American Water Heater 80 Thermal Efficiency UltraLow NOx Heavy Duty Commercial Gas Water Heater BCL3 User Manual

							31
Chemical Hazard
• Product contains phosphoric acid.
• Keep out of reach of children.
• Use rubber or neoprene gloves.
UN•LIME  contains  phosphoric  acid.  In  case  of  external  contact, 
flush with cool water. If irritation persists, get medical attention. If 
swallowed, give 1 or 2 glasses of water or milk and call physician.
Get  immediate  medical  attention  for  eyes.  Keep  out  of  reach  of 
children.
NOTE: THE USE OF RUBBER OR NEOPRENE GLOVES IS 
RECOMMENDED, ESPECIALLY IF YOU HAVE ANY OPEN 
SORES OR CUTS TO AVOID UNNECESSARY IRRITATION 
OR DISCOMFORT.
1. Turn  off  fuel  and/or  power  supply  to  heater.  Also,  turn  off 
power  to  any  electrical  device  or  equipment,  which  is 
attached, or part of the system.
2.  Open  hot  water  side  of  faucet  closest  to  heater  and  allow 
water to run until it is cool enough to handle safely.
3.  Close cold water inlet valve to heater.
4.  Connect  hose  to  drain  valve  at  bottom  of  heater  and  start 
draining heater into suitable floor drain area.
5.  Remove relief valve while heater is draining. NOTE: Do not 
replace relief valve until deliming is completed. Relief valve 
opening  will  also  act  as  a  vent  in  case  of  possible  contact 
between  the  delimer  and  the  anode  rod(s),  which  may 
produce flammable hydrogen-air mixtures.
6.  If relief valve appears to be limed-up, place it in a clean glass or 
plastic container adequate in size so that you can pour enough 
UN•LIME®  into  the  container  to  cover  the  valve  and  allow 
space for foaming. When foaming stops, run fresh cool water 
into the container and rinse the relief valve for a few minutes.
7.  If heater does not drain completely after a reasonable length 
of  time,  turn  off  the  main  water  supply  valve  to  stop  water 
from entering the tank due to a by-pass problem or defective 
cold  water  inlet  valve.  Also,  check  for  clogged  drain  valve 
opening.  Heater  must  be  completely  drained  before 
introducing UN•LIME.
8.  Remove the cleanout cover and place a clean plastic bucket 
next to the cleanout opening.
Partially  open  the  cold  water  inlet  valve  to  allow  time  to 
accomplish the following and then close the valve.
While  the  water  is  being  run  through  the  tank,  insert  a  stiff 
wire, copper tube flattened at one end or an opened wire coat 
hanger  through  the  cleanout  opening  and  scrape  out  any 
loose  deposits  of  scale  or  sediment. This  is  an  economical 
way to avoid unnecessary usage of the deliming solution.
Repeat the opening and closing of the cold water inlet valve 
as  necessary  but  be  sure  the  heater  is  completely  drained 
when ready to introduce the UN•LIME.
Upon completion, reinstall the cleanout cover and use a new 
cleanout cover gasket (part number 9004099215).
Remove the drain valve.
NOTE: Un•Lime is not available for use in Canada.
Hydrochloric base acids are not recommended for use on glass 
lined tanks.
Observe handling instructions on label of product being used. 
TANK CLEANOUT PROCEDURE
The following practices will ensure longer life and enable the unit 
to operate at its designed efficiency:
1. Once a month the heater should be flushed. Open the drain 
valve and allow two gallons of water to drain from the heater. 
Inlet  water  valve  should  remain  open  to  maintain  pressure 
in tank.
2.  A  cleanout  opening  is  provided  for  periodic  cleaning  of 
the  tank.  Gas  must  be  shut  off  and  heater  drained  before 
opening cleanout.
To clean heater through cleanout opening, proceed as follows:
3.  Drain heater.
4.  Remove outer cover plate from lower side of heater jacket.
5.  Remove  six  (6)  hex  head  screws  securing  tank  cleanout 
plate and remove plate.
