LOCATED OR PROTECTED SO IT
9
"A"
"B"
RIGHT
LEFT
SIDE
SIDE
0
0
"C"
"D"
BACK
CEILING
0
12"
(30.5 cm)
Insulation Blanket
Breathing Hazard - Carbon Monoxide Gas
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Insulation blankets are available to the general public for external
use on gas water heaters but are not necessary with these
products. The purpose of an insulation blanket is to reduce the
standby heat loss encountered with storage tank heaters. The
water heaters covered by this manual meet or exceed the Energy
Policy Act standards with respect to insulation and standby heat
loss requirements, making an insulation blanket unnecessary.
Should you choose to apply an insulation blanket to this
heater, you should follow these instructions. See the Features
and Components section of this manual for identification of
components mentioned below. Failure to follow these instructions
can restrict the air flow required for proper combustion, potentially
resulting in fire, asphyxiation, serious personal injury or death.
FIGURE 6
Installation On Combustible Flooring
• DO NOT apply insulation to the top of the water heater, as this
will interfere with safe operation of the exhaust inducer.
The (A)BCG385T500-8N/(A)BCG385T500-8P is approved for
installations on combustible flooring when installed with NSF Leg
Kit number 9003425205
• DO NOT cover the gas valve, thermostat or the TemperaturePressure Relief Valve.
• DO NOT allow insulation to come within 2” (5 cm) of the burners,
to prevent blockage of combustion air flow to the burners.
• DO NOT allow insulation to come within 9 inches (23 cm)
of floor, (within 2 inches (5 cm) of bottom cover) to prevent
blockage of combustion air flow to the burners..
• DO NOT cover the instruction manual. Keep it on the side of
the water heater or nearby for future reference.
• DO obtain new warning and instruction labels from the
manufacturer for placement on the blanket directly over the
existing labels.
• DO inspect the insulation blanket frequently to make certain it
does not sag, thereby obstructing combustion air flow.
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.
FIGURE 7
1. Unit needs to be lifted in a way not to damage unit or laid
on it’s side to access the bottom of the legs.
See the Maintenance Section in this manual for sediment and
lime scale removal procedures.
2. Slide leg extension under leg and the bolt up through the
bottom hole located in the bottom of the leg.
Circulation Pumps
3. Once in place, screw nut down and secure.
A circulating pump is used when a system requires a circulating
loop or there is a storage tank used in conjunction with the water
heater. See Water Piping Diagrams in this manual for installation
location of circulating pumps.
4. Front of leg should line up with front of leg extension as
shown in Figure 7 to make sure weight of unit is distributed
through the leg extension.
10
ON
See the Circulation Pump Wiring Diagrams (Figure 8, Figure
9) in this manual for electrical hookup information. Install in
accordance with the current edition of the National Electrical
Code, NFPA 70 or the Canadian Electrical Code, CSA C22.1.
Breathing Hazard - Carbon Monoxide Gas
All-bronze circulators are recommended for used with commercial
water heaters.
Under no circumstances should
the input exceed the rate shown
on the water heater’s rating label.
Some circulating pumps are manufactured with sealed bearings
and do not require further lubrication. Some circulating pumps
must be periodically oiled. Refer to the pump manufacturer’s
instructions for lubrication requirements.
Overfiring could result in damage to
the water heater and sooting.
Gas and carbon monoxide detectors
CIRCULATINGare
PUMP
WIRING DIAGRAM
available.
DISHWASHER LOOP WITH TOGGLE SWITCH
CIRCULATING PUMP WIRING DIAGRAM
STORAGE TANK OR BUILDING RECIRCULATION
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH APPLIANCE AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
Breathing carbon
monoxide canFIELD
cause
brain damage
or
DISHWASHER
SUPPLIED
TEMPERATURE
death. AlwaysTOGGLE
read and understand
instruction
manual.
CONTROL
INSTALLED
IN THE
FIELD SUPPLIED TEMPERATURE CONTROL
INSTALLED IN THE STORAGE TANK
OR CIRCULATING LOOP RETURN LINE
SWITCH
NOTE: USE SEPARATE
120 VAC POWER
Propane
Installations
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH APPLIANCE AS THIS
INSTALLATIONS
ABOVE 2000 FEET (610 METERS) REQUIRE
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROLOF
SYSTEM
REPLACEMENT
BURNER ORIFICES IN ACCORDANCE
OPERATION.
WITH CURRENT EDITION OF THE NATIONAL FUEL GAS CODE
HOT
(ANSI L1
Z223.1).
FOR CANADIAN INSTALLATIONS CONSULT
CANADIAN INSTALLATIONS CODE CAN/CSA B149.1. FAILURE
TO REPLACE
WILL RESULT IN IMPROPER
AND
120ORIFICES
VAC
CIRC
INEFFICIENTPOWER
OPERATION OF THE APPLIANCE
RESULTING
PUMP
MOTOR
IN THE PRODUCTION OF INCREASED LEVELS
OF CARBON
MONOXIDE GAS IN EXCESS OF SAFE LIMITS WHICH COULD
L2 NEUTRAL
RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
L1 HOT
120 VAC
POWER
CIRC
PUMP
MOTOR
L2 NEUTRAL
FIGURE 8.
You should contact your gas supplier for any specific changes
which may be required in your area.
CIRCULATING PUMP WIRING DIAGRAM
DISHWASHER LOOP WITH TOGGLE SWITCH
E CONTROL
ANK
N LINE
CIRCULATING LOOP RETURN LINE
DISHWASHER
TOGGLE
SWITCH
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 over firing of the heater causing sooting, poor
combustion and/or unsatisfactory heater performance.
FIELD SUPPLIED TEMPERATURE
CONTROL INSTALLED IN THE
CIRCULATING LOOP RETURN LINE
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH APPLIANCE AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
Ratings specified by manufacturers for most appliances apply for
elevations up to 2000 feet (610m). For elevations above 2000 feet
(610), ratings must be reduced at the rate of 4% for each 1000
feet (305m) above sea level. For example, if a heater is rated at
78,000 Btuh (22.9 Kwh) at sea level, to rate the heater at 4000 feet
(1219m), you subtract 4 (once for each thousand feet) x.04 (4%
input reduction) x 78,000 (original rating) from the original rating.
L1 HOT
120 VAC
POWER
CIRC
PUMP
MOTOR
Therefore, to calculate the input rating at 4,000 feet (1219m): 4 x
.04 x 78,000 = 12,480 Btuh (3.7 Kwh), 78,000 (22.9 Kwh) - 12,480
(3.7 Kwh) = 65,520 Btuh (19.2 Kwh). At 6000 feet (1829m) the
correct input rating should be 59,280 Btuh (17.4 Kwh).
L2 NEUTRAL
FIGURE 9.
Natural Gas Installations
High Altitude Installations
The natural gas fired version of the water heater covered by this
manual is certified for use without modification for altitudes up to
10,100 feet.
For installations above 10,100 feet call the technical support
phone number listed on the back cover of this manual for further
technical assistance. Call the local gas or utility company to verify
Btu per cubic foot content before calling for technical assistance
and have that information available.
Fire and Explosion Hazard
Under no circumstances should the
input exceed the rate shown on the
water heater’s rating label.
Overfiring could result in fire or
explosion.
Gas and carbon monoxide detectors are
available.
Note: The actual firing rate of the water heater must not exceed
the input rating on the water heater's rating label under any
circumstances.
Note: Due to the input rating reduction at high altitudes, the
output rating of the appliance is also reduced and should be
compensated for in the sizing of the equipment for applications.
11
Installation Requirements
Gas Pressure Requirements
Water Temperature Control and Mixing Valves
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Natural gas models require a minimum gas supply pressure of
4.5” W.C. Propane gas models require a minimum gas supply
pressure of 11" W.C. The minimum supply pressure is measured
while gas is not flowing (static pressure) AND while gas is flowing
(dynamic pressure). The supply pressure (static and dynamic)
should never fall below the specified minimum supply pressure.
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. See Supply Gas Regulator section and Gas Piping
section of this manual.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Water heated to a temperature which will satisfy clothes
washing, dish washing, and other sanitizing needs can scald
and cause permanent injury upon contact. Short repeated
heating cycles caused by small hot water uses can cause
temperatures at the point of use to exceed the water heater’s
temperature setting by up to 20°F (11°C).
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) AND while
gas is flowing (dynamic pressure).
Some people are more likely to be permanently injured by
hot water than others. These include the elderly, children, the
infirm and the physically/mentally disabled. Table 6 shows the
approximate time-to-burn relationship for normal adult skin. If
anyone using hot water provided by the water heater being
installed fits into one of these groups or if there is a local code
or state law requiring a certain water temperature at the point
of use, then special precautions must be taken.
Supply Gas Regulator
The water heater covered by this manual may require
the installation of a supply gas regulator. If the supply gas
pressure exceeds 14 inches W.C. a supply gas regulator must
be used. If the gas supply pressure exceeds 14" W.C. in a
multiple water heater installation, each water heater must
have its own supply gas regulator. If required, the supply gas
regulator shall be rated at or above the Btu/hr input rating of
the water heater it supplies.
In addition to using the lowest possible temperature setting
that satisfies the demand of the application a Mixing Valve
should be installed at the water heater (see Figure 10) or at
the hot water taps to further reduce system water temperature.
Supply gas regulators shall have inlet and outlet connections
not less than the minimum supply gas line size for the water
heater they serve as shown in Table 9. The Maxitrol 325-7L or
equivalent is recommended.
Mixing valves are available at plumbing supply stores.
Consult a Qualified Installer or Service Agency. Follow mixing
valve manufacturer’s instructions for installation of the valves.
Table 6.
Power Supply
Water Temperature
180°F (82°C)
170°F (77°C)
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.
