American Water Heater Heavy Duty Commercial Gas BCG3 User Manual

							 COMMERCIAL GAS WATER HEATERS
Instruction Manual
PRINTED 1215  197935-006
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
MODELS BCG3 & ABCG3
SERIES 118/119
INSTALLATION - OPERATION - SERVICE  
- MAINTENANCE - LIMITED WARRANTY
Read and understand this instruction
m anual and the safety message s
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in deat h
or serious injury.
T his manual must remain with th e
water heater.Thank you for buying this energy efficient water heater. 
We appreciate your confidence in our products.
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  b y  a  qualified  installer,
service agency or the gas supplier.•
•
•
•
www. americanwaterheate r.co m
American Wa ter Heater
Johnson City, TN 37605
LOW LEADCONTENT 
						

							2Air From Other Indoor Spaces ........................................................
18
Technical Data Venting .............................................................. 19 -20
Mechanical Venting  ......................................................................... 21
WATER HEATER INSTALLATION ................................................. 21-24
Water Line Connections .................................................................. 21
T&P Valve Discharge Pipe .............................................................. 21
Installation Diagrams - Top Inlet /Outlet Usage ............................... 22
Heater Wiring  .................................................................................. 23
Gas Piping  ....................................................................................... 24
Gas Line Leak Testing .................................................................... 24
Purging  ............................................................................................ 24
OPER ATION  ........................................................................................ 25
Prior to Start Up .............................................................................. 25
SEQUENCE OF OPER ATION ............................................................ 25
Sequence of Operation Flow Chart ................................................ 26
Lighting & Operation Labels ...................................................... 27-2 8
Adjustments ..................................................................................... 29
Checking Venting  ............................................................................ 29
Checking the Input .......................................................................... 29
MAINTENANCE  ................................................................................... 31
Venting System  ............................................................................... 31
Remote Storage Tank Temperature Control ................................... 31
Temperature-Pressure Relief Valve Test ........................................ 31
Anode Rod Inspection ................................................................ 31- 32
Draining and Flushing  ..................................................................... 32
Recommended Procedure for Periodic Removal or Lime Deposits 
from the Tank Type Commercial Water Heaters ............................ 32
DeLiming Solvents  .......................................................................... 33
Tank Cleanout Procedure ............................................................... 33
Deliming Using Flo-Jug Method  ................................................33-34
Pilot Burner ...................................................................................... 34
Main Burner  ..................................................................................... 35
Gas Control Valve  ........................................................................... 35
SERVICE  ............................................................................................. 35
Electrical Servicing  ......................................................................... 35
TROUBLESHOOTING  ......................................................................... 36
Ignition Module  ................................................................................ 36
Flue Damper  .................................................................................... 36
Effikal RVGP-KSF Series Flue Damper Trouble Shooting Guide ........ 37
Troubleshooting Checklist  ............................................................... 38
FOR YOUR INFORMATION ................................................................ 39
Start up Conditions ......................................................................... 39
Operational Conditions  ................................................................... 39
WATER PIPING DIAGR AMS .......................................................... 40-54
MANIFOLD KITS ................................................................................. 55
NOTES  ............................................................................................ 56-58
WARR ANT Y  ........................................................................................ 59
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE ........................................ 3
APPROVALS  .......................................................................................... 3
GENER AL SAFET Y INFORMATION ................................................. 4-5
Precautions  ....................................................................................... 5
Grounding Instructions ...................................................................... 5
Hydrogen Gas Flammable ................................................................ 5
INTRODUCTION  ................................................................................... 6
Abbreviations Used  ........................................................................... 6
Qualifications  .................................................................................... 6
Preparing for the Installation ............................................................. 6
