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American Water Heater Heavy Duty Commercial Gas BCG3 User Manual
American Water Heater Heavy Duty Commercial Gas BCG3 User Manual
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21 grounding shall be done in accordance with the current edition of the Canadian Electrical Code CSA C22.1 and/or local codes. VENT INSTALLATION Seal all joints between the power venter and the vent termination. This is to prevent leakage of exhaust products into the room(s) due to positive pressure of blower. The “Sequence of Operation” description will be the same with mechanical venting except; When the water heater thermostat calls for heat: Thermostat contacts “Close” and the power venter blower (120 VAC) is energized. Sufficient draft must be established for the “Draft Prover Switch (N.O.)” to “Close”. When the draft prover switch “Closes” the relay coil of the flue damper is energized. WATER HEATER INSTALLATION MECHANICAL VENTING SINGLE UNIT INSTALLATION When mechanical venting of these heaters is desired, the following kits are available. Models with inputs from 120,000 to 200,000 btu/h part number 9005381205 Models with inputs from 250,000 to 390,000 btu/h part number 9003434205 Where an approved power venter is to be installed to operate in conjunction with the water heater thermostat, the following codes must be adhered to. Field wiring should conform to the current edition of the National Electrical Code NFPA 70. For Canadian installations the electrical connections and 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 40. The water heater may be installed by itself, or with a separate storage tank. When used with a separate storage tank, the circulation may be either by gravity or by means of circulating pump. 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 the Water Piping Diagrams beginning on page 40. NOTE: In addition to the factory installed Temperature-Pressure Relief Valve (T&P 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 Temperature-Pressure Relief Valve installed. Call the toll free technical support phone number listed on the back cover of this manual for further assistance in sizing a T&P valve for remote storage tanks. T&P VALVE DISCHARGE PIPE Explosion Hazard Te mperature-Pressure Relief Valve must comply with ANSI Z21.22- CSA 4.4 and ASME code. Properly sized temperature- pressure relief valve must be installed in opening provided. Can result in overheating and excessive tank pressure . Can cause serious injury or death. WATER LINE CONNECTIONS The water piping installation must conform to these instructions and to all local code authority having jurisdiction. Good practice requires that all heavy piping be supported. Read and observe all requirements in the following sections before installation of the water piping begins: 1. Water Temperature Control and Mixing Valves on page 13. 2. Dishwashing Machines on page 14. 3. Temperature-Pressure Relief Valve on page 14-15. 4. Closed Systems and Thermal Expansion on page 14. 5. For multiple water heater installations see Water Piping Diagrams beginning on page 40. WATER (POTABLE) HEATING AND SPACE HEATING 1. All piping components connected to this unit for space heating applications shall be suitable for use with potable water. 2. Toxic chemicals, such as those used for boiler treatment, shall NEVER be introduced into this system. 3. This unit may NEVER be connected to any existing heating system or component(s) previously used with a non-potable water heating appliance. 4. When the system requires water for space heating at temperatures higher than required for domestic water purposes, a tempering valve must be installed. Please refer to installation diagrams beginning on page 40 of this manual for suggested piping arrangements. 5. These water heaters cannot be used in space heating applications only THERMOMETERS (NOT SUPPLIED) Thermometers should be obtained and field installed as shown in the installation diagrams. Thermometers are installed in the system as a means of detecting the temperature of the outlet water supply.
22 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 14-15 for information on replacement and other requirements. Water Damage Hazard Temperature-Pressure Relief V alve discharge pipe must terminate at adequate drain. CAUTION 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. T&P VALVE DISCHARGE PIPE REQUIREMENTS: • Shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions. • Shall not be plugged or blocked. • Shall not be exposed to freezing temperatures. • Shall be of material listed for hot water distribution. • Shall be installed so as to allow complete drainage of both 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. • Shall not have any valve or other obstruction between the relief valve and the drain. INSTALLATION DIAGRAMS - TOP INLET/OUTLET USAGE Use of the top inlet water connection requires 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. TUBE INLET INSTALLATION FIGURE 19.