12
Time to Produce 2nd & 3rd
Degree Burns on Adult Skin
Nearly instantaneous
Nearly instantaneous
160°F (71°C)
About 1/2 second
150°F (66°C)
140°F (60°C)
130°F (54°C)
120°F (49°C)
About 1-1/2 seconds
Less than 5 seconds
About 30 seconds
More than 5 minutes
A properly sized thermal expansion tank must be installed on
all closed systems to control the harmful effects of thermal
expansion. Contact a local plumbing service agency to have a
thermal expansion tank installed.
HOT WATER
OUTLET
See Water Line Connections on page 19 and the Water Piping
Diagrams beginning on page 34.
12” TO 15”
(30-38 cm)
TEMPERED WATER
OUTLET
Temperature-Pressure Relief Valve
CHECK
VALVE
COLD
WATER
INLET
CHECK
VALVE
Explosion Hazard
MIXING
VALVE
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
TO TANK
INLET
Properly sized temperaturepressure relief valve must be
installed in opening provided.
Figure 10
Dishwashing Machines
Can result in overheating and
excessive tank pressure.
All dishwashing machines meeting the National Sanitation
Foundation requirements are designed to operate with water
flow pressures between 15 and 25 pounds per square inch (103
kPa and 173 kPa). Flow pressures above 25 pounds per square
inch (173 kPa), or below 15 pounds per square inch (103 kPa),
will result in improperly sanitized dishes. Where pressures are
high, a water pressure reducing or flow regulating control valve
should be used in the 180°F (82°C) line to the dishwashing
machine and should be adjusted to deliver water pressure
between these limits.
Can cause serious injury or death.
This water heater is provided with a properly rated/sized and
certified combination Temperature-Pressure Relief Valve (T&P
valve) by the manufacturer. The valve is certified by a nationally
recognized testing laboratory that maintains periodic inspection
of production of listed equipment of materials as meeting the
requirements for Relief Valves for Hot Water Supply Systems,
ANSI Z21.22 • CSA 4.4, and the code requirements of ASME.
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°C) water at the point of take-off to
the dishwashing machine.
If replaced, the new T&P valve must meet the requirements
of local codes, but not less than a combination TemperaturePressure Relief Valve rated/sized and certified as indicated in
the above paragraph. The new valve must be marked with a
maximum set pressure not to exceed the marked hydrostatic
working pressure of the water heater (150 psi = 1,035 kPa) and
a discharge capacity not less than the water heater Btu/hr or kW
input rate as shown on the water heater’s model rating label.
Adjust flow by throttling a full port ball valve installed in the
circulating line on the outlet side of the pump. Never throttle flow
on the suction side of a pump. See Water Piping Diagrams in
this manual.
NOTE: In addition to the factory installed Temperature-Pressure
Relief Valve on the water heater, each remote storage tank that
may be installed and piped to a water heating appliance must also
have its own properly sized, rated and approved TemperaturePressure Relief Valve installed. Call the toll free technical
support phone number listed on the back cover of this manual
for technical assistance in sizing a Temperature-Pressure Relief
Valve for remote storage tanks.
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.
For safe operation of the water heater, the Temperature-Pressure
Relief Valve must not be removed from its designated opening
nor plugged. The Temperature-Pressure Relief Valve must be
installed directly into the fitting of the water heater designed for the
relief valve. Install discharge piping so that any discharge will exit
the pipe within 6 inches (15.2 cm) above an adequate floor drain,
or external to the building. In cold climates it is recommended
that it be terminated at an adequate drain inside the building. Be
certain that no contact is made with any live electrical part. The
discharge opening must not be blocked or reduced in size under
any circumstances. Excessive length, over 30 feet (9.14 m), or
use of more than four elbows can cause restriction and reduce
the discharge capacity of the valve.
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.
13
No valve or other obstruction is to be placed between the
Temperature-Pressure Relief Valve and the tank. Do not connect
discharge piping directly to the drain unless a 6” (15.2 cm)
air gap is provided. To prevent bodily injury, hazard to life, or
property damage, the relief valve must be allowed to discharge
water in adequate quantities should circumstances demand. If
the discharge pipe is not connected to a drain or other suitable
means, the water flow may cause property damage.
If you do not understand these instructions or have any questions
regarding the Temperature-Pressure Relief Valve call the toll free
number listed on the back cover of this manual for technical
assistance.
Contaminated Air
CAUTION
Breathing Hazard - Carbon Monoxide Gas
Install water heater in accordance with
the Instruction Manual and NFPA 54 or
CAN/CSA-B149.1.
To avoid injury, combustion and ventilation
air must be taken from outdoors.
Do not place chemical vapor emitting
products near water heater.
Water Damage Hazard
• Temperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
T&P Valve Discharge Pipe Requirements:
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
• Shall not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restrictions.
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.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
• Shall be of material listed for hot water distribution.
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.
• Shall be installed so as to allow complete drainage of both
the Temperature-Pressure Relief Valve and the discharge
pipe.
• Must terminate a maximum of six inches above a floor
drain or external to the building. In cold climates, it is
recommended that the discharge pipe be terminated at an
adequate drain inside the building.
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).
• Shall not have any valve or other obstruction between the
relief valve and the drain.
Air Requirements
Burn hazard.
Hot water discharge.
Breathing Hazard - Carbon Monoxide Gas
Keep clear of TemperaturePressure Relief Valve
discharge outlet.
Install water heater in accordance with
the Instruction Manual and NFPA 54 or
CAN/CSA-B149.1.
To avoid injury, combustion and ventilation
air must be taken from outdoors.
Do not place chemical vapor emitting
products near water heater.
The Temperature-Pressure Relief Valve must be manually
operated at least twice a year. Caution should be taken to ensure
that (1) no one is in front of or around the outlet of the TemperaturePressure Relief Valve discharge line, and (2) the water manually
discharged will not cause any bodily injury or property damage
because the water may be extremely hot. If after manually
operating the valve, it fails to completely reset and continues to
release water, immediately close the cold water inlet to the water
heater, follow the draining instructions in this manual, and replace
the Temperature-Pressure Relief Valve with a properly rated/sized
new one.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
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.
NOTE: The purpose of a Temperature-Pressure Relief Valve is
to prevent excessive temperatures and pressures in the storage
tank. The T&P valve is not intended for the constant relief of
thermal expansion. A properly sized thermal expansion tank must
be installed on all closed systems to control thermal expansion,
see Closed Water Systems and Thermal Expansion on page 13.
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 that follows.
14
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.
through the water heater’s vent system causing poor combustion.
Sooting, serious damage to the water heater and the risk of fire
or explosion may result. It can also create a risk of asphyxiation.
Louvers and Grilles
The free areas of the fresh air openings in the instructions that
follow do not take in to account the presence of louvers, grilles
or screens in the openings.
Unconfined Space
An Unconfined Space is one whose volume IS NOT LESS THAN
50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the
total input rating of all appliances installed in the space. Rooms
communicating directly with the space, in which the appliances
are installed, through openings not furnished with doors, are
considered a part of the unconfined space.
The required size of openings for combustion, ventilation
and dilution air shall be based on the “net free area” of each
opening. Where the free area through a design of louver or
grille or screen is known, it shall be used in calculating the
size of opening required to provide the free area specified.
Where the louver and grille design and free area are not
known, it shall be assumed that wood louvers will have 25%
free area and metal louvers and grilles will have 75% free
area. Non motorized louvers and grilles shall be fixed in the
open position.
Makeup air requirements for the operation of exhaust fans,
kitchen ventilation systems, clothes dryers and fireplaces shall
also be considered in determining the adequacy of a space to
provide combustion, ventilation and dilution air.
Unusually Tight Construction
In unconfined spaces in buildings, infiltration may be adequate
to provide air for combustion, ventilation and dilution of flue
gases. However, in buildings of unusually tight construction (for
example, weather stripping, heavily insulated, caulked, vapor
barrier, etc.) additional air must be provided using the methods
described in the Confined Space section that follows.
Vent Adapter
The (A)BCG385T500-8N/(A)BCG385T500-8P model is shipped
with a 6" to 8" diameter vent adapter (Fig. 11). The vent adapter
fits on top of the installed blower exhaust. Use only vent
adapters supplied with the unit. The venting must comply with
the NATIONAL FUEL GAS CODE, ANSI Z223.1/NFPA 54 and
for Canadian installations consult the Canadian Installation Code
CAN/CSA B149.1-00.
Confined Space
A Confined Space is one whose volume IS LESS THAN 50 cubic
feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input
rating of all appliances installed in the space.
Openings must be installed to provide fresh air for combustion,
ventilation and dilution in confined spaces. The required size for
the openings is dependent on the method used to provide fresh
air to the confined space AND the total Btu/hr input rating of all
appliances installed in the space.
Exhaust Fans
Where exhaust fans are installed, additional air shall be provided
to replace the exhausted air. When an exhaust fan is installed
in the same space with a water heater, sufficient openings to
provide fresh air must be provided that accommodate the
requirements for all appliances in the room and the exhaust fan.
Undersized openings will cause air to be drawn into the room
Figure 11
vENTING INSTALLATION
Venting
• 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.
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.
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 page 18.
This water heater must be vented in compliance with all local
codes, the current revision of the National Fuel Gas Code
(ANSI-Z223.1) and with the Category I Venting Tables.
FIGURE 12
• Where a separate vent connection is not available and the
vent pipe from the heater must be connected to a common
If any part of the vent system is exposed to ambient temperatures
below 40°F it must be insulated to prevent condensation.
15
Outdoor Air Through One Opening
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 13 and Table 7 should be used for horizontally manifolding
two or more heaters.
Figure 15
Alternatively a single permanent opening, commencing within 12
inches (300 mm) of the top of the enclosure, shall be provided. See
Figure 15. The water heater shall have clearances of at least 1 inch
(25 mm) from the sides and back and 6 inches (l50 mm) from the
front of the appliance. The opening shall directly communicate with
the outdoors or shall communicate through a vertical or horizontal
duct to the outdoors or spaces that freely communicate with the
outdoors and shall have a minimum free area of the following:
FIGURE 13
Fresh Air Openings For Confined Spaces
The following instructions shall be used to calculate the size,
number and placement of openings providing fresh air for
combustion, ventilation and dilution in confined spaces. The
illustrations shown in this section of the manual are a reference
for the openings that provide fresh air into confined spaces
only. DO NOT refer to these illustrations for the purpose of vent
installation. See Venting Installation on page 15 for complete
venting installation instructions.
