American Water Heater (A)BCG38T500-8P manual

1 Service Handbook PRINTED IN THE U . S .A 0510 318664-000 SERVICING SHOULD ONL Y BE PERFORMED BY A QUALIFIED SER VICE AGENT . COMMERCIAL GAS W A TER HEA TERS INST ALLA TION CONSIDERA TIONS - PRE SERVICE CHECKS - W A TER HEA TER CONSTRUCTION - OPERA TION & SERVICE - TROUBLESHOOTING P.O. Box 1597 Johnson City, TN 37605 INST ALLA TION CONSIDERA T[...]

2 Servicing should only be performed by a Quali fi ed Service Agent INTRODUCTION ............................................................3 Qualifications ........................................................... 3 Service W arning........................................................3 Service Reminder ......................................[...]

3 Servicing should only be performed by a Quali fi ed Service Agent INTRODUCTION INTRODUCTION This Service Manual is designed to be an aid in servicing and troubleshooting American models (A)BCG385T500-8N/8P Series 120/121 commercial water heaters. The instructions and illustrations contained in this service manual will provide you with troublesho[...]

4 Servicing should only be performed by a Quali fi ed Service Agent REQUIREMENTS REQUIREMENTS INSTRUCTION MANUAL Have a copy of the instruction manual that came with the water heater on hand for the model being serviced. Instruction manuals can be obtained at the American W ater Heaters web site (www .americanwaterheater .com) or by calling techni[...]

5 Servicing should only be performed by a Quali fi ed Service Agent INST ALLA TION CONSIDERA TIONS INST ALLA TION CONSIDERA TIONS Installation information given in this service manual IS NOT a complete installation instruction. Installation information covered in this service manual has a limited focus as it applies to servicing. This service manu[...]

6 Servicing should only be performed by a Quali fi ed Service Agent INST ALLA TION CONSIDERA TIONS AIR REQUIREMENTS Carefully review the requirements for combustion and ventilation air in the instruction manual that came with the water heater . Failure to meet these requirements when the water heater is installed or overlooking their importance wh[...]

7 Servicing should only be performed by a Quali fi ed Service Agent INST ALLA TION CONSIDERA TIONS Insufficient Make-up Air , Negative Air Pressure, and Downdrafts A lack of combustion and ventilation air can create a negative ambient air pressure in the installed space. The vent system on one or more gas fired appliances can experience down draft[...]

8 Servicing should only be performed by a Quali fi ed Service Agent INST ALLA TION CONSIDERA TIONS Make-up Air: Direct Communication with Outdoors A fresh supply of make-up air for combustion can be supplied to the water heater through make-up air ducts, which directly communicate with the outdoors. (Not Direct V ent.) T wo openings are required: [...]

9 Servicing should only be performed by a Quali fi ed Service Agent INST ALLA TION CONSIDERA TIONS Contaminated Air Carefully review the warnings concerning contaminated combustion and ventilation air in the instruction manual that came with the water heater . Combustion air that is contaminated can greatly diminish the life span of the water heat[...]

10 Servicing should only be performed by a Quali fi ed Service Agent INST ALLA TION CONSIDERA TIONS T able 2 MINIMUM CLEARANCES T O COMBUSTIBLE SURF ACES “A” - Right Side “B” - Left Side “C” - Back 5” (12.7 cm) 5” (12.7 cm) 5” (12.7 cm) A, B, and C clearances to non-combustible surfaces is “0” inches. A 20” clearance to cov[...]

11 Servicing should only be performed by a Quali fi ed Service Agent INST ALLA TION CONSIDERA TIONS VENTING The (A)BCG385T500-8N/8P water heater is classified by ANSI as a Category I (non- condensing, negative pressure venting) appliance. It is approved for type B vent. The blower (draft inducer) does not pressurize the exhaust. NOTE: This section[...]

12 Servicing should only be performed by a Quali fi ed Service Agent OPERA TION AND SERVICE OPERA TION AND SER VICE SEQUENCE OF OPERA TION 1. Call for heat is activated when temperature sensed from Thermistor Probes falls below the Thermostat setting. 2. Blower (Draft Inducer) is energized. 3. Ignition Control Board verifies that the Blower Prover[...]

13 Servicing should only be performed by a Quali fi ed Service Agent OPERA TION AND SERVICE ELECTRICAL SEQUENCE 1. Switch Power on to unit. 2. Thermostat calls for heat. 3. Ignition Control Board performs diagnostic check on system components. 4. On completion of diagnostics check, the Ignition Control Board energizes the Blower (Draft Inducer). 5[...]

