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Summary of Contents for American Water Heater HCG-60T120
- Page 1 COMMERCIAL GAS WATER HEATERS SERVICE HANDBOOK HIGH EFFICIENCY COMMERCIAL GAS SERIES FOR MODELS: • HCG-60T120 • AHCG-60T120 • HCG-100T150 • AHCG-100T150 • HCG-100T199 • AHCG-100T199 • HCG-100T250 • AHCG-100T250 PRINTED 0508 198153-000...
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Page 2: Table Of Contents
High-Efficiency Commercial Gas Series - Service Manual TABLE OF CONTENTS INTRODUCTION..................................2 QUALIFICATIONS..................................2 TOOLS REQUIRED.................................3 GENERAL INFORMATION..............................4 GAS PRESSURE REQUIREMENTS ............................4 GAS PRESSURES – 120 and 150 KBtu/hr MODELS......................5 GAS VALVE 120 KBtu/hr MODEL............................6 GAS VALVE 150 KBtu/hr MODEL............................6 GAS PRESSURES 199 and 250 KBtu/hr MODELS.........................7 GAS VALVE 199 and 250 KBtu/hr MODELS...........................8 VENTING TABLES...................................9 VENTING - ALL MODELS –... -
Page 3: Introduction
High-Efficiency Commercial Gas Series - Service Manual INTRODUCTION The service manual is designed to aid in The information contained in this manual is servicing and troubleshooting High-Efficiency designed answer commonly faced Commercial Gas Series water heaters in the situations encountered in the operation of field. -
Page 4: Tools Required
High-Efficiency Commercial Gas Series - Service Manual TOOLS REQUIRED ELECTRICAL MULTIMETER CAPABLE OF MEASURING CONTINUITY/ OHMS, AC ● & DC VOLTS, AMPERES, MICROAMPERES, MILLIVOLTS, and FREQUENCY(Hz) UEi Model DL289 or equivalent ○ ● DIGITAL MANOMETER + 60” W. C. in .01” increments Note: A digital manometer is required for testing pressure switches and can replace a gas pressure gauge, draft gauge or slack tube manometer for checking gas pressure. -
Page 5: General Information
High-Efficiency Commercial Gas Series - Service Manual GENERAL INFORMATION INSTALLATION REQUIREMENTS FOR THE equipment is installed in a crawl space or an attic, COMMONWEALTH OF MASSACHUSETTS the hard wired carbon monoxide detector with alarm For all side wall terminated, horizontally vented and battery back-up may be installed on the next power vent, direct vent, and power direct vent gas adjacent floor level. -
Page 6: Gas Pressures - 120 And 150 Kbtu/Hr Models
High-Efficiency Commercial Gas Series - Service Manual GAS PRESSURES – 120 and 150 KBtu/hr MODELS CHECKING THE FIRING RATE ADJUSTMENT PROCEDURE: GAS PRESSURE a. Attach a manometer to the manifold pressure tap on the gas valve – refer to the table on page 4 for 120 AND 150 MODELS correct pressure. -
Page 7: Gas Valve 120 Kbtu/Hr Model
High-Efficiency Commercial Gas Series - Service Manual GAS VALVE 120 KBtu/hr MODEL The gas control valve on the 120 KBtu/hr model has a built in adjustable pressure regulator. The adjustment screw is accessed by removing the cap screw market regulator in the illustration. -
Page 8: Gas Pressures 199 And 250 Kbtu/Hr Models
High-Efficiency Commercial Gas Series - Service Manual GAS PRESSURES 199 and 250 KBtu/hr MODELS HIGH ALTITUDE INSTALLATION ADJUSTMENT PROCEDURE: The 199 and 250 models are suitable for GAS PRESSURE installation up to 10,100 feet above sea level 199 AND 250 MODELS with no adjustments. -
Page 9: Gas Valve 199 And 250 Kbtu/Hr Models
High-Efficiency Commercial Gas Series - Service Manual GAS VALVE 199 and 250 KBtu/hr MODELS Pressure readings may be taken on the gas Note: Manometer tubing shown is not valve by connecting a manometer to the supplied with the water heater. pressure ports on the valve. -