1. 1 square inch per 3000 Btu/hr (733 mm2 per kW) of the total
input rating of all appliances located in the enclosure, and
2. Not less than the sum of the areas of all vent connectors in
the space.
Outdoor Air Through Two Horizontal Ducts
Outdoor Air Through Two Openings
Figure 16
The confined space shall be provided with two permanent
horizontal ducts, one commencing within 12 inches (300 mm) of
the top and one commencing within 12 inches (300 mm) of the
bottom of the enclosure. The horizontal ducts shall communicate
directly with the outdoors. See Figure 16.
Figure 14
The confined space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. The openings shall communicate directly with the
outdoors. See Figure 14.
Each duct opening shall have a minimum free area of 1 square
inch per 2,000 Btu/hr (1100 mm2 per kW) of the aggregate input
rating of all appliances installed in the enclosure.
Each opening shall have a minimum free area of 1 square inch
per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating
of all appliances installed in the enclosure. Each opening shall
not be less than 100 square inches (645 cm2).
When ducts are used, they shall be of the same cross sectional
area as the free area of the openings to which they connect.
The minimum dimension of rectangular air ducts shall be not less
than 3 inches.
16
Outdoor Air Through Two Vertical Ducts
When ducts are used, they shall be of the same cross sectional
area as the free area of the openings to which they connect.
The minimum dimension of rectangular air ducts shall be not less
than 3 inches.
The illustrations shown in this section of the manual are a
reference for the openings that provide fresh air into confined
spaces only.
Air From Other Indoor Spaces
Do not refer to these illustrations for the purpose of vent
installation. See Venting Installation on page 15 for complete
venting installation instructions.
Figure 18
The confined space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. See Figure 18.
Figure 17
The confined space shall be provided with two permanent vertical
ducts, one commencing within 12 inches (300 mm) of the top and
one commencing within 12 inches (300 mm) of the bottom of the
enclosure. The vertical ducts shall communicate directly with the
outdoors. See Figure 17.
Each opening shall communicate directly with an additional
room(s) of sufficient volume so that the combined volume of all
spaces meets the criteria for an Unconfined Space.
Each opening shall have a minimum free area of 1 square inch
per 1,000 Btu/hr (2200 mm2 per kW) of the aggregate input rating
of all appliances installed in the enclosure. Each opening shall
not be less than 100 square inches (645 cm2).
Each duct opening shall have a minimum free area of 1 square
inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input
rating of all appliances installed in the enclosure.
17
TABLE 7. 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 13) and tables
below which give sizing and data based upon NFPA 54/ANSI
Z223. 2006.
Model 500
Input: 500,000 btu/hr
Total Vent Height (Feet)
Vent connector size: 8 inches
6
8
10
15
30
50
100
9
8
8
7
9
9
8
8
7
9
9
8
7
7
30
50
100
Input (btu/hr)
Rise
500,000
1 Ft.
-
10
10
10
500,000
2 Ft.
10
10
10
500,000
3 Ft.
10
10
9
20
Vent Connector Diameter (Inches)
Multiple Fan Assisted Water Heaters
Total Vent Height (Feet)
Number of 500
Heaters
Combined
Input (btu/hr)
6
8
10
15
20
2
1,000,000
14
14
12
12
10
10
9
8
3
1,500,000
16
16
14
14
14
12
12
10
4
2,000,000
18
18
16
16
14
14
12
12
30
50
100
Manifold and Common Vent Diameter (Inches)
Combination of Multiple Fan Assisted and Natural Draft Water Heaters
Total Vent Height (Feet)
Number of 500
Heaters
Combined
Input (btu/hr)
6
8
10
15
20
2
1,000,000
16
14
14
14
12
12
10
9
3
1,500,000
18
18
16
16
14
14
12
10
4
2,000,000
20
20
18
18
16
16
14
12
Manifold and Common Vent Diameter (Inches)
18
water heater installation
Water Line Connections
This water heater is provided with a properly rated/sized and
certified combination temperature - pressure (T&P) relief valve
by the manufacturer. See Temperature-Pressure Relief Valve
on pages 13-14 for information on replacement and other
requirements.
This manual provides detailed installation diagrams (see pages
34-48 of this manual) for typical methods of application for the
water heater(s).
Water (potable) Heating And Space Heating
CAUTION
1. All piping components connected to this unit for space
heating applications shall be suitable for use with potable
water.
Water Damage Hazard
2. Toxic chemicals, such as those used for boiler treatment,
shall NEVER be introduced into this system.
• Temperature-Pressure Relief Valve discharge
3. This unit may NEVER be connected to any existing
heating system or component(s) previously used with a
non-potable water heating appliance.
pipe must terminate at adequate drain.
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 34-48 of this manual
for suggested piping arrangements.
Install a discharge pipe between the T&P valve discharge opening
and a suitable floor drain. Do not connect discharge piping
directly to the drain unless a 6” (15.2 cm) air gap is provided.
To prevent bodily injury, hazard to life, or property damage, the
relief valve must be allowed to discharge water in adequate
quantities should circumstances demand. If the discharge pipe is
not connected to a drain or other suitable means, the water flow
may cause property damage.
Thermometers (not Supplied)
Thermometers should be obtained and field installed as shown in
the installation diagrams.
T&P Valve Discharge Pipe Requirements:
Thermometers are installed in the system as a means of detecting
the temperature of the outlet water supply.
• Shall not be smaller in size than the outlet pipe size
of the valve, or have any reducing couplings or other
restrictions.
Water Piping Diagrams
This manual provides detailed water piping diagrams for typical
methods of application for the water heaters, see Water Piping
Diagrams beginning on page 34.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
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.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both
the Temperature-Pressure Relief Valve and the discharge
pipe.
• Must terminate a maximum of six inches above a floor
drain or external to the building. In cold climates, it is
recommended that the discharge pipe be terminated at an
adequate drain inside the building.
Adjust flow by throttling a full port ball valve installed in the
circulating line on the outlet side of the pump. Never throttle flow
on the suction side of a pump.
T&P Valve Discharge Pipe
• Shall not have any valve or other obstruction between the
relief valve and the drain.
The type, size and location of the relief valves must be in
accordance with local codes. The locations of the relief valves
shown in the installation diagrams are typical. See pages 34-48.
The heater has a factory installed high temperature limit switch
and temperature and pressure relief valve.
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
Cold water lines to heater should be installed as shown in
order to minimize gravity circulation of hot water to building
cold water lines.
Properly sized temperaturepressure relief valve must be
installed in opening provided.
A listed temperature and pressure relief valve of adequate capacity
is installed on the heater. The locations shown in the installation
diagrams on pages 34-48 are typical.
Can result in overheating and
excessive tank pressure.
The discharge opening of the temperature and pressure relief
valve must be piped to an open drain and should not be subject
to freezing temperatures.
Can cause serious injury or death.
Install in accordance with all local codes.
19
Installation Diagrams - Top Inlet/Outlet Usage
Code Restrictions
Use of the top inlet water connection requires installation of an
inlet dip tube (refer to figure 19). The tube is supplied in the
heater. Follow caution labels if applying heat to this fitting. Do
not allow pipe dope to contact the plastic tube during installation.
Use of the top inlet water connection is not permitted on
installations in the state of North Carolina, due to the material
of the tube (Polypropylene). Where such code restrictions exist,
use only lower inlet tank connection. This may also require a
heat trap - check local codes. The “Top Outlet” connection
may still be used on these applications. Plug or cap all unused
openings in the tank before filling with water.
Tube Inlet Installation
TEMPERATURE SETTING SHOULD NOT EXCEED
SAFE USE TEMPERATURE AT FIXTURES. SEE WATER
TEMPERATURE CONTROL AND MIXING VALVE WARNING
ON PAGE 12. IF HIGHER PREHEAT TEMPERATURES ARE
NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT,
ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED
TO FIXTURES.
Figure 19
20
Heater Wiring
All electrical work must be installed in accordance with the latest version of the National Electrical Code ANSI/NFPA No. 70 and
must conform to all local code authority having jurisdiction. AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF
ELECTRICAL SHOCK OR POSSIBLE ELECTROCUTION.
If any of the original wire as supplied with the appliance must be replaced, use only type 105°C thermoplastic or equivalent and 2500C
type F must be used for the flame sensor and igniter leads.
The controls of this water heater are polarity sensitive. Be certain to properly wire the hot and neutral connections.
FIGURE 20
21
Gas Piping
DISCONNECT THE HEATER AND ITS MANUAL GAS SHUTOFF
VALVE FROM THE GAS SUPPLY PIPING SYSTEM DURING ANY
SUPPLY PRESSURE TESTING EXCEEDING 1/2 PSIG. GAS
SUPPLY LINE MUST BE CAPPED WHEN DISCONNECTED
FROM THE HEATER. FOR TEST PRESSURES OF 1/2 PSIG OR
LESS THE APPLIANCE NEED NOT BE DISCONNECTED, BUT
MUST BE ISOLATED FROM THE SUPPLY PRESSURE TEST
BY CLOSING THE MANUAL GAS SHUTOFF VALVE.
Contact your local gas service company to ensure that adequate
gas service is available and to review applicable installation
codes for your area.
Size the main gas line in accordance with Table 9. The figures shown
are for straight lengths of pipe at 0.5 in. W.C. pressure drop, which is
considered normal for low pressure systems. Note: Fittings such as
elbows, tees and line regulators will add to the pipe pressure drop.
Also refer to the latest version of the National Fuel Gas Code.
GAS PIPING AND DIRT LEG INSTALLATION
Schedule 40 Metallic Pipe is the preferred material for the gas
line of this water heater. It is imperative to follow the sizing
recommendations in the latest version of the National Fuel Gas
Code if Corrugated Stainless Steel Tubing (CSST) is used as the
gas line for this water heater.