23 HEATER WIRING All electrical work must be installed in accordance with the current edition of the National Electrical Code ANSI/NFPA No. 70 or Canadian Electrical Code CSA C22.1 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 water heater must be replaced, use only type 105°C thermoplastic or equivalent 250 0C 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. 13 42 C P M X MV MV/PV PV 24 V GND 24 V SP ARKER GND-BURNE R HONEYWELL IGNITION DAMPER DRIVE ON/OFF SWITCH LOWER PROBE UPPER PROBE/ECO 11 E79 LINE IN 1 2 3 4 NEUTRAL GND NA TURAL GAS VA LVE PV PV THTR MV MV/PV MV PROP ANE GAS VA LVE 120 vac 24 VA C TO IGNITION CONTRO L DAMPER DRIVE 24 VAC 24 NEUTRA L FACT OR Y WIRED BY INST ALLER IF ANY OF THE ORIGINAL WIRE AS SUPPLIED MUST BE REPLACED, USE ONL Y TYPE 105O C THERMOPLASTIC OR EQUI VALENT . FLAME SENSOR IGNITION CABLE MUST BE 250O C TYPE F. 330548-000 REV 00 W W W Y BLK BLKBLK W R R Y BLK BL W LEGEND: W --WHITE BLK--BLACK BL--BLUE R--RED Y --YELLOW FIGURE 20.
24 GAS PIPING 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 7. 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. Schedule 40 Steel or Wrought Iron 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.TABLE 7. GAS SUPPLY PIPE LENGTHS (IN FEET) Maximum Equivalent Pipe Length - Natural Gas Only Input rate (BTU/HR) Schedule 40 Steel or Wrought Iron Pipe 1/2" 3/4" 1"1 1/4" 1 1/2" 120,000 2070200 200200 154,000 1040150 200200 180,000 -30 100 200200 199,000 -30 90200 200 250,000 -20 60200 200 275,000 -10 50200 200 310,000 -10 40150 200 366,000 --30 100 200 390,000 --20 100 200 Fitting Type* Equivalent length in feet 45°Ell 0.71.01.21.61.9 90°Ell 1.62.12.63.54.0 Te e 3.14.15.26.98.0 Natural Gas 0.60 Specific Gravity, 0.50" W.C. Pressure Drop *Screwed Fittings It is important to guard against gas valve fouling from contaminants in 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. To trap any dirt or foreign material in the gas supply line, a sediment trap must be incorporated in the piping (see Figure 21). The sediment trap 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. To prevent damage, care must be taken not to apply too much torque when attaching gas supply pipe to gas valve inlet. 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. GAS METER SIZE – NATURAL GASES ONLY 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. GAS PIPING AND SEDIMENT TRAP INSTALLATION FIGURE 21. GAS LINE LEAK TESTING Fire and Explosion Hazard 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 NFP A 54. Use joint compound or Teflon tape compatible with propane gas. Any time work is done on the gas supply system perform a leak test to avoid the possibility of fire or explosion. 1. For test pressures exceeding 1/2 psi (3.45 kPa) disconnect the water heater and its Main Gas Shutoff Valve from the gas supply piping system during testing, see Figure 21. The gas supply line must be capped when disconnected from the water heater. 2. For test pressures of 1/2 psi (3.45 kpa) or less, the water heater need not be disconnected, but must be isolated from the supply gas line by closing the Main Gas Shutoff Valve during testing. 3. Coat all supply gas line joints and connections upstream of the water heater with a non-corrosive soap and water solution to test for leaks. Bubbles indicate a gas leak. Do not use matches, candles, flame or other sources of ignition for this purpose. 4. Repair any leaks before placing the water heater in operation. PURGING Gas line purging is required with new piping or systems in which air has entered. Purging should be performed per the current edition of NFPA 54 the National Fuel Gas Code.