FEATURES AND COMPONENTS ........................................................ 7
The Eliminator (Self Cleaning System) ............................................. 7
High Limit Switch  ............................................................................... 7
Electronic Ignition Control ................................................................. 7
Automatic Flue Damper .................................................................... 7
Uncrating  ........................................................................................... 7
INSTALLATION CONSIDERATIONS  ...............................................8 -12
Rough In Dimensions  ........................................................................ 8
Locating The Water Heater ............................................................. 10
Clearances  ...................................................................................... 10
NSF Leg Kit ...................................................................................... 11
Insulation Blanket  ............................................................................. 11
Hard Water ....................................................................................... 11
Circulation Pumps  ....................................................................... 11 -12
High Altitude Installations  ............................................................... 12
INSTALLATION REQUIREMENTS  .....................................................13
Gas Supply Systems  ....................................................................... 13
Supply Gas Regulator ..................................................................... 13
Power Supply .................................................................................. 13
Water Temperature Control and Mixing Valves .............................. 13
Dishwashing Machines  ................................................................... 14
Closed Water Systems .................................................................... 14
Thermal Expansion  ......................................................................... 14
Temperature-Pressure Relief Valve ...........................................14 -15
Contaminated Air  ............................................................................ 15
Air Requirements  ............................................................................ 15
Unconfined Space  ........................................................................... 16
Confined Space  ............................................................................... 16
VENTING INSTALLATION  .................................................................. 16
Venting  ............................................................................................ 16
Vent Reducer .................................................................................. 16
Multiple Heater Manifold ................................................................. 17
Fresh Air Opening for Confined Spaces ......................................... 17
Outdoor Air Through Two Openings ............................................... 17
Outdoor Air Through One Opening ................................................ 17
Outdoor Air Through Two Horizontal Ducts .................................... 17
Outdoor Air Through Two Vertical Ducts ........................................ 18  
						

							3
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.
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.
DANGER
W ARNING
CAUTION
CAUTION
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
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 possibl
e
injury or death .
W ARNING indicates a potentially hazardou s
situation which, if not avoided, could resul t
in injury or death.
CAUTION indicates a potentially hazardou s
situation which, if not avoided, could result in
minor or moderate injury .
CAUTION used without the safety aler t
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
APPROVALS
Note: ASME construction is optional on the water heaters covered in this manual.
LOW LEAD
CONTENT  
						

							4
GENERAL SAFETY INFORMATION
Fire or Explosion Hazard
Read instruction manual befor e
installing, using or servicing water heater .
Avoid all ignition sources if you smell gas .
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating label.
Keep ignition sources away from faucets after extended
periods of non-use. Maintain required clearances to combustibles. Do not expose water heater controls to excessive gas
pressure.
Property Damage Hazard
All water heaters eventually leak.
Do not install without adequate drainage.
CAUTION
Tu
rn of f power to the water heater
before performing any service .
Electrical Shock Hazard

Label all wires prior to disconnecting
when performing service. Wiring error s
can cause improper and dangerous
operation.
Ve rify proper operation after servicing.
Failure to follow these instructions ca n
result in personal injury or death.
Fire and Explosion Hazar d
Leak test before placing the
water heater in operation.
Disconnect gas piping and main
gas shutof f valve before leak
testing.
Install sediment trap in
accordance with NF PA 54.
Use joint compound or 
Teflon tape
compatible with propane gas .
Fire Hazard
 For continued protection agains t
risk of fire:
 Do not install water heater on
carpeted floo r.
 Do not operate water heater if
any part has been exposed to  
flooding or water damage.
Fire and Explosion Hazar d
Turn of f gas lines during installation.
Contact a qualified installer or servic e
technician for installation and service.
Excessive gas pressure to gas valve ca n
cause serious injury or death. Do not use water heater with any gas
other than the gas shown on the rating
label.  
Jumping out control circuits or components can
result in property damage, personal injury or death.
Service should only be performed by a qualified service
technician 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 .
Any bypass or alteration of the water
heater controls and/or wiring will result in voiding the water heater 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.