THE HEATER IS NOT INTENDED FOR OPERATION AT HIGHER
THAN 14.0” W.C.- NATURAL GAS, (1/2 POUND PER SQUARE
INCH GAGE) SUPPLY GAS PRESSURE. EXPOSURE TO
HIGHER SUPPLY PRESSURE MAY CAUSE DAMAGE TO THE
GAS VALVE WHICH COULD RESULT IN FIRE OR EXPLOSION.
IF OVERPRESSURE HAS OCCURRED SUCH AS THROUGH
IMPROPER TESTING OF GAS LINES OR EMERGENCY
MALFUNCTION OF THE SUPPLY SYSTEM, THE GAS VALVE
MUST BE CHECKED FOR SAFE OPERATION. MAKE SURE THAT
THE OUTSIDE VENTS ON THE SUPPLY REGULATORS AND THE
SAFETY VENT VALVES ARE PROTECTED AGAINST BLOCKAGE.
THESE ARE PARTS OF THE GAS SUPPLY SYSTEM, NOT THE
HEATER. VENT BLOCKAGE MAY OCCUR DURING ICE STORMS.
FIGURE 21
TABLE 9 - GAS SUPPLY PIPE LENGTH (FEET)
Schedule 40 metallic
pipe nominal dia.
3/4"
1"
1 1/4"
1 1/2"
2"
2 1/2"
Purging
500,000 btu/hr input rate
Gas line purging is required with new piping or systems in which
air has entered.
Maximum Equivalent Pipe Length (Feet)
Natural Gas
10
60
150
200
200
Propane
10
40
150
350
400
400
PURGING SHOULD BE PERFORMED BY PERSONS
EXPERIENCED IN THIS TYPE GAS SERVICE. TO AVOID RISK
OF FIRE OR EXPLOSION, PURGE DISCHARGE MUST NOT
ENTER CONFINED AREAS OR SPACES WHERE IGNITION CAN
OCCUR. THE AREA MUST BE WELL VENTILATED AND ALL
SOURCES OF IGNITION MUST BE INACTIVATED OR REMOVED.
GAS METER SIZE — NATURAL GASES ONLY
Natural Gas: 0.60 Specific Gravity, 0.50"W.C. pressure drop
Propane Gas: 1.50 Specific Gravity, 0.50"W.C. pressure drop
Be sure the gas meter has sufficient capacity to supply the full
rated gas input of the water heater as well as the requirements of
all other gas fired equipment supplied by the meter. If gas meter
is too small, ask the gas company to install a larger meter having
adequate capacity.
IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING
FROM CONTAMINANTS IN THE GAS WAYS. SUCH FOULING
MAY CAUSE IMPROPER OPERATION, FIRE OR EXPLOSION.
IF COPPER SUPPLY LINES ARE USED THEY MUST BE
INTERNALLY TINNED AND CERTIFIED FOR GAS SERVICE.
BEFORE ATTACHING THE GAS LINE, BE SURE THAT ALL GAS
PIPE IS CLEAN ON THE INSIDE.
Gas Pressure Regulator
The gas pressure regulator is built into the gas valve and is equipped to
operate on the gas specified on model and rating plate. The regulator
is factory adjusted to deliver gas to burner at correct water column
pressure allowing for a nominal pressure drop through the controls.
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. 21). THE DIRT LEG MUST BE READILY
ACCESSIBLE AND NOT SUBJECT TO FREEZING CONDITIONS.
INSTALL IN ACCORDANCE WITH RECOMMENDATIONS OF
SERVING GAS SUPPLIERS. REFER TO THE LATEST VERSION
OF THE NATIONAL FUEL GAS CODE.
The minimum gas supply pressure for input adjustment must not
be less than 4.5” W.C. (1.12 kPa) for natural gas or 11.0"W.C.
(2.74 kPa) for propane gas.
Do not subject the combination gas valve to inlet gas
pressures of more than 14.0” W.C. (3.48 kPa). A service regulator
is necessary if higher gas pressures are encountered.
To prevent damage, care must be taken not to apply too much
torque when attaching gas supply pipe to gas valve inlet.
The manifold gas pressure specified in Table 10 refers to the gas
pressure measured at the pressure tap of the automatic gas valve
when the burners are firing.
Apply joint compounds (pipe dope) sparingly and only to the male
threads of pipe joints. Do not apply compounds to the first two threads.
Use compounds resistant to the action of liquefied petroleum gases.
TABLE 10 - MANIFOLD GAS PRESSURE IN INCHES OF
WATER COLUMN (ALL MODELS*)
BEFORE PLACING THE HEATER IN OPERATION, CHECK FOR
GAS LEAKAGE. Use soap and water solution or other material
acceptable for the purpose in locating the leaks. DO NOT USE
MATCHES, CANDLES, FLAME OR OTHER SOURCES OF
IGNITION FOR THIS PURPOSE.
TYPE OF GAS
NATURAL
3.5 (0.87 kPa)
22
PROPANE
10.0 (2.49 kPa)
OPERATION
IMPORTANT
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 chamber to clear. IF YOU
DETECT GAS ODOR AT THE END OF THIS PERIOD DO NOT
PROCEED WITH LIGHTING. RECOGNIZE THAT GAS ODOR,
EVEN IF IT SEEMS WEAK, MAY INDICATE PRESENCE OF
ACCUMULATED GAS SOMEPLACE IN THE AREA WITH
RISK OF FIRE OR EXPLOSION. SEE THE FRONT PAGE FOR
STEPS TO BE TAKEN.
A qualified person must perform the initial firing of the heater. At
this time the user should not hesitate to ask the individual any
questions which they may have in regard to the operation and
maintenance of the unit.
An Operational Checklist is included on page 33 of this manual.
By using this checklist the user may be able to make minor
operational adjustments and avoid unnecessary service calls.
However, the user should not attempt repairs which are not listed
under the USER column.
All gas and water lines must be leak tested and open.
General
Read SEQUENCE OF OPERATION section of this manual prior
to lighting and operating this appliance.
NEVER OPERATE THE HEATER WITHOUT FIRST BEING
CERTAIN IT IS FILLED WITH WATER AND A TEMPERATURE
AND PRESSURE RELIEF VALVE IS INSTALLED IN THE
RELIEF VALVE OPENING OF THE HEATER.
With above conditions satisfied, start the unit in accordance with
the instructions on the operating label attached to the heater. For
your convenience a copy of the instructions are shown on page
24. Each heater is equipped with an ignition control board. The
controller will try three times to light the main burner before going
into lockout. After the controller tries three times, it will wait one
hour before trying to light the unit again. This cycle will continue
until the main burners are ignited or the unit is shut down.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL
TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL
VALVE TO THE APPLIANCE.
Before proceeding with the operation of the unit make sure
the water heater and system are filled with water and all air is
expelled.
ADJUSTMENTS
ON INITIAL STARTUP SOME ADJUSTMENTS ARE NECESSARY.
Filling
1. CHECK MANIFOLD AND INLET GAS PRESSURES.
1. Close the heater drain valve by turning handle clockwise.
2. Open a nearby hot water faucet to permit the air in the system
to escape.
3. Fully open the cold water inlet pipe valve allowing the heater
and piping to be filled.
4. Close the hot water faucet as water starts to flow.
5. The heater is ready to be operated.
2. CYCLE CHECK - CHECK AT LEAST ONE BURNER
OPERATION - WHEN THERMOSTAT IS SATISFIED,
BURNER WILL SHUT OFF AND INDUCER WILL STOP
RUNNING. ON CALL FOR HEAT - THE INDUCER WILL
COME ON AND CLOSE THE PRESSURE SWITCH AND THE
IGNITION SEQUENCE DESCRIBED ABOVE WILL BEGIN,
SEE “SEQUENCE OF OPERATION”.
SEQUENCE OF OPERATION
The following information will describe the Sequence of Operation
for this appliance.
Board waits 3 seconds and then shuts off power to the Silicon
Nitride Ignitor.
11. From the time the Silicon Nitride Ignitor’s power is shut off,
the Ignition Control Board waits 3 more seconds to monitor
the Flame Sensor.
1. Switch power on to unit.
2. Thermostat calls for heat.
3. Ignition Control Board performs diagnostic check on system
components.
12. If the Flame Sensor does not detect a strong enough flame,
the Ignition Control Board shuts off the Gas Valve and allows
the Exhaust Inducer to purge the unit for 20 seconds. At that
time, the Ignition Control Board restarts with step 7. It will try
and ignite the main burners 2 more times. If the unit does not
light, the Ignition Control Board will wait one hour and then
restart at step 3. This cycle will continue until the unit lights
or the power is shutoff to the unit.
4. On completion of diagnostics check, the Ignition Control Board
sends signal to Exhaust Inducer.
5. Exhaust Inducer begins drawing air through appliance closing
the Prover Switch.
6. On completion of Prover Switch engagement, the Ignition
Control Board begins the ignition cycle.
7. The Ignition Control Board provides power to the Silicon
Nitride Ignitor.
13. If the Flame Sensor detects a strong flame, the Ignition Control
Board will allow the unit to operate until the thermostat is
satisfied.
8. The Silicon Nitride Ignitor heats up for approximately 17 to
20 seconds.
9. At the end of Silicon Nitride Ignitor’s warm-up, the Ignition
Control Board opens the Gas Valve.
14. Once the unit is satisfied, the Ignition Control Board will shut
off the Gas Valve and the unit will be in standby mode until
another call for heat is initiated by the thermostat.
10. From the time the Gas Valve opens, the Ignition Control
See the flow chart on page 32 for more information.
23
Lighting & Operation Label
FOR YOUR SAFETY READ BEFORE OPERATING
you do not follow these instructions exactly, a fire or explosion
WARNING If
may result causing property damage, personal injury, or loss of life.
FLAMMABLE
If you cannot reach your gas supplier, call the fire department.
