American Water Heater (A)BCG38T500-8P, (A)BCG385T500-8N manual

COMMERCIAL GAS WATER HEATER

SERVICE MANUAL

TABLE OF CONTENTS

INTRODUCTION	3
Qualifications	3
Service Warning	3
Service Reminder	3
REQUIREMENTS	4
Instruction Manual	4
Tools Required	4
Tools Optional	4
INSTALLATION CONSIDERATIONS	5
Water Piping	5
Closed Water Systems	5
Thermal Expansion	5
Gas Pressure Requirements	5
Air Requirements	6
Air Supply	6
Insufficient Make-up Air, Negative Air Pressure,
and Downdrafts	7
Make-up Air: Direct Communication with Out-
doors	8
Contaminated Air	9
Clearances (Water Heater)	9
Clearances (Exterior)	10
Venting	11
OPERATION AND SERVICE	12
Sequence of Operation	12
Electrical Sequence	13
Wiring Diagram	14
Operating Sequence - Flow Chart	15
Gas Control Valve	16
Measuring Gas Pressures	16
Manifold Pressure Adjustment	17
Main Valve Solenoid Connections	17

Gas Control Valve/Burner Area View		18
Blower Prover Switch - Settings		19
Thermostat and Ignition control Board View		20
White Rodgers Integrated Control - Thermostat		21
White Rodgers Ignition Control Board		21
Pre-Service Checklist		22
TROUBLESHOOTING		23
Ignition Control Board: Error Codes		23
1	Flash	23
2	Flashes	23
3	Flashes	24
4	Flashes	24
6	Flashes	24
7	Flashes	24
8	Flashes	25
Continuous Flash		25
Continuous On		25
Integrated Heater Control: Display Lights		26
Test 1: 120 VAC to Heater Check		27
Test 2: Polarity Check		28
Test 3: Continuity Check of High Limit (ECO)		29
Test 4: Upper Temperature Probe
Continuity Check		30
Test 5: Calling for Heat - No Blower Operation		31
Test 6: Blower On, No Ignition		32
Test 7: Blower On, Blower Prover Switch Closed,
No Igniter Operation		33
Test 8: Igniter Heats, No Main Burner		34
Test 9: Igniter Heats, No Main Burner		35
Test 10: Main Burner Ignition for Less than
Five Seconds		36
Test 11: Water Heater Shutting Off Below Setting ..		37

Servicing should only be performed by a Qualified Service Agent

2