  
						

							5
PRECAUTIONS
DO  NOT  USE  THIS WATER HEATER  IF  ANY  PART  HAS 
BEEN  EXPOSED  TO  FLOODING  OR  WATER  DAMAGE. 
Immediately call a qualified service technician to inspect the 
water  heater  and  to  make  a  determination  on  what  steps 
should be taken next.
If the unit is exposed to the following, do not operate heater 
until  all  corrective  steps  have  been  made  by  a  qualified 
service technician.
1.  External fire.
2.  Damage.
3.  Firing without water.
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, 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.
HYDROGEN GAS FLAMMABLE
Explosion Hazard
Flammable hydrogen gases
may be present .
Keep all ignition sources away
from faucet when turning on
hot water.
Hydrogen  gas  can  be  produced  in  a  hot  water  system  served 
by this water heater that has not been used for a long period of 
time (generally two weeks or more). Hydrogen gas is extremely 
flammable.  To  reduce  the  risk  of  injury  under  these  conditions, 
it  is  recommended  that  a  hot  water  faucet  served  by  this  water 
heater 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.
GENERAL SAFETY INFORMATION
Verify the power to the water heater is turned off before performing any \
service procedures.
Read and understand this instructio n
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 .
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury .
Feel water before bathing or
showering.
Te mperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Explosion Hazard
Overheated water can caus e
water tank explosion.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
GENERAL SAFETY INFORMATION
Improper installation, use and service may result in property damage.
 Do not operate water heater if any part has been exposed 
to flooding or water damage.
 Inspect 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 .
CAUTION  
						

							6
INTRODUCTION
Thank  You  for  purchasing  this  water  heater.  Properly  installed 
and maintained, it should give you years of trouble free service.
ABBREVIATIONS USED
Abbreviations found in this Instruction Manual include :•  ANSI - American National Standards Institute
•  ASME - American Society of Mechanical Engineers
•  AHRI - Air-Conditioning, Heating and Refrigeration Institute
•  NEC - National Electrical Code
•  NFPA - National Fire Protection Association
•  UL - Underwriters Laboratory
•  CSA - Canadian Standards Association
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 
below) in the field involved. Installation skills such as plumbing, 
air supply, venting, gas supply and electrical supply are required 
in addition to electrical testing skills when performing service.
ANSI Z223.1 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.”
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.
PREPARING FOR THE INSTALLATION
1.  Read  the  “General  Safety”  section,  page  4-5  of  this  manual 
first  and  then  the  entire  manual  carefully.    If  you  don’t  follow  the  safety  rules,  the  water  heater  will  not  operate  properly.  
It  could  cause  DEATH,  SERIOUS  BODILY  INJURY AND/OR 
PROPERTY DAMAGE.
  This manual contains instructions for the installation, operation, 
and maintenance of the gas-fired water heater.  It also contains 
warnings  throughout  the  manual  that  you  must  read  and  be 
aware of.  All warnings and all instructions are essential to the 
proper operation of the water heater and your safety.  Since we 
cannot put everything on the first few pages, READ THE ENTIRE 
MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE 
THE WATER HEATER.
2.   The  installation  must  conform  with  these  instructions  and  the 
local code authority having jurisdiction. In the absence of local 
codes,  the  installation  must  comply  with  the  current  editions   
of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or CAN/
CSA-B149.1  the  Natural  Gas  and  Propane  Installation  Code. 
All  documents  are  available  from  the  Canadian  Standards 
Association,  8501  East  Pleasant  Valley  Road,  Cleveland,  OH 
44131.  NFPA  documents  are  also  available  from  the  National 
Fire Protection Association, 1 Batterymarch Park, Quincy, MA 
02269. 
3.   If  after  reading  this  manual  you  have  any  questions  or  do 
not understand any portion of the instructions, call the local   
gas utility or the manufacturer whose name appears on the 
rating plate.
4.   Carefully  plan  the  place  where  you  are  going  to  put  the 
water heater. Correct  combustion, vent action, and vent pipe 
installation are very important in preventing death from possible 
carbon monoxide poisoning and fires.