A. This appliance does not have a pilot. It is equipped with an ignition device which
automatically lights the burner. Do not try to light the burner by hand.
C. Use only your hand to push in or turn the gas control knob. Never use tools. If
B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell
next to the floor because some gas is heavier than air and will settle on the floor.
the knob will not push in or turn by hand, don't try to repair it. Call a qualified
service technician. Force or attempted repair may result in a fire or explosion.
"WHAT TO DO IF YOU SMELL GAS"
D. Do not use this appliance if any part has been under water. Immediately call a
Do not try to light any appliance.
Do not touch any electric switch; do not use any telephone in your building.
qualified service technician to inspect the appliance and to replace any part of
Immediately call your gas supplier from a neighbor's telephone. Follow the
gas suppliers instructions.
the control system and any gas control which has been under water.
OPERATING INSTRUCTIONS
1.
STOP! Read the safety information above on this label.
2. Set thermostat to lowest setting.
3. Turn off all electric power to the appliance.
GAS
CONTROL
KNOBS
PSI
IN
4. This appliance is equipped with an ignition device which automatically lights
the burner. Do not try to light the burner by hand.
5. Push in gas control knobs slightly and turn clockwise
6.
ON
to off.
Wait five(5) minutes to clear out any gas. If you then smell gas,
Follow "B" in the safety information above on this label. If you
OFF
STOP!.
don't
smell gas, go on to next step.
PSI
7.
Turn gas control knobs counterclockwise
8.
Turn on all electric power to the appliance.
9.
Set thermostat to desired setting.
10.
to "ON".
IN
If the appliance will not operate, follow the instructions "To Turn Off Gas To Appliance"
ON
OFF
and call your service technician or gas supplier.
FOR YOUR SAFETY READ BEFORE OPERATING
1.
Set the thermostat to lowest setting.
2.
Turn off all electric power to appliance if service is to be performed.
3.
Push in gas control knobs slightly and turn clockwise
FIGURE 22
24
to "OFF". Do not force.
Check Venting
The following steps shall be followed with each appliance
connected to the venting system placed in operation, while any
other appliances connected to the venting system are not in
operation.
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and horizontal pitch,
as required in the National Fuel Gas Code, ANSI Z223.1or the
CAN/CGA B149 Installation Codes and these instructions.
Determine that there is no blockage or restriction, leakage,
corrosion and other deficiencies which could cause an unsafe
condition.
FIGURE 23
Main Burner
The main burner, figure 24, should display the following
characteristics:
3. So far as is practical, close all building doors and windows
and all doors between the space in which the water heater(s)
connected to the venting system are located and other spaces
of the building. Turn on all appliances not connected to the
venting system. Turn on all exhaust fans, such as range hoods
and bathroom exhausts, so they shall operate at maximum
speed. Close fireplace dampers.
• Cause rapid ignition and carry across entire burner.
• Give reasonably quiet operation during ignition, burning, and
extinction.
• Cause no excessive lifting of flame from burner ports.
4. Follow the lighting instruction. Place the water heater being
inspected in operation. Adjust thermostat so appliance shall
operate continuously.
FIGURE 24
5. Test for spillage at the burner level after 5 minutes of main
burner operation.
If the preceding burner characteristics are not evident, check for
accumulation of lint, scale or other foreign debris that restricts or
blocks the air openings to the burner or heater.
6. After it has been determined that each water heater connected
to the venting system properly vents when tested as outlined
above, return doors, windows, exhaust fans, fireplace dampers
and any other gas burning appliance to their previous conditions
of use.
NOTE:
1.Remove main burners from unit.
2. Check that burner venturi and ports are free of foreign debris.
7. If improper venting is observed during any of the above tests,
the venting system must be corrected.
3. Clean burners with bristle brush and/or vacuum cleaner - DO
NOT distort burner ports or pilot location.
FAILURE TO CORRECT BACK DRAFTS MAY CAUSE AIR
CONTAMINATION AND UNSAFE CONDITIONS.
4.Reinstall burners in unit. Make sure front and rear of burners
are installed correctly in burner support brackets.
• If the back draft cannot be corrected by the normal method or
if a suitable draft cannot be obtained, a blower type flue gas
exhauster must be employed to assure proper venting and
correct combustion.
Also check for good flow of combustion and ventilating air to the
unit. Maintain a clear area around the heater at all times.
Gas Valves
Figure 25 shows the type of combination manual gas control valve
and regulator used on these heaters.
Check the Igniter Assembly
If the gas valve becomes defective, repairs should not be
attempted. A new valve should be installed in place of the
defective one.
At least once a year, check the igniter assembly, Figure 23, and
the main burner, Figure 24, for proper operation. Refer to the
following igniter assembly and main burner sections.
Igniter Assembly
For access to igniter assembly, unfasten two screws to burner
cover and remove. Locate the burner with the igniter assembly
and remove screw holding burner to manifold. Slide burner out
to access igniter assembly.
Servicing of the igniter assembly includes keeping the igniter free
of lint, scale or any other foreign debris.
FIGURE 25
25
Checking the Input
For appliance installation locations with elevations above 2000
feet, refer to HIGH ALTITUDE INSTALLATIONS section of this
manual for input reduction procedure.
Should it be necessary to adjust the gas pressure to the burners
to obtain the full input rate, the steps below should be followed:
(3600/7.56) X 1050 = 500,000 Btuh (Compare with the
BCG385T500-8N model and rating.)
1. Attach a pressure gauge or a manometer to the manifold
pressure tap on the gas valve and refer to Table 3, page 8 for
correct manifold pressure.
3. Remove the regulator adjustment sealing cap, fig. 25, and adjust
the pressure by turning the adjusting screw with a screwdriver.
2. Use this formula to “clock” the meter. Be sure that other gas consuming appliances are not operating during this interval.
Clockwise to increase gas pressure and input rate.
Counterclockwise to decrease gas pressure and input rate.
(3600/T) x H = Btuh
4. “Clock” the meter as in step 2 above.
T = Time in seconds to burn one cubic foot of gas.
5. Repeat steps 3 and 4 until the specified input rate is achieved.
6. Turn the gas control knob to PILOT. Remove the pressure
gauge and replace the sealing cap and the threaded plug in
the pressure tap opening.
H = Btu’s per cubic foot of gas.
Btuh = Actual heater input.
Example: (Using BCG385T500-8N heater)
UNDER NO CIRCUMSTANCES SHOULD THE GAS INPUT
EXCEED THE INPUT SHOWN ON THE HEATER MODEL AND
RATING PLATE. OVERFIRING COULD RESULT IN DAMAGE
OR SOOTING OF THE HEATER.
T = 7.56 seconds
H = 1050 Btu
Btuh = ?
mAINTENANCE
Venting System
When checking the Temperature-Pressure Relief Valve operation,
make sure that (1) no one is in front of or around the outlet of the
Temperature-Pressure Relief Valve discharge line, and (2) that
the water discharge will not cause any property damage, as the
water may be extremely hot. Use care when operating valve as
the valve may be hot.
Examine the venting system every six months for obstructions
and/or deterioration of the vent piping.
Remove all soot or other obstructions from chimney which will
retard free draft.
Remote Storage Tank Temperature Control
To check the relief valve, lift the lever at the end of the valve
several times, see Figure 26. The valve should seat properly and
operate freely.
The water temperature in the remote storage tank (if used) is
controlled by the storage tank temperature control. The sensing
element is mounted in the hot water storage tank, see Water
Piping Diagram section.
If after manually operating the valve, it fails to completely reset
and continues to release water, immediately close the cold water
inlet to the water heater and drain the water heater according to
the Draining and Flushing instructions on page 27. Replace the
Temperature-Pressure Relief Valve with a properly rated/sized new
one, see Temperature-Pressure Relief Valve on pages 13-14 for
instructions on replacement.
A change in water temperature in the storage tank lower than
the tank temperature control setting will cause the sensor to
activate the circulating pump. The pump then circulates the water
through the heater where the thermostat senses the drop in water
temperature and activates main burner operation of the appliance.
If the storage tank temperature control is out of calibration, replace
with new control.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL
TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE
TO THE APPLIANCE.
Temperature-Pressure Relief Valve Test
FIGURE 26
If the Temperature-Pressure Relief Valve on the water heater
weeps or discharges periodically, this may be due to thermal
expansion.
NOTE: Excessive water pressure is the most common cause of
Temperature-Pressure Relief Valve leakage. Excessive water
system pressure is most often caused by "thermal expansion"
in a "closed system." See Closed Water Systems and Thermal
It is recommended that the Temperature-Pressure Relief Valve
should be checked to ensure that it is in operating condition every
6 months.
26
Draining and Flushing
Expansion on page 13. The Temperature-Pressure Relief Valve is
not intended for the constant relief of thermal expansion.
Temperature-Pressure Relief Valve leakage due to pressure build
up in a closed system that does not have a thermal expansion
tank installed is not covered under the limited warranty. Thermal
expansion tanks must be installed on all closed water systems.
Burn harzard.
Hot water discharge.
DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF
VALVE OPENING. THIS CAN CAUSE PROPERTY DAMAGE,
SERIOUS INJURY OR DEATH.
Keep hands clear of drain
valve discharge.
It is recommended that the water heater storage tank be drained
and flushed every 6 months to reduce sediment buildup. The
water heater should be drained if being shut down during freezing
temperatures.
TO DRAIN THE WATER HEATER STORAGE TANK:
1. Turn off the electrical supply to the water heater.
2. Turn off the gas supply at the Main Gas Shutoff Valve if
the water heater is going to be shut down for an extended
period.
3. Ensure the cold water inlet valve is open.
4. Open a nearby hot water faucet and let the water run until
the water is no longer hot.
Hot Water Odor
On occasion, hot water may develop a strong odor. If this occurs
drain the heater completely, flush thoroughly, and refill. If the problem
persists, chlorination of the heater and replacement of magnesium
anodes with aluminum anodes may correct the condition.