14 Servicing should only be performed by a Quali fi ed Service Agent OPERA TION AND SERVICE WIRING DIAGRAM THERMOST A T IGNITION BOARD UPPER PROBE/ PROBE THERMOPLASTIC OR EQUIV ALENT . MUST BE REPLACED USE ONL Y TYPE 105 C IF ANY OF THE ORIGINAL WIRE AS SUPPLIED BOARD , DIGIT AL THERMOST A T AND CONTROLS. WHEN EQUIPPED WITH WHITE-RODGERS IGNITION [...]

15 Servicing should only be performed by a Quali fi ed Service Agent OPERA TION AND SERVICE OPERA TING SEQUENCE - FLOW CHART Figure 1 1 Po wer On C a ll for Heat S elf diagnos t ic c hec k is perf ormed ( C orrec t s t at e of Bl ow er Prov er S w it c h and EC O i s v erif ied ) ( polari t y , eart h gr ound , and I gni ter pres enc e are v er if[...]

16 Servicing should only be performed by a Quali fi ed Service Agent OPERA TION AND SERVICE GAS CONTROL V AL VE This gas valve is a 24 volt AC combination-step opening valve. It includes two valves assembled in parallel, connected by a wiring harness. Note that the valves have fixed pressure regulation and are not adjustable. However , the manifol[...]

17 Servicing should only be performed by a Quali fi ed Service Agent OPERA TION AND SERVICE Manifold Pressure Adjustment The main gas regulators are found beneath the silver or black cap screws. (Natural Gas valves have silver caps; Propane valves have a black caps). Remove the caps to access the outlet (manifold) pressure adjustment screw . IMPOR[...]

18 Servicing should only be performed by a Quali fi ed Service Agent OPERA TION AND SERVICE GAS CONTROL V AL VE/BURNER AREA VIEW Honeywell Gas Va l v e Main Burner Shield Rollout Shield Radiation Shield Main Burner with Hot Surface Igniter (HSI) mounted Figure 14 T able 3 HOT SURF ACE IGNITER (HSI) V olts AC Nominal 80 V AC Ohms Resistance 1 1.0 -[...]

19 Servicing should only be performed by a Quali fi ed Service Agent OPERA TION AND SERVICE BLOWER PROVER SWITCH - SETTINGS V ent Connection Exhaust/Outlet Blower Prover Switch Blower (Draft Inducer) Optional Hot W ater Outlet Figure 15 T able 4 BLOWER PROVER SWITCH T ABLE Model Pressure Setting to Close Switch (Inches W .C.) (A)BCG385T500-8N/8P -[...]

20 Servicing should only be performed by a Quali fi ed Service Agent OPERA TION AND SERVICE THERMOST A T AND IGNITION CONTROL BOARD VIEW Figure 16[...]

21 Servicing should only be performed by a Quali fi ed Service Agent OPERA TION AND SERVICE WHITE RODGERS INTEGRA TED CONTROL - THERMOST A T Figure 17 WHITE RODGERS IGNITION CONTROL BOARD Figure 18 Display LED Label Display LEDs T o Upper T emp. Probe T o Ignition Control Board T o Lower T emp. Probe Fuse Pin Number Label 120 V AC from Ignition Co[...]

22 Servicing should only be performed by a Quali fi ed Service Agent OPERA TION AND SERVICE PRE-SER VICE CHECKLIST Use the following checklist BEFORE you begin servicing the water heater . 1. Have you removed the cover from the controls? • Did you take notice of the status lights on the upper water heater control? • Did you take notice of the [...]

23 Servicing should only be performed by a Quali fi ed Service Agent TROUBLESHOOTING TROUBLESHOOTING IGNITION CONTROL BOARD: ERROR CODES The White Rodgers ignition control board will display a flashing error code with an LED light located on the upper left corner of the Ignition Control Board (Figure 18) when there is a problem. There is a distinc[...]

24 Servicing should only be performed by a Quali fi ed Service Agent TROUBLESHOOTING 3 FLASHES Blower prover (air pressure) switch failed to close its normally open contacts after blower (draft inducer) was energized. Blower will run indefinitely , waiting for the blower prover switch circuit to close. 1 Check air pressure reading at blower prover[...]

25 Servicing should only be performed by a Quali fi ed Service Agent TROUBLESHOOTING 4 Check molex plug connector between igniter/flame sensor assembly and control board; Also check flame sense (12 pin) plug connection at control board. 8 FLASHES Igniter not sensed and/or water heater not grounded. 1 T est igniter resistance. It should should be 1[...]

26 Servicing should only be performed by a Quali fi ed Service Agent TROUBLESHOOTING INTEGRA TED HEA TER CONTROL: DISPLA Y LIGHTS Power Energy Cut Off Status Call for Heat Reset Status LED ST A TUS INDICA TION ACTION Calling for heat Normal status. No action required. The ECO (Energy Cut-Off) has opened. • Check for excessively hot water (203° [...]