  E x a m i n e  t h e  l o c a t i o n  t o  e n s u r e  t h e  w a t e r  h e a t e r  c o m p l i e s  w i t h 
the “Locating the New Water Heater” section in this manual.
5.   For  California  installation  this  water  heater  must  be  braced, 
anchored,  or  strapped  to  avoid  falling  or  moving  during 
an  earthquake.  See  instructions  for  correct  installation 
procedures.  Instructions  may  be  obtained  from  California 
Office  of  the  State  Architect,  400  P  Street,  Sacramento,   
CA 95814.
6.   Massachusetts Code requires this water heater to be installed in 
accordance with Massachusetts 248-CMR 2.00: State Plumbing 
Code and 248-CMR 5.00. 
						

							7
THE ELIMINATOR (SELF-CLEANING SYSTEM)
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  pipe  nipple  portion  of  the  Eliminator,  that 
must be aligned with top of inlet spud. A label above the jacket hole 
has an arrow that will point to marked portion of  pipe nipple if the 
orientation is correct. If the arrow does not point within the marked 
range on pipe nipple, adjust the pipe nipple to correct. A pipe union 
is supplied with the Eliminator to reduce probability of misaligning 
the Eliminator accidentally while tightening the connection to inlet 
water supply line. Improper orientation of the Eliminator can cause 
poor performance of heater and can significantly reduce outlet water 
temperatures during heavy draws.
Note: The Eliminator may have 1, 3 or 7 cross tubes.
FIGURE 1.
HIGH LIMIT SWITCH
The  digital  thermostat  (Figure  2)  contains  the  high  limit  (energy 
cutout) switch. The high limit switch interrupts main burner gas flow 
should the water temperature reach 203°F (95°C).
In the event of high limit switch operation, the water heater cannot be 
restarted unless the water temperature is reduced to approximately 
120°F (49°C). The high limit reset button on the front of the control 
then needs to be depressed.
Continued manual resetting of high limit control, preceded by higher 
than usual water temperature is evidence of high limit switch operation. 
The following is a possible reason for high limit switch operation:
• A malfunction in the thermostatic controls would allow the gas 
control  valve  to  remain  open  causing  water  temperature  to 
exceed the thermostat setting. The water temperature would 
continue to rise until high limit switch operation.
Contact your dealer or service agent if continued high limit switch 
operation occurs.
DIGITAL THERMOSTAT
FIGURE  2.
ELECTRONIC IGNITION CONTROL
Each  heater  is  equipped  with  a  Honeywell  ignition  module. 
The  solid  state  ignition  control  ignites  the  pilot  burner  gas 
by creating a spark at the pilot assembly. See Figure 3. Pilot 
gas  is  ignited  and  burns  during  each  running  cycle.  The 
main burner and pilot gases are cut off during the OFF cycle. 
Pilot gas ignition is proven by the pilot sensor. Main burner 
ignition will not occur if the pilot sensor does not first sense 
pilot ignition.
IGNITION  MODULE
FIGURE 3.
AUTOMATIC FLUE DAMPER
All  units  are  equipped  with  an  automatic  flue  damper  that 
reduces heat loss during the OFF cycles.
Each automatic flue damper drive assembly is equipped with a  
“Service Switch”, as shown in Figure 4
The  “Service  Switch”  has  2  positions:  AUTOMATIC 
OPER ATION and HOLD OPEN DAMPER. For normal operation 
the switch should be in the AUTOMATIC OPER ATION position.
If there is a problem with the damper the “Service Switch” can 
be placed in the HOLD OPEN DAMPER position. When the 
switch  is  placed  in  the  HOLD  OPEN  DAMPER  position  the 
damper disc will rotate to the open position and the heater may 
be used until vent assembly is repaired or replac ed. DO NOT 
t u r n  t h e  d a m p e r  d i s c  m a n u a l l y ;  d a m a g e  w i l l  o c c u r  t o  t h e  d r i v e 
assembly if operated manually. Refer to TESTING DAMPER 
OPER ATION section of this manual for additional information.