Page 10: Venting Tables
High-Efficiency Commercial Gas Series - Service Manual VENTING TABLES Maximum equivalent feet of intake air and vent pipe using 3” PVC is 50 feet (15.2m). Equivalent feet must include any 90° elbows (two 45° elbows equal one 90° elbow). Three inch diameter 90° elbows are equivalent to 5' (1.5m) of pipe. -
Page 11: Venting - All Models - Single Pipe Power Vent - Using Room Air
High-Efficiency Commercial Gas Series - Service Manual VENTING - ALL MODELS – SINGLE PIPE POWER VENT – USING ROOM AIR MINIMUM 18 INCHES (46 CM) MINIMUM 18 INCHES (46 CM) Technical Literature Department Ashland City, Tennessee © 2008 Servicing should only be performed by a Qualified Service Agent... -
Page 12: Venting - All Models - Two Pipe Direct Vent - Using Outside Air
High-Efficiency Commercial Gas Series - Service Manual VENTING – ALL MODELS – TWO PIPE DIRECT VENT – USING OUTSIDE AIR MINIMUM 18 INCHES (46 CM) MINIMUM 18 INCHES (46 CM) Technical Literature Department Ashland City, Tennessee © 2008 Servicing should only be performed by a Qualified Service Agent... -
Page 13: Vent / Intake Air Terminations
High-Efficiency Commercial Gas Series - Service Manual VENT / INTAKE AIR TERMINATIONS WHEN LOCATING THE VENT AND INTAKE AIR TERMINATIONS ON A SIDEWALL, THE FOLLOWING SPECIFICATIONS PERTAINING TO LOCATION AND CLEARANCES MUST BE FOLLOWED. 1. The intake vent terminal and the exhaust vent terminal must terminate on the same exterior wall and must be located at a minimum of 24"... -
Page 14: Direct Vent Installations
High-Efficiency Commercial Gas Series - Service Manual DIRECT VENT INSTALLATIONS The intake air connection on the water heater contains a mesh screen to prevent large particles from entering the blower. WHEN THE WATER HEATER IS INSTALLED DIRECT VENT (TWO PIPES), THE BALANCE PLATE AND MESH SCREEN MUST BE REMOVED BEFORE GLUING PIPE TO THE CONNECTOR. -
Page 15: Control Overview
High-Efficiency Commercial Gas Series - Service Manual CONTROL OVERVIEW Interaction with the control system is done through the The table of status icons describes graphically User Interface Module (UIM).The default screen is operational details of the water heater. Below is a referred to as the “desktop”... -
Page 16: Adjusting Tank Temperature - Operating Set Point - Differential
High-Efficiency Commercial Gas Series - Service Manual ADJUSTING TANK TEMPERATURE – OPERATING SET POINT - DIFFERENTIAL The Operating Set Point of this water heater ACTION: determines the regulated temperature for the water in Press Change then use the UP and DOWN buttons to the tank. -
Page 17: Changing The Display Units
High-Efficiency Commercial Gas Series - Service Manual CHANGING THE DISPLAY UNITS The desktop menu has the option of selecting ACTION: between degrees Fahrenheit and degrees Celsius for Press Update to accept the change or Cancel to temperature displays. This can be found in the reject it. -
Page 18: Fault And Warning Conditions - Advanced Diagnostic Information
High-Efficiency Commercial Gas Series - Service Manual FAULT AND WARNING CONDITIONS – ADVANCED DIAGNOSTIC INFORMATION The water heater control system has the ability to Faults: This is a safety related condition that has been monitor almost all aspects of the water heater's detected by the control system. -
Page 19: Current Fault Or Warning
High-Efficiency Commercial Gas Series - Service Manual CURRENT FAULT OR WARNING When a fault or warning condition has been declared by the control system it will automatically be displayed on the UIM display and the back light will blink. You can choose to leave the current fault or warning ACTION: message by pressing the Back key. -