5. Close the cold water inlet valve to the water heater.
6. Connect a hose to the water heater drain valve and terminate
it to an adequate drain.
7. Open the water heater drain valve and allow all the water to
drain from the storage tank.
Occasionally water softener companies recommend removal of
heater anodes for odor reasons.
8. Close the water heater drain valve when all water in the
storage tank has drained.
Unauthorized removal of the anode(s) will void the warranty. For
further information contact your dealer.
9. Close the hot water faucet opened in Step 4.
Anode Rod Inspection
10. If the water heater is going to be shut down for an extended
period, the drain valve should be left open.
CAUTION
TO FLUSH THE WATER HEATER STORAGE TANK:
Property Damage Hazard
1. Turn off the electrical supply to the water heater.
• Avoid water heater damage.
• Inspection and replacement of anode rod required.
2. Ensure the cold water inlet valve is open.
3. Open a nearby hot water faucet and let the water run until
the water is no longer hot. Then close the hot water faucet.
The heater tank is equipped with anode rods to provide corrosion
control. At least once a year the anode rods should be checked
to determine if replacement is necessary. Initially the anode rods
are approximately 7/8” in diameter with a 1/8” diameter steel core
wire running down the center of the anode material. THE ANODES
SHOULD BE REPLACED when the 1/8” diameter core wire is
visible as this means that the anode material has been expended
in the control of corrosion.
4. Connect a hose to the drain valve and terminate it to an
adequate drain.
5. Ensure the drain hose is secured before and during the
entire flushing procedure. Flushing is performed with system
water pressure applied to the water heater.
6. Open the water heater drain valve to flush the storage tank.
7. Flush the water heater storage tank to remove sediment and
allow the water to flow until it runs clean.
For models with top inlet and outlet, it is recommended that, before
removing the inner cover for cleaning, inspection or removal of
inner parts, you obtain two new nipple collars, part no. 9005783205.
The nipple collars on the heater will usually be damaged when
removed. New nipple collars will insure that the seal is such as to
prevent leakage of flue products when properly installed.
8. Close the water heater drain valve when flushing is
completed.
9. Remove the drain hose.
10. Fill the water heater - see Filling The Water Heater in this
manual.
NOTE: Anode rod inspection may need to be made more frequently
in areas subject to acid rain that obtains their water supply from
surface water as the low pH will accelerate anode activity.
11. Turn on the electrical supply to place the water heater back
in operation.
CAUTION: Close cold water inlet valve serving heater and open
nearby hot water faucet to relieve the pressure in the heater before
attempting to remove anode(s) for inspection.
12. Allow the water heater to complete several heating cycles to
ensure it is operating properly.
27
Recommended Procedure for Periodic Removal
of Lime Deposits from Tank Type Commercial
Water Heaters
NOTE: Un•Lime is not available for use in Canada.
The amount of calcium carbonate (lime) released from water is
in direct proportion to water temperature and usage, see chart.
The higher the water temperature or water usage, the more lime
deposits are dropped out of the water. This is the lime scale
which forms in pipes, heaters and on cooking utensils.
Observe handling instructions on label of product being used.
Lime accumulation not only reduces the life of equipment but also
reduces efficiency of the heater and increases fuel consumption.
1. Once a month the heater should be flushed. Open the drain
valve and allow two gallons of water to drain from the heater.
Inlet water valve should remain open to maintain pressure in
tank.
Hydrochloric base acids are not recommended for use on glass
lined tanks.
Tank Cleanout Procedure
The following practices will ensure longer life and enable the unit
to operate at its designed efficiency:
The usage of water softening equipment greatly reduces the hardness
of the water. However, this equipment does not always remove all of
the hardness (lime). For this reason it is recommended that a regular
schedule for deliming be maintained.
2. A cleanout opening is provided for periodic cleaning of the
tank. Gas must be shut off and heater drained before opening
cleanout.
The time between cleaning will vary from weeks to months
depending upon water conditions and usage.
To clean heater through cleanout opening, proceed as follows:
The depth of lime buildup should be measured periodically.
Heaters equipped with cleanouts will have about 2" of lime
buildup when the level of lime has reached the bottom of the
cleanout opening. A schedule for deliming should then be set
up,based on the amount of time it would take for a 1" buildup
of lime. It is recommended that the water heater initially be
inspected after 6 months.
3. Drain heater.
Example 1:
7. Inspect cleanout plate gasket, if new gasket is required,
replace with part no. 9004099215.
4. Remove outer cover plate from lower side of heater jacket.
5. Remove six (6) hex head screws securing tank cleanout plate
and remove plate.
6. Remove lime, scale, or sediment using care not to damage
the glass lining.
The initial inspection after 6 months shows 1/2" of lime accumulation.
Therefore, the heater should be delimed once a year.
8. Install cleanout plate. Be sure to draw plate up tight by
tightening screws securely.
Example 2:
9. Replace outer jacket cover plate.
The initial inspection after 6 months shows 2" of lime accumulation.
Therefore, the heater should be delimed every 3 months.
In some water areas the sediment might not be removed by this
method and may result in the water heater making rumbling or
boiling noises. To dissolve and remove these more stubborn
mineral deposits, A. O. Smith UN•LIME Professional Delimer
should be used.
Deliming Using Flo-Jug Method
UN•LIME in the 5 gallon size is recommended for deliming of all
models. Contact your local A.O. Smith dealer, distributor or, A.O.
Smith Water Products Company:
Telephone: (800) 433-2545
Fax: (800) 433-2515
Website: www.hotwater.com/parts
Prepare the Water Heater
To delime the water heater using the Flo-Jug method, first
prepare the heater for deliming.
Explosion Hazard
FIGURE 27.
Flammable hydrogen gases
may be present.
Deliming Solvents
Keep all ignition sources away
from faucet when turning on
hot water.
A. O. Smith recommends the use of UN•LIME for deliming. UN•LIME
is a patented food grade acid which is safe to handle and does not
create the harmful fumes which are associated with other products.
UN•LIME may be obtained from your dealer, distributor or A. O.
Smith Product Service Division. Order Part Number 9005416105,
1 gallon, packed 4 gallons per case or Part Number 9005417105,
5 gallon container.
Do not smoke or have open flame or sparks in vicinity of heater.
Do not mix UN•LIME with other chemicals. Do not allow contact
with magnesium, aluminum or galvanized metals.
28
Prepare the Up-N-Down Transfer Kit
The next step is the preparation of the Up-N-Down Transfer Kit,
if you have not already done so:
Chemical Hazard
1. With the 5 gallon Up-N-Down container in the vertical position,
unscrew the plastic vent cap in the handle and pierce the
plastic membrane over the vent boss under the cap to allow
the container to vent.
• Product contains phosphoric acid.
• Keep out of reach of children.
Note: If your container does not have the vent cap and vent
boss, drill a 3/16” hole in the handle. When you have finished
deliming you will be able to plug this drilled vent with the
stainless steel screw that is supplied with the kit.
• Use rubber or neoprene gloves.
UN•LIME contains phosphoric acid. In case of external contact,
flush with cool water. If irritation persists, get medical attention. If
swallowed, give 1 or 2 glasses of water or milk and call physician.
2. Remove the container’s cap and cut the plastic membrane
located in the 3/4” IPT opening in the cap. Take care to not
damage the threads.
Get immediate medical attention for contact with eyes. Keep out
of reach of children.
3. Find the 3/4” male adapter, apply teflon tape to the threaded
end and screw it into the 3/4” IPT opening in the cap.
NOTE: THE USE OF RUBBER OR NEOPRENE GLOVES IS
RECOMMENDED, ESPECIALLY IF YOU HAVE ANY OPEN
SORES OR CUTS TO AVOID UNNECESSARY IRRITATION
OR DISCOMFORT.
4. Put cap with male adapter back on the container and slide
3/4” hose over end of male adapter and fasten in place using
hose clamp provided.
1. Turn off fuel and/or power supply to heater. Also, turn off power
to any electrical device or equipment, which is attached, or
part of the system.
Delime using Flo-Jug Method
5. Slide the hose clamp over end of hose and slide hose over the
male adapter in the water heater drain opening and secure in
place using hose clamp.
2. Open hot water side of faucet closest to heater and allow
water to run until it is cool enough to handle safely.
3. Close cold water inlet valve to heater.
6. Lift container to the “Pour” Position, see Figure 28, being
careful to keep the vent in the handle above the liquid level
and pour the UN•LIME into the heater.
4. Connect hose to drain valve at bottom of heater and start
draining heater into suitable floor drain area.
5. Remove relief valve while heater is draining. NOTE: Do not
replace relief valve until deliming is completed. Relief valve
opening will also act as a vent in case of possible contact
between the delimer and the anode rod(s), which may
produce flammable hydrogen-air mixtures.
7. Lower container, you may have to place the container on its
empty carton to prevent the UN•LIME from flowing back into
the container.
8. Let UN•LIME remain in the heater for 5 minutes and then
lower the container to the “Drain” Position, see Figure 28.
6. If relief valve appears to be limed-up, place it in a clean glass or
plastic container adequate in size so that you can pour enough
UN•LIME® into the container to cover the valve and allow
space for foaming. When foaming stops, run fresh cool water
into the container and rinse the relief valve for a few minutes.
9. Deliming activity is indicated by foaming on the surface of the
UN•LIME. If there is deliming activity, repeat steps 6 thru 8.
Normally, lime removal will be completed within one hour.
Severe build-up of lime may take longer than an hour to complete
descaling.
7. If heater does not drain completely after a reasonable length
of time, turn off the main water supply valve to stop water from
entering the tank due to a by-pass problem or defective cold
water inlet valve. Also, check for clogged drain valve opening.
Heater must be completely drained before introducing UN•LIME.
Note: To check UN•LIME for continued use, place some scale
or white chalk in a glass with a small amount of UN•LIME. If
the material is vigorously dissolved by the UN•LIME, it can be
reused; if not, the UN•LIME should be replaced.
8. Remove the cleanout cover and place a clean plastic bucket
next to the cleanout opening.