25 is locked out, the power to the unit must be cycled to restart the Ignition Control. 8. If the pilot flame is proved during the ignition trial period, the Ignition Control turns off the Spark Ignitor and opens the Main Gas Valve. 9. The Ignition Control allows a 2 second pilot flame stabilization period to insure that the pilot flame is not extinguished by the main burner light-off process. 10. The Ignition Control monitors the Flame Sensor during the heating cycle. If the flame signal is lost, the Ignition Control shuts the Main Gas Valve and Pilot Gas Valve and re-starts the ignition process at step 4. 11. Once the unit is satisfied, the Ignition Control will shut off the Main Gas Valve and the Pilot Gas Valve and the unit will be in standby mode until another call for heat is initiated by the thermostat. See the flow chart on page 26 for more information. Light the water heater in accordance with the Lighting and Operation Instruction label on the water heater and in this manual on pages 27 and 28. The water heaters covered by this manual are equipped with an electronic control system that automatically sequences the Igniter, the 24 VAC Gas Valve, the Burner ignition, and flame sensing. Before attempting start up, thoroughly study and know the exact Sequence Of Operation. See written Sequence Of Operation on page 25 and Sequence Of Operation Flow Chart on page 26. Be c er tain that the water heater is full of water, that air is purged from the gas and water lines and that there are no leaks in the gas and water lines. Ensure all inlet water valves are open. FILLING THE WATER HEATER Follow these steps to fill the water heater prior to start up. 1. Close the heater drain valve. 2. Open a nearby hot water faucet to permit air in system to escape. 3. Fully open the cold water inlet valve allowing the piping and water heater to fill with water. 4. Close hot water faucet opened in Step 2 as water starts to flow. Read SEQUENCE OF OPER ATION section of this manual prior to lighting and operating this water 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 pages 27 and 28. Fire or Explosion Hazar d Read instruction manual befor e installing, using or servicing water heater . To avoid risk of fire or explosion purge discharge must not enter into confined areas or spaces where ignition can occur . The area must be well ventilated and all sources of ignition must be deactivated or removed. Gas line purging is required with new piping or systems in which air has entered. PRIOR TO START UP Installation and start up of this water heater requires abilities and skills equivalent to that of a licensed tradesman in the field involved, see Qualifications on page 6. Do not place the water heater in operation if any part has been under water. Immediately call a qualified service technician to inspect the water heater and to replace any part of the control system and any gas control which has been under water. OPERATION SEQUENCE OF OPERATION The following information will describe the Sequence of Operation for this water heater. 1. Switch power on to unit. 2. Thermostat calls for heat. 3. Ignition Control performs diagnostic self check on system components. 4. The Ignition Control begins the trial for ignition. 5. The Ignition Control turns on the Spark Igniter and opens the Pilot Gas Valve. 6. The Ignition Control monitors the Flame Sensor during the ignition trial period. 7. If the Ignition Control does not sense the pilot flame during the ignition trial period, the Ignition Control shuts the Pilot Gas Valve and turns off the Spark Igniter. Depending on the water heater model, the Ignition Control will either retry the ignition trial at step 4 or lockout the ignition sequence. If the ignition sequence
26 SEQUENCE OF OPERATION FLOW CHART Description of this flow chart can be found in the “SEQUENCE OF OPERATION” section found on page 25. FLOW CHART 1. A A IDLE (NOT POWERED) “CALL FOR HEAT ” RECEIVED FROM THERMOSTAT POWER TO MODULE AND SELF CHECK TRIAL FOR IGNITIO N (TIMER ST ARTED) FLAME PROVED? CLOSE PILOT GAS VA LVE SP ARK OFF (BEFORE TRIAL FOR IGNITION TIMER EXPIRES) SP ARK OFF OPEN MAIN GA S VA LVE FLAME ST ABILIZA TION (2 SECONDS) RUN NO NO NO YES YES YES “CALL FOR HEAT ” ENDS? FLAME LOST? CLOSE MAIN GAS VA LVE AND PILOT GAS VA LVE CLOSE MAIN GAS VA LVE AND PILOT GAS VA LVE SP ARK ON OPEN PILOT GAS VALVE RETR Y DELA Y (5 MINUTES) WA IT FO R “CALL FOR HEAT ” TO BE REMOVED ACTIVA TE ALARM CONT ACT(S) (OPTIONAL) RETR Y OR LOCKOUT MODEL? LOCKOUT RETR Y