FLUE DAMPER
FIGURE 4.
UNCRATING
The heater is shipped with the flue damper already installed. The
wiring conduit runs from the thermostat to the damper drive cover.
Before turning unit on, check to make sure the wiring conduit is
securely plugged into damper drive.
FEATURES AND COMPONENTS  
						

							8
ROUGH IN DIMENSIONS
INSTALLATION CONSIDERATIONS
TABLE 1. BCG370T1205_ THROUGH (A)BCG3100T3998_ 
MODELINPUT 
RATE 
BTU/HR.APPROX. TANK  CAP. A
BC D EFGAS INLET G HVENT 
DIA.  I J CONNECTIONS
APPROXIMATE 
SHIP WEIGHT
INLET OUTLET
TOP FRONT BACKTOPFRONT BACKSTD.ASME
BCG3 
70T120 120,000 
BTU/Hr.
35 Kw/Hr 71 Gal
268 L
69-3/4”  
177 cm 4-1/4” 
11 cm 59-1/2”  
151 cm 50-7/8”  
129 cm19-11/16”  50 cm 19” 
48 cm 1/2” 
1/2”51-7/8” 
132 cm 6” 
15 cm 27-3/4” 
71 cm 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT400 Lbs
182 Kg NA
NA
BCG3 
80T150 154,000 
BTU/Hr
45 Kw/Hr 81 Gal
307 L
73” 
185 cm 4-1/4” 
11 cm 66-1/2” 
169 cm 57-7/8”  
147 cm19-11/16”  50 cm 19”
48 cm 1/2” 
1/2”59” 
150 cm 6”
15 cm 27-3/4” 
71 cm 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT470 Lbs
213 Kg NA
NA
BCG3 
80T180 180,000 
BTU/Hr
53 Kw/Hr 81Gal
307 L
67-1/2”  
171 cm 4-1/2” 
12 cm 62” 
157 cm 53-5/8”  
136 cm 20-1/2”  
52 cm 21”
53 cm 1/2” 
1/2”54-5/8”  
139 cm 6”
15 cm 27-3/4”  
71 cm 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT470 Lbs
213 Kg NA
NA
BCG3 
100T199 199,000 
BTU/Hr 
58 kW/Hr 100 Gal
379 L
75” 
192 cm 4-1/2” 
12 cm 70” 
178 cm 61-5/8”  
157 cm 20-1/2”  
52 cm 21”
53 cm 1/2” 
1/2”62-58” 
159 cm 6”
15 cm 27-3/4”
71 cm 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT603 Lbs
273 Kg NA
NA
BCG3 
80T199 199,000 
BTU/Hr 
58 kW/Hr 81 Gal
307 L
67-1/2”  
171 cm 4-1/2” 
12 cm 62” 
157 cm 53-5/8”  
136 cm 20-1/2”  
52 cm 21”
53 cm 1/2” 
1/2”54-5/8”  
139 cm 6”
15 cm 27-3/4”  
71 cm 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT470 Lbs
213 Kg NA
NA
(A)BCG3  100T200 199,000 
BTU/Hr 
58 kW/Hr 100 Gal
379 L
72”  
183 cm 4-1/2” 
12 cm 65-1/8” 
165 cm 55-7/8”  
142 cm 19-3/4”  
50 cm 23”
58 cm 1/2” 
1/2”56-3/8”  
143 cm 6”
15 cm 30-1/4”  
77 cm 1-1/2" NPT
1-1/2" NPT 2" NPT
2" NPT2" NPT
2" NPT1-1/2" NPT
1-1/2" NPT 2" NPT
2" NPT2" NPT
2" NPT630 Lbs
