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American Water Heater (A)BCG38T500-8P manual Requirements, Instruction Manual, Tools Required

Models: (A)BCG38T500-8P (A)BCG385T500-8N

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REQUIREMENTS

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 Water Heaters web site (www.americanwaterheater.com) or by calling technical support at 800-456-9805.

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 the water heater. This Service Manual does not replace or supersede the instruction manual that came with the water heater. Always refer to the instruction manual that came with the water heater for complete installation instructions.

TOOLS REQUIRED

•Phillips head screwdriver

•standard screwdrivers

•3/8 and 7/16 inch open end wrench

•set of marked drill bits

•electrical multimeter tester capable of measuring continuity, AC voltage, and DC voltage

•gas pressure gauge or manometer

•water pressure gauge

•thermometer (range 0 - 220 degrees F)

•1/2 inch socket with extension for removal of the clean out cover

•1-1/16 inch socket with extension for anode removal

TOOLS OPTIONAL

•Two digital manometers range -20.00 to +20.00” W.C., resolution 0.01” W.C. Recommend UEI model EM200, TPI model 620 or equivalent.

Servicing should only be performed by a Qualiﬁed Service Agent

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American Water Heater (A)BCG38T500-8P, (A)BCG385T500-8N Requirements, Instruction Manual, Tools Required, Tools Optional

Contents

MODELS ABCG385T500-8N ABCG38T500-8P Service HandbookINSTALLATION CONSIDERATIONS - PRE SERVICE CHECKS - OPERATION & SERVICE -TROUBLESHOOTINGCOMMERCIAL GAS WATER HEATER SERVICE MANUAL TABLE OF CONTENTS Servicing should only be performed by a Qualiﬁed Service AgentSERVICE WARNING SERVICE REMINDERINTRODUCTION QUALIFICATIONSREQUIREMENTS INSTRUCTION MANUALTOOLS REQUIRED TOOLS OPTIONALINSTALLATION CONSIDERATIONS WATER PIPINGGAS PRESSURE REQUIREMENTS Closed Water SystemsAIR REQUIREMENTS Air SupplyInsufficient Make-up Air, Negative Air Pressure, and Downdrafts Make-up Air Direct Communication with Outdoors CLEARANCES WATER HEATER Contaminated AirCLEARANCES EXTERIOR VENTING OPERATION AND SERVICE SEQUENCE OF OPERATIONELECTRICAL SEQUENCE WIRING DIAGRAM OPERATION AND SERVICEServicing should only be performed by a Qualiﬁed Service Agent WIRING DIAGRAM FOR ABCG385T500-8N/8POPERATING SEQUENCE - FLOW CHART OPERATION AND SERVICEServicing should only be performed by a Qualiﬁed Service Agent Below 0.1 uA DC Flame SenseGAS CONTROL VALVE Measuring Gas PressuresManifold Pressure Adjustment Main Valve Solenoid ConnectionsGAS CONTROL VALVE/BURNER AREA VIEW OPERATION AND SERVICEServicing should only be performed by a Qualiﬁed Service Agent Honeywell Gas Valve Main Burner ShieldBLOWER PROVER SWITCH - SETTINGS OPERATION AND SERVICE THERMOSTAT AND IGNITION CONTROL BOARD VIEWServicing should only be performed by a Qualiﬁed Service Agent WHITE RODGERS INTEGRATED CONTROL - THERMOSTAT WHITE RODGERS IGNITION CONTROL BOARDOPERATION AND SERVICE Servicing should only be performed by a Qualiﬁed Service AgentPRE-SERVICE CHECKLIST TROUBLESHOOTING IGNITION CONTROL BOARD ERROR CODES1 FLASH System has locked out after 3 trials for ignition 2 FLASHES6 FLASHES Reversed polarity in power supply 3 FLASHES4 FLASHES 7 FLASHESCONTINUOUS FLASH 8 FLASHES Igniter not sensed and/or water heater not groundedCONTINUOUS ON Internal control board failure INTEGRATED HEATER CONTROL DISPLAY LIGHTS INDICATIONACTION STATUSTEST 1 120 VAC TO HEATER CHECK ConditionsTEST thenTEST 2 POLARITY CHECK TROUBLESHOOTINGServicing should only be performed by a Qualiﬁed Service Agent Check from on/off switch center and white wire terminals to groundTEST 3 CONTINUITY CHECK OF HIGH LIMIT ECO ThenSee Ignition Control Board Error Codes TROUBLESHOOTINGTEST 4 UPPER TEMPERATURE PROBE CONTINUITY CHECK OHMS RESISTANCE TABLEOhms TROUBLESHOOTINGTEST 5 CALLING FOR HEAT - NO BLOWER OPERATION TROUBLESHOOTINGServicing should only be performed by a Qualiﬁed Service Agent ConditionsTEST 6 BLOWER ON, NO IGNITION TROUBLESHOOTINGServicing should only be performed by a Qualiﬁed Service Agent Prover SwitchTEST 7 BLOWER ON, BLOWER PROVER SWITCH CLOSED, NO IGNITER OPERATION TROUBLESHOOTINGServicing should only be performed by a Qualiﬁed Service Agent Continuity check - Power off- Plug removed from E4 receptaclesTEST 8 IGNITER HEATS, NO MAIN BURNER TROUBLESHOOTINGServicing should only be performed by a Qualiﬁed Service Agent TESTTEST 9 IGNITER HEATS, NO MAIN BURNER TROUBLESHOOTINGServicing should only be performed by a Qualiﬁed Service Agent ConditionsTEST 10 MAIN BURNER IGNITION FOR LESS THAN FIVE SECONDS TROUBLESHOOTINGServicing should only be performed by a Qualiﬁed Service Agent ConditionsTEST 11 WATER HEATER SHUTTING OFF BELOW SETTING TROUBLESHOOTINGServicing should only be performed by a Qualiﬁed Service Agent WATER HEATER SHUTTING OFF BELOW SETTINGServicing should only be performed by a Qualiﬁed Service Agent Servicing should only be performed by a Qualiﬁed Service Agent P.O. Box 1597, Johnson City, TN Phone 800-456-9805 Fax Copyright 2010 American Water Heater Company. All rights reserved