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American (A)BCL3100T2506NOX, Instruction Manual

The American (A)BCL3100T2506NOX is a high-quality product that requires a comprehensive Instruction Manual for optimal use. To fully benefit from its features, download the user manual for free from manualshive.com. This manual provides detailed information and step-by-step instructions to assist users in gaining the maximum potential of their American (A)BCL3100T2506NOX.

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28

SEQUENCE OF OPERATION FLOW CHART

Description of this flow chart can be found in the “SEQUENCE OF OPERATION” section found on page 27.

Thermostat calls for heat

Switch power on to unit

Blower engages Prover Switch

Ignition Control monitors 

flame signal

Loss of flame signal?

YES

YES

NO

NO

Blower power relay is energized to 

start blower

Ignion Control provides power to Spark 

Igniter and Pilot Gas Valve and monitors 

Flame Sensor to determine if Burner is lit

24VAC power to the Ignion 

Control and self check

Trial for ignion

Spark Off and Open main Gas Valve

5 minutes retry 

delay

Close pilot gas 

valve and Spark off

Flame Proved?

Close Main valve 

and Pilot valve

30 Seconds Prepurge

Thermostat is sasfied

Blower – off; Blower Prover – opens

Ignion Control – off; Gas Valve – closes

FIGURE 24.

Summary of Contents for (A)BCL3100T2506NOX

Page 1: ...e 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 g...

Page 2: ...Y 51 TABLE OF CONTENTS SAFE INSTALLATION USE AND SERVICE 3 APPROVALS 3 GENERAL SAFETY INFORMATION 4 Precautions 5 Grounding Instructions 5 Hydrogen Gas Flammable 5 INTRODUCTION 6 Abbreviations Used 6 Qualifications 6 Preparing for the Installation 6 FEATURES AND COMPONENTS 6 Controls 6 The Eliminator self cleaning system 6 High Limit Switch 7 Electronic Ignition Control 7 Blower Burner Assembly 7 ...

Page 3: ...e type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury DANGER WARNING 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 possib...

Page 4: ...ance with NFPA 54 Use joint compound or Teflon tape compatible with propane gas Fire and Explosion Hazard Turn off gas lines during installation Contact a qualified installer or service technician for installation and service Excessive gas pressure to gas valve can cause serious injury or death Do not use water heater with any gas other than the gas shown on the rating label Turn off power to the ...

Page 5: ...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 Verify the power to the water heater is turned off before performing any service procedures Read and understand this instruction manual and the safety messages herein before ...

Page 6: ...rything on the first few pages RE AD THE ENTIRE MANUAL BE FORE 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 I...

Page 7: ...t 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 Contact your dealer or service agent if...

Page 8: ... 1309 1212 1091 935 909 818 727 654 606 595 545 519 503 467 BCL380T1996NOX 199 81 80 GPH 531 478 382 354 319 273 265 239 212 191 177 174 159 152 147 137 58 307 LPH 2009 1808 1447 1340 1206 1033 1005 904 804 723 670 658 603 574 556 517 BCL3100T1996NOX 199 100 80 GPH 531 478 382 354 319 273 265 239 212 191 177 174 159 152 147 137 58 378 LPH 2009 1808 1447 1340 1206 1033 1005 904 804 723 670 658 603 ...

Page 9: ...The panel must be strong enough to carry the weight of the heater when full of water A service clearance of at least 24 61 cm should be maintained from serviceable parts TABLE 4 MINIMUM CLEARANCES TO COMBUSTIBLE OR NON COMBUSTIBLE CONSTRUCTION Model A Right Side B Left Side C Back D Ceiling All 0 0 0 12 0 cm 0 cm 0 cm 30 5 cm LOCATING THE WATER HEATER Property Damage Hazard All water heaters event...

Page 10: ... 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 w...

Page 11: ...ome 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 CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK OR BUILDING RECIRCULATION FIELD SUPPLIED TEMPERATURE CONTROL INSTALLED IN THE STORAGE TANK OR CIRCULATING LOOP RETURN LINE CIRC PUM...

Page 12: ... with all gas burning equipment running at maximum rate dynamic pressure The gas supply pressure must be stable within 1 5 W C 0 37 kPa from static to dynamic pressure to provide good performance Pressure drops that exceed 1 5 W C 0 37 kPa may cause rough starting noisy combustion or nuisance outages Increases or spikes in static pressure during off cycles may cause failure to ignite or in severe ...