Partially open the cold water inlet valve to allow time to
accomplish the following and then close the valve.
While the water is being run through the tank, insert a stiff
wire, copper tube flattened at one end or an opened wire coat
hanger through the cleanout opening and scrape out any
loose deposits of scale or sediment. This is an economical
way to avoid unnecessary usage of the deliming solution.
Repeat the opening and closing of the cold water inlet valve
as necessary but be sure the heater is completely drained
when ready to introduce the UN•LIME.
Upon completion, reinstall the cleanout cover and use a new
cleanout cover gasket (part number 9004099215).
Remove the drain valve.
9. Install the long plastic male adapter insert fitting into the drain
valve opening of heater after applying Teflon tape or paste to
threads. Tighten firmly by hand and use wrench or adjustable
pliers to check for secure connection. Do not over tighten to
avoid damage to threads and fittings.
FIGURE 28.
29
Ignition Module System
System Diagnostics
Your water heater is equipped with an ignition module that
incorporates a diagnostic system to assist in troubleshooting the
appliance. The indicator codes on the ignition module are as follows:
Before calling your service agent, the following checklist should
be examined to eliminate obvious problems from those requiring
replacement or servicing.
TABLE 11:
1 FLASH
2 FLASHES
3 FLASHES
4 FLASHES
6 FLASHES
• Check that “main manual gas shutoff 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.
7 FLASHES
• Check electrical supply to the appliance for possible blown
(or tripped) fusing or power interruption. Also check the 3
amp fuse on the front of the digital thermostat (Fig. 2).
8 FLASHES
System lockout (retries or cycles exceeded)
Pressure switch stuck close
Pressure switch stuck open
Open on high temperature limit switch (eco)
115 volt AC power reversed (check polarity)
Low flame sense signal (make sure flame sensor is in
burner flame)
Check ignitor
continuous flash -> continuous flame sensed > 5 seconds without
gas valve
• Is the water temperature in tank below the thermostat dial
setting on the appliance thermostat (calling for heat)?
continuous on -> internal control failure - replace ignition control
module.
• It is possible that the high limit (E.C.O.) has functioned to
shut off the appliance. See High Limit page 7 - High Limit
Switch for reset procedure. Contact your service agent if limit
continues to function to shut off appliance.
Use this diagnostic system in conjunction with the “OPERATIONAL
CHECKLIST” and the “SEQUENCE OF OPERATION” to
troubleshoot the appliance.
SERVICE
Electrical Servicing
The installer may be able to observe and correct certain problems
which may arise when the unit is put into operation. HOWEVER,
it is recommended that only qualified service agents, using
appropriate test equipment, be allowed to service the heater.
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN
SERVICING CONTROLS. WIRING ERRORS CAN CAUSE
IMPROPER AND DANGEROUS OPERATION.
As preliminary step, check wiring against diagram, check for
grounded, broken or loose wires. Check all wire ends to be sure
that they are making good contact.
VERIFY PROPER OPERATION AFTER SERVICING.
for your information
Start Up Conditions
Moisture from the products of combustion condense on the cooler
tank surfaces and form drops of water which may fall onto the
burner or other hot surfaces to produce a “sizzling” or “frying” noise.
SMOKE/ODOR
It is not uncommon to experience a small amount of smoke and
odor during the initial start-up. This is due to burning off of oil
from metal parts, and will disappear in a short while.
Operational Conditions
SMELLY WATER
The water heater has at least one anode rod for corrosion
protection of the tank. Certain water conditions will cause a
reaction between this rod and the water. The most common
complaint associated with the anode rod is one of a “rotten egg
smell” in the hot water. The smell is a result of four factors which
must all be present for the odor to develop:
STRANGE SOUNDS
Possible noises due to expansion and contraction of some metal
parts during periods of heat-up and cool-down do not necessarily
represent harmful or dangerous conditions.
Condensation causes sizzling and popping within the burner area
during heating and cooling periods and should be considered
normal. See “Condensation” in this manual.
a. A concentration of sulfate in the supply water.
CONDENSATION
b. Little or no dissolved oxygen in the water.
Whenever the water heater is filled with cold water, some
condensate will form while the burner is on. A water heater may
appear to be leaking when in fact the water is condensation.
This usually happens when:
c. A sulfate reducing bacteria which has accumulated
within the water heater (this harmless bacteria is
nontoxic to humans).
a. A new water heater is filled with cold water for the first time.
d. An excess of active hydrogen in the tank. This is caused
by the corrosion protective action of the anode.
b. Burning gas produces water vapor in water heaters,
particularly high efficiency models where flue temperatures
are lower.
Smelly water may be eliminated or reduced in some water heater
models by replacing the anode(s) with one of less active material,
and then chlorinating the water heater tank and all water lines.
c. Large amounts of hot water are used in a short time and the
refill water in the tank is very cold.
Contact the local water heater supplier or service agency for
30
system are used (such as a dishwasher or washing machine). If
hydrogen gas is present, there will probably be an unusual sound
similar to air escaping through the pipe as the hot water faucet
is opened. There must be no smoking or open flame near the
faucet at the time it is open.
further information regarding anode replacement and this
chlorination treatment.
If the smelly water persists after the anode replacement and
chlorination treatment, we can only suggest that chlorination or
aeration of the water supply be considered to eliminate the water
problem.
HIGH WATER TEMPERATURE SHUT OFF SYSTEM
Do not remove the anode leaving the tank unprotected. By doing
so, all warranty on the water heater tank is voided.
This water heater is equipped with an automatic reset type high
limit (Energy Cutoff) sensor. The high limit switch interrupts
the main burner gas flow should the water temperature reach
203°F (95°C).
“AIR” IN HOT WATER FAUCETS
HYDROGEN GAS: Hydrogen gas can be produced in a hot
water system that has not been used for a long period of time
(generally two weeks or more). Hydrogen gas is extremely
flammable and explosive. To prevent the possibility of injury
under these conditions, we recommend the hot water faucet,
located farthest away, be opened for several minutes before
any electrical appliances which are connected to the hot water
The high limit will automatically reset when the water temperature
drops below 120°F (49°C). After cooling the tank temperature,
turn off the water heater for at least 10 seconds by using the
switch on front of the control box. Turn on the water heater. If
this fails to correct the problem, contact your plumber or service
representative.
31
Sequence of Operation Flow Chart
Description of this flow chart can be found in the “SEQUENCE OF OPERATION” section found on page 23.
FIGURE 29
32
operational checklist
COMPLAINT
CAUSE
USER
REMEDY
Thermostat set too low.
Set thermostat dial to a higher
temperature
Upper and/or lower temperature
probe out of calibration.
Call service agent
Thermostat set too low.
Set thermostat dial to a higher
temperature
Upper and/or lower temperature
probe out of calibration.
Call service agent
Main manual gas shutoff valve
partially closed.
Open main manual gas shutoff
valve to fullest extent.
Heater too small for demand.
Space usage to give heater time
to restore water temperature.
Heater recovery is slower.
Call service agent
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 accumulation on
bottom of tank.
Ticking or metallic sounds.
Expansion and contraction normal.
Pounding.
Air chambers in piping have
become waterlogged.
Drain piping system and refill.
Heater must be off while this is
being done.
Too much primary air.
Call service agent.
Overfired heater; Incorrect
burners or orifice for type of gas
used.
Call service agent.
Drain valve not closed tightly.
If drain valve cannot be closed
tightly, replace.
Possible condensation if tank
is undersized or stored water is
below 110 degrees.
Increase tank temperature
setting (have service agent add
a mixing valve if setting will be
above 120 degrees).
If leakage source cannot be
corrected or identified, call
service agent.
Shut off gas supply to heater
and close cold water inlet valve
to heater.
Heater is over fired
Shut off gas supply to heater
and call a service agent.
*Water not hot enough
*Insufficient hot water
*See WATER TEMPERATURE
CONTROL WARNING (on page
12).
Combustion noises.
Water leaks.
Gas odors.
Possible gas leaks.
SERVICE AGENT
Check continuity and resistance (Ohms)
of upper and lower temperature probes.
Replace probes if out of specification.
Check continuity and resistance (Ohms)
of upper and lower temperature probes.
Replace probes if out of specification.
Check gas input. If incorrect, adjust gas
pressure or replace burner orifices.
Drain a quantity of water through
drain valve. If rumbling persists, Delime heater.
call a service agent.
Shut off gas supply to heater
and call gas company at once
33
Check and correct as necessary.
Repair or in case of suspected tank
leakage, be certain to confirm before
replacing heater.
Check for sooted flue passage.
Check for obstructed vent line.