6.  Remove lime, scale, or sediment using care not to damage 
the glass lining.
7.  Inspect  cleanout  plate  gasket,  if  new  gasket  is  required, 
replace with part no. 9004099215.
8.  Install  cleanout  plate.  Be  sure  to  draw  plate  up  tight  by 
tightening screws securely.
9.  Replace outer jacket cover plate. 
In  some  water  areas  the  sediment  might  not  be  removed 
by  this  method  and  may  result  in  the  water  heater  making 
rumbling or boiling noises. To dissolve and remove these more 
stubborn  mineral  deposits,  UN•LIME  Professional  Delimer 
should be used.
DELIMING USING FLO-JUG METHOD
UN•LIME  in  the  5  gallon  size  is  recommended  for  deliming  of 
all models. Contact your local dealer, distributor or water heater 
manufacturer.
Prepare the Water Heater
To  delime  the  water  heater  using  the  Flo-Jug  method,  first 
prepare the heater for deliming.
Explosion Hazard
Flammable hydrogen gases
may be present .
Keep all ignition sources away
from faucet when turning on
hot water.
Do not smoke or have open flame or sparks in vicinity of heater. 
Do not mix UN•LIME with other chemicals. Do not allow contact 
with magnesium, aluminum or galvanized metals. 
						

							32
The installer may be able to observe and correct certain problems 
which may arise when the unit is put into operation. HOWEVER, 
it  is  recommended  that  only  a  qualified  service  agency,  using 
appropriate test equipment, be allowed to service the heater.
As  preliminary  step,  check  wiring  against  diagram,  check  for 
grounded, broken or loose wires.  Check all wire ends to be sure 
that they are making good contact.
IGNITION CONTROL SYSTEM
Before  calling  your  qualified  service  agency,  the  following 
checklist  should  be  examined  to  eliminate  obvious  problems 
from those requiring replacement or servicing.
• Check that “main gas shutoff valve” is fully open and that gas 
service has not been interrupted.
•  Check electrical supply to the water heater for possible blown 
(or tripped) fusing or power interruption. Also check the 3 amp 
fuse on the front of the digital thermostat (Fig. 2).
•  Is  the  water  temperature  in  tank  below  the  thermostat  dial 
setting on the water heater thermostat (calling for heat)?
•  It is possible that the high limit (E.C.O.) has functioned to shut 
off  the  water  heater.  See  page  7  -  High  Limit  Switch  for  reset 
procedure.  Contact  your  service  agent  if  limit  continues  to 
function to shut off water heater.  and pour the UN•LIME into the heater.
7.   Lower  container,  you  may  have  to  place  the  container  on 
its empty carton to prevent the UN•LIME from flowing back 
into the container.
8.  Let  UN•LIME  remain  in  the  heater  for  5  minutes  and  then 
lower the container to the “Drain” Position, see Figure 27.
9.   Deliming activity is indicated by foaming on the surface of the 
UN•LIME. If there is deliming activity, repeat steps 6 thru 8.
Normally, lime removal will be completed within one hour.  Severe 
build-up of lime may take longer than an hour to complete descaling.
Note:  To  check  UN•LIME  for  continued  use,  place  some  scale 
or  white  chalk  in  a  glass  with  a  small  amount  of  UN•LIME.    If 
the  material  is  vigorously  dissolved  by  the  UN•LIME,  it  can  be 
reused; if not, the UN•LIME should be replaced.
FIGURE 27.
9.  Install  the  long  plastic  male  adapter  insert  fitting  into  the 
drain  valve  opening  of  heater  after  applying  Teflon  tape  or 
paste to threads. Tighten firmly by hand and use wrench or 
adjustable pliers to check for secure connection. Do not over 
tighten to avoid damage to threads and fittings.
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  plastic  vent  cap  in  the  handle  and 
pierce  the  plastic  membrane  over  the  vent  boss  under  the 
cap to allow the container to vent.