Page 13: ...21 and Water Piping Diagrams starting on page 35 TEMPERATURE PRESSURE RELIEF VALVE Explosion Hazard Temperature 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 This water heater is provided with a pro...

Page 14: ...lve 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 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 ...

Page 15: ...pening 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 AIR REQUIREMENTS Breathing Hazard Carbon Monoxide Gas Install water heater in accordance with the Inst...

Page 16: ...ches 300 mm of the top of the enclosure shall be provided See Figure 14 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 ...

Page 17: ...e aggregate input rating of all appliances installed in the enclosure Each opening shall not be less than 100 square inches 645 cm2 OUTDOOR AIR THROUGH TWO VERTICAL DUCTS 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 Installa...

Page 18: ...l Fuel Gas Code ANSI Z223 1 and with the Category I Venting Tables If any part of the vent system is exposed to ambient temperatures below 40 F 4 4 C it must be insulated to prevent condensation Do not connect the heater to a common vent or chimney with solid fuel burning equipment This practice is prohibited by many local building codes as is the practice of venting gas fired equipment to the duc...

Page 19: ...usands of Btu hr Manifold and Common Vent Diameter Inches 2 308 000 7 7 6 6 6 6 6 6 3 462 000 8 8 7 7 7 6 6 6 4 616 000 9 9 9 8 8 7 7 6 Model BCL380T1806NOX 100T1996NOX Input 180 000 and 199 000 Btu hr Total Vent Height Feet Vent connector size 6 inches 6 8 10 15 20 30 50 100 Input Btu hr Rise Vent Connector Diameter Inches 180 000 1 ft 7 7 6 6 6 6 6 6 199 000 1 ft 7 7 7 6 6 6 6 6 180 000 2ft 6 6 ...

Page 20: ...8 8 8 7 7 7 6 6 Number of Heaters Combined Input Btu hr 2 620 000 12 10 10 9 9 8 8 7 3 930 000 14 14 12 12 10 10 9 9 4 1 240 000 16 14 14 14 12 12 10 9 Model BCL386T3666NOX Input 366 000 btu hr Total Vent Height Feet Vent connector size 6 inches 6 8 10 15 20 30 50 100 Input Btu hr Rise Vent Connector Diameter Inches 366 000 1 ft 8 8 7 7 6 366 000 2 ft 8 8 8 7 7 6 366 000 3 ft 8 8 8 7 7 6 6 Number ...

Page 21: ... installation of the water piping begins 1 Water Temperature Control and Mixing Valves on page 12 2 Dishwashing Machines on page 13 3 Temperature Pressure Relief Valve on page 13 4 Closed Systems and Thermal Expansion on page 13 5 For multiple water heater installations see Water Piping Diagrams beginning on page 35 Water potable Heating And Space Heating 1 All piping components connected to this ...

Page 22: ... 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 ...

Page 23: ...using In this case 200 C rated wire must be used The controls of this water heater are polarity sensitive Be certain to properly wire the hot and neutral connections 24V 24V GND GND PV MV PV MV SPARK 4 2 BK BK R R R R LOWER PROBE UPPER PROBE THERMOSTAT BLOWER PRESSURE SWITCH 1a 1b 1 120 VAC HOT 120 VAC NUETRAL EARTH GROUND PILOT IGNITION MODULE GAS VALVE BLOWER FACTORY INSTALLED BY INSTALLER POWER...

Page 24: ...ce 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 current edition of the Natio...

Page 25: ...y from faucets after extended periods of non use 1 Close the Main Gas Shutoff Valve see Figure 21 on page 24 2 Purge all air from the supply gas line up to the water heater s Main Gas Shutoff Valve 3 When all air has been purged from the supply gas line tighten all supply gas line connections 4 Check for gas leaks see Gas Line Leak Testing on page 24 and repair any leaks found START UP INITIAL STA...

Page 26: ... the supply gas regulator as necessary Adjust the supply gas regulator s per the regulator manufacturer s instructions to achieve the required static and dynamic supply gas pressure Multiple Water Heater Installations In multiple water heater installations or in installations where the installed water heater s share a common gas supply main with other gas fired appliances the supply gas pressures ...

Page 27: ...rn off the 24vac power to the blower relay and the Ignition Control and the unit will be in standby mode until another call for heat is initiated by the thermostat See the flow chart on page 28 for more detailed information 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 Blower pow...