27 LIGHTING & OPERATION LABEL FIGURE 22. LABEL FOR NATURAL GAS MODELS FOR YOUR SAFETY READ BEFORE OPERATINGOPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING
28 FIGURE 23. LABEL FOR PROPANE GAS MODELS FOR YOUR SAFETY READ BEFORE OPERATINGOPERATING INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE
29 ADJUSTMENTS ON INITIAL STARTUP SOME ADJUSTMENTS MAY BE NECESSARY. Check Manifold and inlet gas pressures (see GAS SUPPLY SYSTEMS on page 13 and CHECKING THE INPUT on page 29-30.) Check Pilot Burner (See Pilot Burner section on page 34.) TESTING DAMPER OPER ATION With the Service Switch in the AUTOMATIC OPER ATION position, check the operation of the flue damper three (3) times with the water operating controls for proper operating sequence: • The damper disc must be open (in the vertical position) before the ignition and combustion process begins. • The damper disc must be in the open position when the main burner is firing. • The gas control valve must close and the main burner must have ceased firing before the damper disc begins its return to the closed (horizontal) position. If during testing of the operation of the damper you find that there is a problem with the operation of the water heater when the Service Switch is in the AUTOMATIC OPER ATION position: Reset the Service Switch to the HOLD OPEN DAMPER position and check operation again. If the water heater does operate when placed in the HOLD OPEN DAMPER position: • Refer to the EFFIKAL RVGP-FSF-SERIES TROUBLESHOOTING GUIDE on page 37. If the water heater does not operate with the Service Switch in either position: • Refer to the Troubleshooting Sections and Troubleshooting Checklist. CHECKING 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. 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. 4. Follow the lighting instruction. Place the water heater being inspected in operation. Adjust thermostat so water heater shall operate continuously. 5. Test for draft hood spillage at the relief opening after 5 minutes of main burner operation. 6. After it has been determined that each appliance 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. 7. If improper venting is observed during any of the above tests, the venting system must be corrected. FAILURE TO CORRECT BACK DR AFTS MAY CAUSE AIR CONTAMINATION AND UNSAFE CONDITIONS. • 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 ass ure proper venting and correct combustion. CHECKING THE INPUT For installation locations with elevations above 2000 feet, refer to HIGH ALTITUDE INSTALLATIONS section of this manual for input reduction procedure. 1. Attach a pressure gauge or a manometer to the manifold pressure tap on the gas control valve and refer to Table 8, for correct manifold pressure. 2. Use this formula to “clock” the meter. Be sure that other gas consuming appliances are not operating during this interval. (3600/T) x H = Btuh T = Time in seconds to burn one cubic foot of gas. H = Btu’s per cubic foot of gas. Btuh = Actual heater input. Example: T = 15.1 seconds H = 1050 Btu Btuh = ? (3600/15.1) x 1050 = 250,000 TABLE 8. APPROXIMATE TIME REQUIRED TO CONSUME 1 CU. FT. OF GAS AT FULL CAPACITY INPUT RATE (BTUH) TYPE OF GAS BTUH PER CU. FT. TIME REQ’D TO CONSUME 1 CU. FT. OF GAS 120,000 NATURAL PROPANE 1050 2500 31. 5 SEC. 75.0 SEC. 154,000 NATURAL PROPANE 1050 2500 24.5 SEC. 58.4 SEC. 180,000 NATURAL PROPANE 1050 2500 21.0 SEC. 50.0 SEC. 199,000 NATURAL PROPANE 1050 2500 19.0 SEC. 45.2 SEC. 250,000 NATURAL PROPANE 1050 2500 15.1 SEC. 36.0 SEC. 251,000 NATURAL PROPANE 1050 2500 15.1 SEC. 35.9 SEC. 275,000 NATURAL PROPANE 1050 2500 13.7 SEC. 32.7 SEC. 305,000 NATURAL PROPANE 1050 2500 12.4 SEC. 29.5 SEC. 365,000 NATURAL PROPANE 1050 2500 10.4 SEC. 24.7 SEC. 390,000 NATURAL PROPANE 1050 2500 9.7 SEC. 23.1 SEC.
30 FIGURE 24. 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. Should it be necessary to adjust the gas pressure to the burners to obtain the full input rate, the steps below should be followed: 3. Remove the regulator adjustment sealing cap and adjust the pressure by turning the adjusting screw with a screwdriver. See Figure 24. Clockwise to increase gas pressure and input rate. Counterclockwise to decrease gas pressure and input rate. 4. “Clock” the meter as in step 2 above. 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 Allen wrench set screw in the pressure tap opening.