Note:  If  your  container  does  not  have  the  vent  cap  and 
vent boss, drill  a 3/16” hole in the handle.   When you have 
finished deliming you will be able to plug this drilled vent with 
the stainless steel screw that is supplied with the kit.
2.  Remove  the  container’s  cap  and  cut  the  plastic  membrane 
located in the 3/4” IPT opening in the cap.  Take care to not 
damage the threads.
3.  Find the 3/4” male adapter, apply teflon tape to the threaded 
end and screw it into the 3/4” IPT opening in the cap.
4.  Put  cap  with  male  adapter  back  on  the  container  and  slide   
3/4” hose over end of male adapter and fasten in place using 
hose clamp provided.
Delime using Flo-Jug Method
5.  Slide the hose clamp over end of hose and slide hose over 
the  male  adapter  in  the  water  heater  drain  opening  and 
secure in place using hose clamp.
6.  Lift  container  to  the  “Pour”  Position,  see  Figure  27,  being 
careful to keep the vent in the handle above the liquid level 
SERVICE
SYSTEM DIAGNOSTICS
Your  water  heater  is  equipped  with  an  ignition  control  that 
incorporates a diagnostic system to assist in troubleshooting the 
water  heater.  The  green  LED  codes  on  the  ignition  module  are 
as follows:
TABLE 9.
2 FLASHES 5 Minutes Retry Delay
3 FLASHES Recycle - flame failed during run
4 FLASHES Flame sensed out of sequence
6 FLASHES Control Internal Error
7 FLASHES Flame rod shorted to ground
8 FLASHES Low secondary voltage supply
If an internal control failure is indicated, replace the ignition control.
Use this diagnostic system in conjunction with “ TROUBLESHOOTING” 
and  the  “SEQUENCE  OF  OPER ATION”  to  troubleshoot  the  water 
heater.
ELECTRICAL SERVICING
Label  all  wires  prior  to  disconnection  when  servicing  controls. 
Wiring errors can cause improper and dangerous operation.
Verify proper operation after servicing. 
						

							33
Contact  the  local  water  heater  supplier  or  service  agency  for 
further  information  concerning  an  Anode  Replacement  Kit  and 
this chlorination treatment.
If hot water odor persists after anode replacement and chlorination 
treatment,  we  can  only  suggest  that  chlorination  or  aeration  of 
the water supply be considered to eliminate the water problem.
Do  not  remove  the  anode  rod  leaving  the  tank  unprotected.  By 
doing so, all warranty on the water heater tank is voided.
“AIR” IN HOT WATER FAUCETS
HYDROGEN  GAS:  Hydrogen  gas  can  be  produced  in  a  hot 
water system that has not been used for a long period of time 
(generally  two  weeks  or  more).  Hydrogen  gas  is  extremely 
flammable  and  explosive.  To  prevent  the  possibility  of  injury 
under  these  conditions,  we  recommend  that  the  hot  water 
faucet located farthest away from the water heater be opened 
for  several  minutes  before  any  electrical  appliances  which 
are  connected  to  the  hot  water  system  are  used  (such  as  a 
dishwasher or washing machine). If hydrogen gas is present, 
there will probably be an unusual sound similar to air escaping 
through  the  pipe  as  the  hot  water  faucet  is  opened.  There 
must be no smoking or open flame near the faucet at the time 
it is open.
HIGH WATER TEMPERATURE SHUT OFF SYSTEM
This  water  heater  is  equipped  with  a  manual  reset  type  high 
limit  (Energy  Cutout)  switch.  The  high  limit  switch  interrupts 
the  main  burner  gas  flow  should  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 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 will disappear in a short while.
Strange Sounds
Possible noises due to expansion and contraction of some metal 
parts during periods of heat-up and cool-down do not necessarily 
represent harmful or dangerous conditions.
Condensation causes sizzling and popping within the burner area 
during  heating  and  cooling  periods  and  should  be  considered 
normal.