Page 28: ... NO Blower power relay is energized to start blower Igni onControlprovidespowertoSpark IgniterandPilotGasValveandmonitors FlameSensortodetermineifBurnerislit 24VAC power to the Igni on Control and self check Trial for igni on Spark Off and Open main Gas Valve 5 minutes retry delay Close pilot gas valve and Spark off Flame Proved Close Main valve and Pilot valve 30 Seconds Prepurge Thermostat is sa...

Page 29: ... thermal expansion in a closed system See Closed Water Systems and Thermal 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...

Page 30: ...n this manual 11 Turn on the electrical supply to place the water heater back in operation 12 Turn on the gas supply to the water heater at the Main Gas Shutoff Valve 13 Allow the water heater to complete several heating cycles to ensure it is operating properly PERIODIC REMOVAL OF LIME DEPOSITS FROM TANK TYPE COMMERCIAL WATER HEATERS The amount of calcium carbonate lime released from water is in ...

Page 31: ...out 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 9004099...

Page 32: ...pplying 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 Prepare the Up N Down Transfer Kit The next step is the preparation on the Up N Down Transfer Kit if you have not already done so 1 With the 5 gallon Up N Down container in the vertical position unscrew the pla...

Page 33: ...not be restarted unless the water temperature is reduced to approximately 120 F 49 C The high limit reset button on the front of the thermostat then needs to be depressed See Figure 2 for the location of the reset button START UP CONDITIONS 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...

Page 34: ... blockage and or flue gas exhaust blockage Water temperature too hot Thermostat set too high Set thermostat to a lower setting Rumbling Sediment accumulation on bottom of tank Drain a quantity of water through drain valve If rumbling persists call a qualified service agency Delime heater Ticking or metallic sounds Expansion and contraction normal Pounding or water hammer Air chambers in piping hav...

Page 35: ...t should be set 5 degrees F higher than the Tank Temperature Control MULTI FLUE 1 UNIT WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDI...

Page 36: ...mostat should be set 5 degrees F higher than the Tank Temperature Control MULTI FLUE 1 UNIT WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES A...

Page 37: ...s and the storage tank s MULTI FLUE 1 UNIT WITH MIXING VALVE TWO TEMPERATURE LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS TE...

Page 38: ...ump between the water heater s and the storage tank s MULTI FLUE 2 UNITS LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS HOT WA...

Page 39: ...stat should be set 5 degrees F higher than the Tank Temperature Control MULTI FLUE 2 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ...

Page 40: ...stat should be set 5 degrees F higher than the Tank Temperature Control MULTI FLUE 2 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ...

Page 41: ...at should be set 5 degrees F higher than the Tank Temperature Control MULTI FLUE 2 UNITS WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ...

Page 42: ...TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS BOOSTER WATER RETURN PRE HEATED WATER TO BOOSTER BOOSTER WATER TO FIXTURES HOT WATER T...

Page 43: ...F VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS EXPANSION TANK BOOSTED WATER OUTLET TYPICAL BOOSTER HEATER PRE HEATER PRE HEATER MUST BE IDENTICAL HEATERS FINISHED FLOOR COLD WATER S...

Page 44: ... LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS HOT WATER TO FIXTURES HOT WATER RETURN COLD WATER SUPPLY EXPANSION TANK PIPE T...

Page 45: ...han the Tank Temperature Control MULTI FLUE 3 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS ...

Page 46: ... than the Tank Temperature Control MULTI FLUE 3 UNITS WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREME...

Page 47: ...URE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS EXPANSION TANK COLD WATER SUPPLY HOT WATER TO FIXTURES FINISHED FLOOR HOT WATER RETURN PIPE T ...

Page 48: ...mperature Control MULTI FLUE 4 UNITS WITH VERTICAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS HOT WATER TO FI...

Page 49: ...Temperature Control MULTI FLUE 4 UNITS WITH HORIZONTAL STORAGE TANK LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VALVE TEMPERATURE GAGE WATER FLOW SWITCH CHECK VALVE WARNING THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND OTHER DEVICES CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS HOT WATER T...

Page 50: ...NOTES 50 ...

Page 51: ...anty WHAT S NOT COVERED Problems caused by improper gas supply line sizing gas type venting connections combustion air voltage wiring or fusing Failure to follow applicable codes Failure to follow printed instructions Abuse misuse accident fire flood Acts of God Improper installation sizing delivery or maintenance Claims related to rust noise smell or taste of water Failure to conduct authorized f...

Page 52: ...American Water Heater Product Service and Support PO Box 1597 500 Princeton Road Johnson City TN 37605 Phone 800 999 9515 Copyright 2015 American Water Heater Company All rights reserved ...

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