286 Kg 725 Lbs
329 Kg
(A)BCG3  100T250 250,000 
BTU/Hr 
72 kW/Hr 100 Gal
379 L
72” 
183 cm 4-1/2” 
12 cm 65-1/8” 
165 cm 55-7/8”  
142 cm 19-1/4”  
50 cm 23”
58 cm 1/2” 
1/2”56-3/8”
143 cm 8”
20 cm 30-1/4”  
77 cm 1-1/2" NPT
1-1/2" NPT 2" NPT
2" NPT2" NPT
2" NPT1-1/2" NPT
1-1/2" NPT 2" NPT
2" NPT2" NPT
2" NPT630 Lbs
286 Kg 725 Lbs
329 Kg
(A)BCG3  65T250 251,000 
BTU/Hr 
73 kW/Hr 65 Gal
246 L
75” 
191 cm 4-1/2” 
12 cm 65-3/4” 
167 cm 57-1/4”  
145 cm 20” 
51 cm NA 
NA1/2” 
1/2”58-3/4”
149 cm 8”
20 cm 27-3/4”  
70 cm NA 
NA1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT NA 
NA1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT750Lbs
341 Kg 862 Lbs
391 Kg
(A)BCG3  100T275 275,000 
BTU/Hr 
80 kW/Hr 100 Gal
379 L
72” 
183 cm 4-1/2” 
12 cm 65-1/8” 
165 cm 55-7/8”  
142 cm 19-3/4”  
50 cm 23”
58 cm 1/2” 
1/2”56-3/8”  
143 cm 8”
20 cm 30-1/4”  
77 cm 1-1/2" NPT
1-1/2" NPT 2" NPT
2" NPT2" NPT
2" NPT1-1/2" NPT
1-1/2" NPT 2" NPT
2" NPT2" NPT
2" NPT630 Lbs
286 Kg 725 Lbs
329 Kg
(A)BCG3  65T300 305,000 
BTU/Hr 
89 kW/Hr 65 Gal
246 L
75” 
191 cm 4-1/2” 
12 cm 65-3/4” 
167 cm 57-1/4”  
145 cm 20” 
51 cm NA 
NA1/2” 
1/2”58-3/4”  
149 cm 8”
20 cm 27-3/4”  
70 cm NA 
NA1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT NA 
NA1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT750 Lbs
341 Kg 862 Lbs
391 Kg
(A)BCG3  85T360 365,000 
BTU/Hr 
107 kW/Hr 85 Gal
322 L
79-1/2”  
202 cm 4-1/2” 
12 cm 70-1/4”  
178 cm 62-1/2”  
159 cm 22-1/2”  
57 cm 23”
58 cm 3/4” 
3/4”63” 
160 cm 8”
20 cm 27-3/4”  
70 cm 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT 1-1/2" NPT
1-1/2" NPT725 Lbs
329 Kg 833 Lbs
379 Kg
(A)BCG3  100T390 390,000 
BTU/Hr 
114 kW/Hr 100 Gal
379 L
75-1/2”  
192 cm 4-1/2” 
12 cm 67-1/2”  
171 cm 58-1/4”  
148 cm 26-3/4”  
68 cm 23”
58 cm 3/4” 
3/4”59” 
150 cm 8”
20 cm 30-1/4”  
77 cm 1-1/2" NPT
1-1/2" NPT 2" NPT
2" NPT2" NPT
2" NPT1-1/2" NPT
1-1/2" NPT 2" NPT
2" NPT2" NPT
2" NPT760 Lbs
345 Kg 874 Lbs
396 Kg
See Models Below
  * BCG370T120 Models are approved for 5” (13 cm) venting using a 6” (15 cm) to 5” (13 cm) reducer .
FIGURE 5.  
						

							9
TABLE 2. HEATER PERFORMANCE DATA (A)BCG3 MODELS
MODELINPUT RATE 
BTUH APPROX. 