OPERATIONAL CONDITIONS
Hot Water Odor
In  each  water  heater  there  is  installed  at  least  one  anode  rod 
for  corrosion  protection  of  the  tank.  Certain  water  conditions 
will  cause  a  reaction  between  this  rod  and  the  water. The  most 
common  complaint  associated  with  the  anode  rod  is  one  of  a 
“rotten  egg  smell”  in  the  hot  water.  The  smell  is  a  result  of  four 
factors which must all be present for the odor to develop:
a.  A concentration of sulfate in the supply water.
b.   Little or no dissolved oxygen in the water.
c.   A sulfate reducing bacteria which has accumulated within the 
water heater (this harmless bacteria is nontoxic to humans).
d.   An  excess  of  active  hydrogen  in  the  tank. This  is  caused  by 
the corrosion protective action of the anode.
Hot  water  odor  may  be  eliminated  or  reduced  in  some  water 
heater models by replacing the anode(s) with one of less active 
material,  and  then  chlorinating  the  water  heater  tank  and  all 
water lines.
FOR YOUR INFORMATION 
						

							34
COMPLAINTCAUSE REMEDY
USER QUALIFIED SERVICE AGENCY
*Water not hot enough Thermostat set too low.Set thermostat dial to a higher 
temperature
Upper and/or lower temperature 
probe out of calibration. Call qualified service agency
Check continuity and resistance (Ohms) 
of upper and lower temperature probes. 
Replace probes if out of specification.
*Insufficient hot water
*See WATER TEMPERATURE 
CONTROL WARNING (on page 
12). Thermostat set too low.
Set thermostat dial to a higher 
temperature
Upper and/or lower temperature 
probe out of calibration. Call qualified service agency
Check continuity and resistance (Ohms) 
of upper and lower temperature probes. 
Replace probes if out of specification.
Main manual gas shutoff valve 
partially closed. Open main manual gas shutoff 
valve to fullest extent.
Heater too small for demand. Space usage to give heater time 
to restore water temperature.
Heater recovery is slower. Call qualified service agencyCheck gas input. If incorrect, check 
for inlet air 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 have 
become waterlogged. Thermal 
expansion tank damaged, 
improperly charged, or 
improperly sized.Drain piping system and refill. 
Heater must be off while this 
is being done. Check thermal 
expansion tank charge pressure 
when the water system pressure 
is zero.Follow the manufacturer's instructions 
for proper charging of the thermal 
expansion tank.
Water leaks. Drain valve not closed tightly.If drain valve cannot be closed 
tightly, replace.
If leakage source cannot be 
corrected or identified, call 
qualified service agency. Shut off gas supply to heater 
and close cold water inlet valve 
to heater.Repair or in case of suspected tank 
leakage, be certain to confirm before 
replacing heater.
Gas odors. Possible gas leaks.Shut off gas supply to heater 
and call gas company at once
TROUBLESHOOTING  
						

							35
NOTES:
1 .  Pref erred  piping  diagram.
2 .  The t emperat ure and  pressure  relief valve  setting  shall not exceed  pressure  rating  of  any  component  in the  syst em.
3 .  Servic e v alv es  are s hown f or serv icing  unit. However , local  codes  shall govern t heir usage.
4 .  The  Tank  Temperat ure Cont rol should  be wired t o and  control the pump  between t he wat er heat er(s)  and the storage t ank(s).
5 .  The  wat er heat er’s  operat ing thermost at  should  be set  5 degrees F higher t han the Tank  Temperat ure Cont rol.MUL TI FLUE  - (1 UNIT) WITH VE RTICAL  STORAGE  TANK
LEGEND
TEMPERA TURE & PRESSURE
RELIEF V ALVEPRESSURE RELIEF V ALVECIRCULA TING PUMPTA NK  TE M PER AT URE CO NTR O LDRAIN
FULL  POR T BALL  VALVETEMPERA TURE GAGEW ATER FLOW SWITCH
CHECK V
ALVE
W ARNING:  THIS DRA WING SHOWS SUGGESTEDPIPING CONFIGURA TION  AND OTHER DEVICES;
CHECK WITH LOCAL  CODES AND ORDINANCES
FOR  ADDITIONAL  REQUIREMENTS.