Page 20: Viewing The Fault History - Water Heater Information
High-Efficiency Commercial Gas Series - Service Manual VIEWING THE FAULT HISTORY – WATER HEATER INFORMATION The control system for this water heater will store a Viewing Information About the Water Heater history of ten of the last Fault and Warning conditions that occurred. -
Page 21: Sequence Of Operation - Text
High-Efficiency Commercial Gas Series - Service Manual SEQUENCE OF OPERATION - TEXT TYPICAL SEQUENCE 10. The combustion blower will run for the duration of the post purge cycle to purge the system of all 1. When the control is powered it should display combustion gases. -
Page 22: Sequence Of Operation - Flow Chart
High-Efficiency Commercial Gas Series - Service Manual SEQUENCE OF OPERATION – FLOW CHART Power on Control displays model, temperature setting and status The control If all checks are If checks are not performs internal passed and there is passed the system checks a call for heat the control will... -
Page 23: Controls - Central Control Board - Ccb
High-Efficiency Commercial Gas Series - Service Manual CONTROLS – CENTRAL CONTROL BOARD – CCB The Central Control Board or CCB is contained in the housing shown below. Access to the This view shows the cover removed from the board and the wiring harness plugs can be CCB. -
Page 24: Controls - Pressure Switches
High-Efficiency Commercial Gas Series - Service Manual CONTROLS – PRESSURE SWITCHES All models are provided with four pressure BLOCKED EXHAUST SWITCH switches. These switches are essential to the The Blocked Exhaust Switch is used to verify the safe and proper operation of the unit. The water heater's vent (exhaust) piping is not restricted. -
Page 25: Controls - Pressure Switches (Cont)
High-Efficiency Commercial Gas Series - Service Manual CONTROLS – PRESSURE SWITCHES (cont) BLOCKED EXHAUST BLOCKED INTAKE AIR LOW GAS PRESSURE PRESSURE SWITCH PRESSURE SWITCH SWITCH M ODEL SWITCH M ODEL PRESSURE M ODEL PRESSURE 120N +1.2”WC M odels 120 - 199 Natural +4.0”WC 150N... -
Page 26: Controls - Igniter, Flame Sensor, Sight Glass, Powered Anodes
High-Efficiency Commercial Gas Series - Service Manual CONTROLS – IGNITER, FLAME SENSOR, SIGHT GLASS, POWERED ANODES The connections for the hot surface igniter The new High Efficiency commercial water and the flame sense rod are shown below. heater is equipped with powered anodes. Also shown is the burner sight glass. -
Page 27: Minimum Igniter / Flame Sensor Current - Control Timing
High-Efficiency Commercial Gas Series - Service Manual MINIMUM IGNITER / FLAME SENSOR CURRENT - CONTROL TIMING HOT SURFACE IGNITER CONTROL TIMING This water is equipped with an electric hot Pre-purge 25 seconds surface igniter. The igniter material is Igniter Warm-up 17 seconds silicone carbide and should not be handled with bare hands because of possible damage... -
Page 28: Blower Speed Control 199 And 250 Kbtu/Hr Models
High-Efficiency Commercial Gas Series - Service Manual BLOWER SPEED CONTROL 199 AND 250 KBtu/hr MODELS The input of the 199 and 250 KBtu/hr to a much higher rate. models is determined by blower speed. The Meter black lead is connected to ground (not input of the water heater may be determined shown) and the red lead is connected to an by clocking the meter as shown on page 5 or... -
Page 29: Wiring Diagram
High-Efficiency Commercial Gas Series - Service Manual WIRING DIAGRAM Technical Literature Department Ashland City, Tennessee © 2008 Servicing should only be performed by a Qualified Service Agent... - Page 30 PO Box 1597, 500 Princeton Road Johnson City, TN 37605 www.americanwaterheater.com...
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