GAL. CAP. EFF. % RECOVERY RATING CAPACITIES (GPH AND LPH)
30°F 40°F 50°F60°F 70°F 80°F 90°F100°F 110°F120°F 130°F140°F
(-)1°C 4°C10°C 15°C 21°C 27°C 32°C38°C43°C49°C54°C60°C
BCG3 
70T120 120,000 BTU/Hr.
35 Kw/Hr 71 Gal
268 L 80388
1469 291
1102 233
882194
734 166
628 145
549 129
488 11 6
439 106
401 97
367 90
341 83
314
BCG3 
80T150 154,000 BTU/Hr
45 Kw/Hr 81 Gal
306 L 80498
1885 373
1412 299
1132 249
943213
806 187
708 166
628149
564136
515124
469 11 5
435 107
405
BCG3 
80T180 180,000 BTU/Hr
53 Kw/Hr 81 Gal
306 L 80579
2192 434
1643 347
1314 289
1094 248
939 217
821 193
731174
650158
598145
549134
507124
469
BCG3 
100T199 199,000 BTU/Hr
58 kW/Hr 100 Gal
379 L 80643
2434 482
1825 386
1461 322
1219 276
1045 241
912214
810193
731175
662161
609148
560132
500
BCG3 
80T199 199,000 BTU/Hr
58 kW/Hr 81 Gal
306 L 80643
2434 482
1825 386
1461 322
1219 276
1045 241
912214
810193
731175
662161
609148
560132
500
(A)BCG3  100T200 199,000 BTU/Hr
58 kW/Hr 100 Gal
379 L 80643
2434 482
1825 386
1461 322
1219 276
1045 241
912214
810193
731175
662161
609148
560132
500
(A)BCG3  100T250 250,000 BTU/Hr
72 kW/Hr 100 Gal
379 L 80808
3059 606
2294 485
1835 404
1529 346
1311 303
1147 269
1020 242
918220
834202
765186
706173
655
(A)BCG3  65T250 251,000 BTU/Hr
73 kW/Hr 65 Gal
246 L 808 11
3071 608
2303 487
1843 406
1536 348
1316 304
1152 270
1024 243
921221
838203
768187
709174
658
(A)BCG3  100T275 275,000 BTU/Hr
80 kW/Hr 100 Gal
379 L 80889
3365 667
2524 533
2019 444
1682 381
1442 333
1262 296
1122 267
1009 242
918222
841205
776190
721
(A)BCG3  65T300 305,000 BTU/Hr
89 kW/Hr 65 Gal
246 L 80986
3732 739
2799 592
2239 493
1866 423
1599 370
1399 329
1244 296
1120 269
1018 246
933228
861 2 11
800
(A)BCG3  85T360 365,000 BTU/Hr
107 kW/Hr 85 Gal
322 L 801180
4466 885
3349 708
2680 590
2233 506
1914 442
1675 393
1489 354
1340 322
1218 295
111 6 272
1031 253
957
(A)BCG3  100T390 390,000 BTU/Hr
114 kW/Hr 100 Gal
379 L 801293
4894 970
3671 776
2936 646
2447 554
2097 485
1835 431
1631 388
1468 353
1335 323
1224
298
1129 277
1049
TABLE 3. GAS AND ELECTRICAL CHARACTERISTICS
Model Type of Gas Gas Supply Pressure
Gas Manifold PressureVolts/HzAmperes
Minimum Maximum
All Models Natural4.5" W.C. (1.12 kPa) 14" W.C. (3.48 kPa) 3.5" W.C. (0.87 kPa) 120/60
						

							10
Flammable  items,  pressurized  containers  or  any  other 
potential  fire  hazardous  articles  must  never  be  placed  on 
or  adjacent  to  the  heater.  Open  containers  or  flammable 
material  should  not  be  stored  or  used  in  the  same  room 
with  the  heater.
The  heater  must  not  be  located  in  an  area  where  it  will 
be  subject  to  freezing.
Locate  it  near  a  floor  drain.  The  heater  should  be  located 
in  an  area  where  leakage  from  heater  or  connections  will 
not  result  in  damage  to  adjacent  area  or  to  lower  floors 
of  the  structure.