Check backdraft or lack of draft
34
ALT. COLD WATER
CONNECTION
HOT WATER
TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (1 UNIT) WITH VERTICAL STORAGE TANK
COLD WATER
SUPPLY
EXPANSION
TANK
DRAIN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
HOT WATER RETURN
FROM FIXTURES
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
water Piping Diagrams
35
HOT WATER TO FIXTURES
ALTERNATE
LOCATION
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (1 UNIT) WITH HORIZONTAL STORAGE TANK
DRAIN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
RETURN FROM
FIXTURES
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
36
HOT
WATER
RETURN
TEMPERED
WATER
OUTLET
COLD
HOT
HOT
WATER
OUTLET
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
EXPANSION
TANK
COLD WATER
SUPPLY
TEMPERED
WATER
RETURN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (1 UNIT) WITH MIXING VALVE TWO TEMPERATURE
DRAIN
PIPE T&P TO
OPEN DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
37
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
PIPE T&P TO
OPEN DRAIN
HOT WATER
TO FIXTURES
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (2 UNITS)
COLD WATER
SUPPLY
EXPANSION
TANK
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
HOT WATER
RETURN
LEGEND
38
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (2 UNITS) WITH VERTICAL STORAGE TANK
ALTERNATE
COLD WATER
CONNECTION
HOT WATER
TO FIXTURES
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
COLD WATER
SUPPLY
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
EXPANSION
TANK
LEGEND
39
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (2 UNITS) WITH VERTICAL STORAGE TANK
ALTERNATE
COLD WATER
CONNECTION
HOT WATER
TO FIXTURES
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
COLD WATER
SUPPLY
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
EXPANSION
TANK
LEGEND
40
PIPE T&P TO
OPEN DRAIN
HOT WATER TO FIXTURES
DRAIN
EXPANSION
TANK
COLD WATER
SUPPLY
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
ALTERNATE
LOCATION
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE - (2 UNITS) WITH HORIZONTAL STORAGE TANK
LEGEND
HOT WATER
RETURN FROM
FIXTURES
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
41
EXPANSION TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
HOT WATER
TO FIXTURES
PRE-HEATED
WATER TO
BOOSTER
DRAIN
BOOSTER
HEATER
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
BOOSTER WATER RETURN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
BOOSTER WATER
TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
1st HEATER
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE (2 UNITS) TWO TEMPERATURE
LEGEND
42
PRE-HEATER
PRE-HEATER
MUST BE IDENTICAL HEATERS
PIPE T&P TO
OPEN DRAIN
DRAIN
BOOSTER RETURN
(IF USED)
EXPANSION
TANK
COLD WATER
SUPPLY
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
HOT OUTLET
AT STORED
TEMPERATURE
BOOSTED
WATER
OUTLET
TYPICAL
BOOSTER
HEATER
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE (2 UNITS) WITH BOOSTER TWO TEMPERATURE
LEGEND
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
43
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
PIPE T&P TO
OPEN DRAIN
HOT WATER
TO FIXTURES
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI-FLUE (3 UNITS)
DRAIN
EXPANSION
TANK
COLD WATER
SUPPLY
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
44
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
ALT. COLD WATER
CONNECTION
EXPANSION TANK
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
COLD WATER
SUPPLY
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
HOT WATER TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI-FLUE (3 UNITS) WITH VERTICAL STORAGE TANK
STORAGE TANK
45
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
STORAGE TANK
HOT WATER TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI-FLUE (3 UNITS) WITH HORIZONTAL STORAGE TANK
ALTERNATE
LOCATION
PIPE T&P TO
OPEN DRAIN
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
EXPANSION TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
46
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
FINISHED FLOOR
HOT WATER
TO FIXTURES
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI FLUE FLUE (4 UNITS)
PIPE T&P TO
OPEN DRAIN
DRAIN
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
COLD WATER
SUPPLY
EXPANSION
TANK
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
47
HEATER
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI-FLUE (4 UNITS) WITH VERTICAL STORAGE TANK
STORAGE TANK
ALT. COLD
WATER
CONNECTION
HOT WATER
TO FIXTURES
DRAIN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
48
HEATER
HEATER
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
DRAIN
STORAGE TANK
ALTERNATE
LOCATION
PIPE T&P TO
OPEN DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
HOT WATER
TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
HEATER
PIPE T&P TO
OPEN DRAIN
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
MULTI-FLUE (4 UNITS) WITH HORIZONTAL STORAGE TANK
LEGEND
EXPANSION TANK
COLD WATER
SUPPLY
HOT WATER
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
MANIFOLD KITS
Manifold Kits
TWO UNIT MANIFOLD KIT
(PART NO. 9003426205)
MODEL
(A)BCG385T500-8N/
(A)BCG385T500-8P
DIMENSION "A"
81.5"
THREE UNIT MANIFOLD KIT
(PART NO. 9003427205)
FOUR UNIT MANIFOLD KIT
(PART NO. 9003428205)
49
COMMERCIAL STORAGE TANK warranty
A. WHO IS COVERED
AMERICAN WATER HEATER COMPANY, (herein collectively referred to as “Manufacturer”) warrants only to the original purchaser (hereinafter
“Owner”) of the storage tank for the period specified below. This warranty is not transferable. The warranty is restricted to the storage tank used
in a commercial application in the United States of America.
B. WHEN IT IS COVERED
The storage tank is warranted only when it is installed, operated and maintained in accordance with the printed instructions accompanying the
storage tank. A storage tank should be installed in such a manner that, if the tank or any connection thereto should leak, the resulting flow of water
will not cause damage to the area in which it is installed. A systems temperature and pressure relief valve must be piped to the nearest drain to
avoid damage in the event the valve is actuated. For detailed instructions read the manual accompanying the water heater and review drawings
in the manual.
C. WHAT THE MANUFACTURER WILL DO AND THE PERIOD OF COVERAGE
1. The Inner Tank - If the inner tank leaks within three years after the original installation, Manufacturer will furnish a new storage tank
of Manufacturer’s then prevailing comparable model. If industry standards, product improvements or product obsolescence prohibits
Manufacturer from furnishing an identical model replacement water heater under this warranty, the Owner will be furnished with a new
storage tank of comparable capacity; however, the Owner will be charged for the additional value of the item(s) which Manufacturer has
incorporated in the replacement storage tank. A prior authorization number must be obtained from the Manufacturer before replacing the
storage tank. This warranty is limited to one replacement storage tank at the original installation site.
2. Component Part - If any component part other than the inner tank proves to Manufacturer’s satisfaction to be defective in material or
workmanship within one year after original installation, the Manufacturer will furnish the Owner with a replacement for the defective part(s).
This warranty is limited to one replacement component part for each original part.
3. Return of Defective Storage Tank and Component Parts - Manufacturer reserves the right to examine the alleged defect in the storage
tank or component part(s), and it will be the Owner’s obligation (see paragraph D.5) to return the storage tank and/or component part(s) to the
Manufacturer.
a.When returning a storage tank it must include ail component parts and the data plate label.
b.When returning component part(s), they must be individually tagged and identified with the storage tank’s product number, model number,
serial number, date of purchase and date of installation.
D. WHAT THIS WARRANTY DOES NOT COVER
1. THE LIMITED WARRANTY STATED HEREIN IS IN LIEU OF ANY AND ALL WARRANTIES, EXPRESS OR IMPLIED (WHETHER
WRITTEN OR ORAL), INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE.
2. MANUFACTURER SHALL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL, SPECIAL OR CONTINGENT DAMAGES OR
EXPENSES, ARISING, DIRECTLY OR INDIRECTLY, FROM ANY DEFECT IN THE STORAGE TANK OR THE USE OF THE STORAGE TANK.
3. Manufacturer shall not be liable for any water damage arising, directly or indirectly, from any defect in the storage tank or component part(s)
or from its use.
4. Manufacturer shall not be liable under this warranty and this warranty shall be void and have no effect if the following events occur:
a.The storage tank or any of its component parts have been subject to misuse, alteration, neglect or accident; or
b.The storage tank has not been installed in accordance with the applicable local plumbing and/or building code(s) and/or regulations; or
c.The storage tank is not installed, operated and maintained in accordance with the printed Manufacturers instructions; or
d.The storage tank or any part has been under water; or
e.The storage tank is exposed to highly corrosive atmospheric conditions; or
f. The storage tank is not continuously supplied with potable water; or
g.The storage tank replacement is requested for reasons of noise, taste, odor, discoloration and/or rust; or
h.The storage tank is not operated within the factory calibrated temperature limits; or
i. The storage tank is supplied or operated with desalinated (deionized) water; or
j. The storage tank is removed from its original installation location; or
k.The storage tank is installed outdoors (this storage tank is intended only for indoor installation); or
l. The storage tank or any of its component parts fail due to lime and/or sediment build-up; or
m.The storage tank does not have installed a temperature and pressure relief valve, certified to ANSI Z21.22 and approved by the American
Society of Mechanical Engineers; or
n.The storage tank or any of its component parts fail because of fire, floods, lightening, or any other act of God; or
o.The storage tank is installed in a closed system without adequate provision for thermal expansion.
5.Except when specifically prohibited by the applicable state law, the Owner, and not the Manufacturer, shall be liable for and shall pay for all
charges for labor or other expenses incurred in the removal, repair or replacement of the water heater or any component part(s) claimed to
be defective or any expense incurred to remedy any defect in the product. Such charges may include, but are not necessarily limited to:
a.All freight, shipping, handling and delivery costs of forwarding a storage tank or replacement part(s) to the owner.
b.All costs necessary or incidental in removing the defective storage tank or component part(s) and installing a new storage tank or component part(s).
c.Any material required to complete, and/or permits required for, installation of a new storage tank or replacement part(s), and
d.All costs necessary or incidental in returning the defective storage tank or component part(s) to a location designated by the manufacturer.
6. The terms of this Limited Warranty cannot be modified by any person, whether or not he/she claims to represent or act on behalf of the
Manufacturer.
E.HOW STATE LAW MAY RELATE TO THIS WARRANTY
Some States do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you. Similarly, some States do
not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. Further, this
warranty gives you specific legal rights and you may also have other rights, which may vary from State to State.
F.HOW THE ORIGINAL OWNER CAN MAKE A WARRANTY CLAIM
1. The Owner should submit the warranty claim directly to Manufacturer’s Service Department, at the address or phone number listed below,
and Manufacturer will arrange for the handling of the claim and if valid, will give the Owner an authorization number which must appear on
any document presented for warranty exchange.
2. Whenever any inquiry or request is made, be sure to include the storage tank’s product number, model number, serial number, date of
purchase, date of installation, maintenance records, and location of installation.
FOR TECHNICAL ASSISTANCE, SERVICE OR WARRANTY INFORMATION
PHONE TOLL FREE: 1-800-456-9805
MONDAY THROUGH FRIDAY 8:00 AM to 8:00 PM EASTERN STANDARD TIME
OR Write to:
American Water Heater Company ATTN.: PRODUCT SERVICES COMMERCIAL DEPARTMENT
P.O. BOX 1597 JOHNSON CITY, TN 37605-1597
50
notes
P.O. Box 1597, Johnson City, TN 37605
Phone: 800-456-9805 • Fax: 800-999-5210
www.americanwaterheater.com
Copyright © 2010 American Water Heater Company. All rights reserved.
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