FINISHED
FLOOR
HOT W ATER
T O FIXTURES
COLD WATER
SUPPLY
EXPANSION
TANK
ALT. COLD WATER
CONNECTION
HOT
 WATER  RETURN
FROM  FIXTURES
PIPE T&P TO
OPEN DRAIN
WATER PIPING DIAGRAMS  
						

							36
NOTES:
1 .  Pref erred  piping  diagram.
2 .  The t emperat ure and  pressure  relief valve  setting  shall not exceed  pressure  rating  of  any  component  in the  syst em.
3 .  Servic e v alv es  are s hown f or serv icing  unit. However , local  codes  shall govern t heir usage.
4 .  The  Tank  Temperat ure Cont rol should  be wired t o and  control the pump  between t he wat er heat er(s)  and the storage t ank(s).
5 .  The  wat er heat er’s  operat ing thermost at  should  be set  5 degrees F higher t han the Tank  Temperat ure Cont rol.MUL TI FLUE  - (1 UNIT) WITH HORIZON TAL  ST ORAGE  TANK
LEGEND
TEMPERA TURE & PRESSURE
RELIEF V ALVEPRESSURE RELIEF V ALVECIRCULA TING PUMPTA NK  TE M PER AT URE CO NTR O LDRAIN
FULL  POR T BALL  VALV
E
TEMPERA TURE GAGEW ATER FLOW SWITCH
CHECK V
ALVE
W ARNING:  THIS DRA WING SHOWS SUGGESTEDPIPING CONFIGURA TION  AND OTHER DEVICES;
CHECK WITH LOCAL  CODES AND ORDINANCES
FOR  ADDITIONAL  REQUIREMENTS.
FINISHED
FLOOR
HOT W ATER  TO  FIXTURES
COLD WATER
SUPPLY HOT WATER
RETURN FROM 
FIXTURES
ALTERNATE
LOCATION CIRCULATING PUMP
EXPANSION
TANK
PIPE T&P TO
OPEN DRAIN  
						

							37
NOTES:
1 .  Pref erred  piping  diagram.
2 .  The t emperat ure and  pressure  relief valve  setting  shall not exceed  pressure  rating  of  any  component  in the  syst em.
3 .  Servic e v alv es  are s hown f or serv icing  unit. However , local  codes  shall govern t heir usage.
4 .  The  Tank  Temperat ure Cont rol should  be wired t o and  control the pump  between t he wat er heat er(s)  and the storage t ank(s).MULTI FLUE  - (1 UNIT) WITH MIXING  VAL VE  TWO  TEMPERA TURE
LEGEND
TEMPERATURE & PRESSURE
RELIEF V ALVEPRESSURE RELIEF V ALVECIRCULA TING PUMPTA NK  TE M PER AT URE CO NTR O LDRAIN
FULL  POR T BALL  VALVETEMPERA TURE GAGEW ATER FLOW SWITCH
CHECK V
ALVE
W ARNING:  THIS DRA WING SHOWS SUGGESTEDPIPING CONFIGURA TION  AND OTHER DEVICES;
CHECK WITH LOCAL  CODES AND ORDINANCES
FOR  ADDITIONAL  REQUIREMENTS.
TEMPERED
WATER
RETURN TEMPERED
WATER
O UTLE T HOT
W ATER
O UTLE T
HOT
WATER
RETURN
COLD WATER
SUPPLY
COLDHOT
EXPANSION
TANK
PIPE T&P TO
OPEN DRAIN  
						

							38
NOTES:
1 .  Pref erred  piping  diagram.
2 .  The t emperat ure and  pressure  relief valve  setting  shall not exceed  pressure  rating  of  any  component  in the  syst em.
3 .  Servic e v alv es  are s hown f or serv icing  unit. However , local  codes  shall govern t heir usage.