When  such  locations  cannot  be  avoided,  a  suitable  metal 
drain  pan  should  be  installed  under  heater.  Such  pans 
should  be  fabricated  with  sides  at  least  2”  deep,  with 
length  and  width  at  least  2”  greater  than  diameter  of 
heater  and  must  be  piped  to  an  adequate  drain.  Pan 
must  not  restrict  combustion  air  flow.
CLEARANCES
These  heaters  are  approved  for  installation  on  combustible 
flooring  in  an  alcove  when  the  minimum  clearance  from 
combustion  or  non-combustible  construction  are  followed 
as  indicated  in  Figure  6  and  Table  4.
In all installations the minimum combustible clearances from 
draft  hood  surface  or  vent  piping  shall  be  6”  (152mm). 
Vent  piping  passing  through  a  combustible  wall  or  ceiling 
must  be  a  continuous  run  (no  joints)  and  retain  6”  (152mm) 
clearance  unless  an  approved  reducing  thimble  is  used.
A  service  clearance  of  24”  (610mm)  should  be  maintained 
from  serviceable  parts,  such  as  relief  valves,  baffles, 
thermostats,  cleanout  openings  or  drain  valves.
TABLE 4. INSTALLATION CLEARANCES
A 
(RIGHT SIDE) B
(LEFTSIDE) C
(BACK) D
(CEILING)
70T120 1” (2.54 cm) 1” (2.54 cm)1” (2.54 cm)12” (30.48 cm)
80T150 1” (2.54 cm) 1” (2.54 cm)1” (2.54 cm)12” (30.48 cm)
80T180 1” (2.54 cm) 1” (2.54 cm)1” (2.54 cm)12” (30.48 cm)
100T199 1” (2.54 cm) 1” (2. 54 cm)1” (2.54 cm)12” (30.48 cm)
80T199 1” (2. 54 cm) 1” (2. 54 cm)1” (2. 54 cm)12” (30.48 cm)
100T200 1” (2. 54 cm) 1” (2. 54 cm)1” (2. 54 cm)12” (30.48 cm)
100T250 2” (5.08 cm) 2” (5.08 cm)2” (5.08 cm)12” (30.48 cm)
65T250 2” (5.08 cm) 2” (5.08 cm)2” (5.08 cm)12” (30.48 cm)
100T275 2” (5.08 cm) 2” (5.08 cm)2” (5.08 cm)12” (30.48 cm)
65T300 2” (5.08 cm) 2” (5.08 cm)2” (5.08 cm)12” (30.48 cm)
85T360 3” (7.75 cm) 3” (7.75 cm)3” (7.75 cm)12” (30.48 cm)
100T390 3” (7.75 cm) 3” (7.75 cm)3” (7.75 cm)12” (30.48 cm)
LOCATING THE WATER HEATER
Property Damage Hazard
All water heaters eventually leak.
Do not install without adequate drainage.
CAUTION
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.
Fire or Explosion Hazar d
Read instruction manual befor e
installing, using or servicing water heater .
Avoid all ignition sources if you smell gas .
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating label.
Keep ignition sources away from faucets after extended
periods of non-use. Maintain required clearances to combustibles. Do not expose water heater controls to excessive gas
pressure.
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  igniter  or  main  burner 
flames  causing  fire  or  explosion.  Some  local  codes  permit 
operation  of  gas  appliances  in  such  areas  if  they  are 
installed  18”  or  more  above  the  floor.  This  may  reduce 
the  risk  if  location  in  such  an  area  cannot  be  avoided.
Do  not  install  this  water  heater  directly  on  a  carpeted  floor.  
A  fire  hazard  may  result.  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.
The  heater  shall  be  located  or  protected  so  it  is  not 
subject  to  physical  damage  by  a  moving  vehicle.
INSTALLATION CONSIDERATIONS