27 Servicing should only be performed by a Quali fi ed Service Agent TROUBLESHOOTING TEST 1: 120 V AC T O HEA TER CHECK Conditions: • No Green Display “Power” LED on. • Plugs are in receptacles. • Supply power breaker is not open. • On/Off heater switch is on. E2 Display LEDs Ignition Control Board Ground 120 V . (E14) From Heater Cont[...]

28 Servicing should only be performed by a Quali fi ed Service Agent TROUBLESHOOTING TEST 2: POLARITY CHECK Conditions: No hot water • Green “Power” LED is on. • T ank is more than 5° F below temperature dial setting. • Red ignition control board diagnostic LED is flashing 6 times between pauses. • Red, diagnostic “Call for Heat” [...]

29 Servicing should only be performed by a Quali fi ed Service Agent TROUBLESHOOTING TEST 3: CONTINUITY CHECK OF HIGH LIMIT (ECO) Conditions: Power On – No Hot W ater • Red, heater control “Call for Heat” LED – on • Red ignition control board diagnostic LED – 4 Flashes • Note LED Flash Code before resetting water heater control. ?[...]

30 Servicing should only be performed by a Quali fi ed Service Agent TROUBLESHOOTING TEST 4: UPPER TEMPERA TURE PROBE CONTINUITY CHECK Conditions: Power On - W ater below temperature set point. • Red, water heater control “Reset Status” LED-OFF • “Call For Heat” LED off. • TEST 4 Upper T emperature probe continuity check Red wire to [...]

31 Servicing should only be performed by a Quali fi ed Service Agent TROUBLESHOOTING TEST 5: CALLING FOR HEA T - NO BLOWER OPERA TION Conditions: Power on • Plugs in Receptacles • Red “ Call for Heat” LED - ON • Blower (Draft Inducer) off • Note flash code on ignition control board diagnostic LED. W ater Heater Control - Thermostat Ign[...]

32 Servicing should only be performed by a Quali fi ed Service Agent TROUBLESHOOTING TEST 6: BLOWER ON, NO IGNITION Conditions: Power on • Plugs in receptacles • Blower (Draft Inducer) operating • No power to Hot Surface Igniter (HSI). Note LED flash code. • Blower Exhaust Blower Prover Switch Blower (Draft Inducer) Hot W ater Outlet Check[...]

33 Servicing should only be performed by a Quali fi ed Service Agent TROUBLESHOOTING TEST 7: BLOWER ON, BLOWER PROVER SWITCH CLOSED, NO IGNITER OPERA TION Conditions: Power on, but no power to igniter • Plugs in receptacles • Blower (Draft Inducer) on • 24V at ignition board E1, Pin 10 • 1 2 3 4 E4 Plug Continuity T est Check E1 pin 10 - 2[...]

34 Servicing should only be performed by a Quali fi ed Service Agent TROUBLESHOOTING TEST 8: IGNITER HEA TS, NO MAIN BURNER 24 V . E1 Plug to Pin 9 E1 Plug to Pin 12 Figure 27 TEST 8 IGNITER HEA TS......NO MAIN BURNER IF ......... then............ short heat up time of igniter check control box grounding. Normal warm up (Approximately 20 seconds) [...]

35 Servicing should only be performed by a Quali fi ed Service Agent TROUBLESHOOTING TEST 9: IGNITER HEA TS, NO MAIN BURNER Conditions: T est 8 completed • T urn off power • Disconnect wires from gas valve • Inlet Outlet Manifold Pressure Ta p Measure Resistance Between Gas V alve T erminals (Main V alve Solenoid Connections) Manifold Pressu[...]

36 Servicing should only be performed by a Quali fi ed Service Agent TROUBLESHOOTING TEST 10: MAIN BURNER IGNITION FOR LESS THAN FIVE SECONDS Conditions: Power On; plug connected • Main Burner ignites for approximately five seconds, then goes out. • T ests 8 and 9 completed • Note the flash code on the ignition board LED. Hot Surface Igniter[...]

37 Servicing should only be performed by a Quali fi ed Service Agent TROUBLESHOOTING TEST 1 1: W A TER HEA TER SHUTTING OFF BELOW SETTING Conditions: Main burner ignited • Stored water is below temperature setting more than 5° F (T ank Average). • Power off • Plug disconnected from heater control board receptacle E3 and E4 • E3 E4 Figure [...]

38 Servicing should only be performed by a Quali fi ed Service Agent NOTES[...]

39 Servicing should only be performed by a Quali fi ed Service Agent NOTES[...]

Copyright © 2010 American Water Heater Company . All rights reserved. P .O. Box 1597, Johnson City , TN 37605 Phone: 800-456-9805 • Fax: 800-999-5210 www .americanwaterheater .com[...]