4 .  The  Tank  Temperat ure Cont rol should  be wired t o and  control the pump  between t he wat er heat er(s)  and the storage t ank(s).MULTI FLUE  - (2 UNITS)
LEGEND
TEMPERA TURE & PRESSURE
RELIEF V ALVEPRESSURE RELIEF V ALVECIRCULA TING PUMPTA NK  TE M PER AT URE CO NTR O LDRAIN
FULL  POR T BALL  VALV
E
TEMPERA TURE GAGEW ATER FLOW SWITCH
CHECK V
ALVE
W ARNING:  THIS DRA WING SHOWS SUGGESTEDPIPING CONFIGURA TION  AND OTHER DEVICES;
CHECK WITH LOCAL  CODES AND ORDINANCES
FOR  ADDITIONAL  REQUIREMENTS.
HOT W ATER
T O  FIXTURES
COLD WATER
SUPPLY HOT WATER
RETURN
EXPANSION
TANK
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN  
						

							39
NOTES:
1 .  Pref erred  piping  diagram.
2 .  The t emperat ure and  pressure  relief valve  setting  shall not exceed  pressure  rating  of  any  component  in the  syst em.
3 .  Servic e v alv es  are s hown f or serv icing  unit. However , local  codes  shall govern t heir usage.
4 .  The  Tank  Temperat ure Cont rol should  be wired t o and  control the pump  between t he wat er heat er(s)  and the storage t ank(s).
5 .  The  wat er heat er’s  operat ing thermost at  should  be set  5 degrees F higher t han the Tank  Temperat ure Cont rol.MUL TI FLUE  - (2 UNITS) WITH VE RTICAL  STORAGE  TANK
LEGEND
TEMPERA TURE & PRESSURE
RELIEF V ALVEPRESSURE RELIEF V ALVECIRCULA TING PUMPTA NK  TE M PER AT URE CO NTR O LDRAIN
FULL  POR T BALL  VALV
E
TEMPERA TURE GAGEW ATER FLOW SWITCH
CHECK V
ALVE
W ARNING:  THIS DRA WING SHOWS SUGGESTEDPIPING CONFIGURA TION  AND OTHER DEVICES;
CHECK WITH LOCAL  CODES AND ORDINANCES
FOR  ADDITIONAL  REQUIREMENTS.
FINISHED
FLOOR
COLD WATER
SUPPLY
HOT WATER
TO FIXTURES
ALTERNATE
COLD  WATER
CONNECTION HOT WATER
RETURN
EXPANSION
TANK
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN  
						

							40
NOTES:
1 .  Pref erred  piping  diagram.
2 .  The t emperat ure and  pressure  relief valve  setting  shall not exceed  pressure  rating  of  any  component  in the  syst em.
3 .  Servic e v alv es  are s hown f or serv icing  unit. However , local  codes  shall govern t heir usage.
4 .  The  Tank  Temperat ure Cont rol should  be wired t o and  control the pump  between t he wat er heat er(s)  and the storage t ank(s).
5 .  The  wat er heat er’s  operat ing thermost at  should  be set  5 degrees F higher t han the Tank  Temperat ure Cont rol.MUL TI FLUE  - (2 UNITS) WITH VE RTICAL  STORAGE  TANK
LEGEND
TEMPERA TURE & PRESSURE
RELIEF V ALVEPRESSURE RELIEF V ALVECIRCULA TING PUMPTA NK  TE M PER AT URE CO NTR O LDRAIN
FULL  POR T BALL  VALV
E
TEMPERA TURE GAGEW ATER FLOW SWITCH
CHECK V
ALVE
W ARNING:  THIS DRA WING SHOWS SUGGESTEDPIPING CONFIGURA TION  AND OTHER DEVICES;
CHECK WITH LOCAL  CODES AND ORDINANCES
FOR  ADDITIONAL  REQUIREMENTS.
FINISHED
FLOOR
COLD WATER
SUPPLY
HOT WATER
TO FIXTURES
ALTERNATE
COLD  WATER
CONNECTION HOT WATER
RETURN
EXPANSION
TANK
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN