Bradford-White Corp 238-47878-00B 04/10 manual

238-47878-00 B 04/10 ACCESSORY MODULE Including Protection, Performance, and Inlet Shut-off Valve Packages INSTALLATION & OPERATION MANUAL With Troubleshooting Guide PLACE THESE INSTRUCTIONS ADJACENT TO WATER HEATER AND NOTIFY OWNER TO KE EP FOR FUTURE REFERENCE - Do not store or use gasoline or other flammable vapors and liquids in the vicinit[...]

Important Information -2- Accessory Module: The Accessory Module is an electronic component that allows the water heater gas control to be connected to the Protection, Performance, and Inlet Shut-off Valve Packages. Accessory Module: Contains: o Accessory Module o Plug-in transformer o Transformer wire harness o (2) gas control harnesses (only (1) [...]

Important Information -3- Protection Package (sold separately): Contains: o Leak sensor (2 piece) o Dam o Leak sensor wire harness o Wire holders o Wire ties o Screws Features: o Senses a collection of water near the water heater o Sounds the alarm to alert homeowners when a water heater leak is detected and verified o Alarm is re-settable and can [...]

Important Information -4- CAUTION The water heater, when se t at a lower temperature setting, is not capabl e of producing hot water of sufficient temperature for sanitizing purposes. NOTICE The water heater is equipped with an energy cu t out device to prevent overheating. Should overheating occur or the gas suppl y fails to shut off, turn off t h[...]

Important Information -5- For energy efficient operation of your water h eater, the suggested initial water temperatu re setting is 120 ˚ F (49 ˚ C). During the winter season, or any col d peri od, you may desire a higher water temperature setting to adjust for the colder incoming water. Thi s adjustment, however, may cau se additional condensati[...]

Table of Contents -6- Page Tools Required ............................................................................................ 7 Package Components ................................................................................. 8 Accessory Module ........................................................................... 8 Protection Pack[...]

Tools Required -7- Slotted Screwdriver Philips Screwdriver 1/8” Drill bit Drill Needle nose pliers Pipe dope Adjustable wrench Caulk gun RTV sealant (silicone) Pipe cutter Propane torch Solder Flux Wire Cutters Wire Strippers Fine Point Marker[...]

Package Components Accessory Module -8- Table 1 Accessory Module Description Quantity 1A Plug-in Transformer 1 2A WV4460 Wire Harness 1 3A Transformer Wire Harness 1 4A WV8840 Wire Harness 1 5A Wire Holders 4 6A Installation & Operation Manual 1 7A Wiring Diagram Label 1 8A Diagnostic Label 1 9A Wire Ties 4 10A Screws 9 11A Accessory Module 1 N[...]

Package Components Protection Package -9- Table 2 Protection Package Description Quantity 1B Leak Sensor Bracket 1 2B Leak Sensor Housing 1 3B Dam 1 4B Screws 6 5B Leak Sensor Wire Harness 1 6B Wire Holders 4 7B Wire Ties 4[...]

Package Components Performance Package -10- Table 3 Performance Package Description Quantity 1C Setback Control Wire Harness 1 2C Integrated Mixing Device, IMD 1 - Cold Water Tee - Mixing Valve - 8” Flexible Connector - 11” Flexible Connector - Instruction & Operation Manual - Thermo-strip 3C Setback Control (batteries included) 1 4C Wire T[...]

Package Components Inlet Shut-off Valve Package -11- Table 4 Inlet Shut-off Valve Description Quantity 1D Inlet Shut-off Valve with Integrated Wire Harness 1 2D ¾” x 1” NPT Brass Bushings 2 3D Wire Ties 4[...]

Wiring Diagram -12-[...]

Accessory Module Installation -13- In the following section, the instructions detail how to inst all the Accessory Module. Properly locating and mounting the Accessory Module is required. Unpack the Accesso ry Module Step 1: Remove the Accessory Module and its comp onent s from their packaging, as shown in Figure 1. Determine the Gas Control Wire H[...]

Accessory Module Installation -14- Determine the Gas Control Wire Harness – cont’d Step 3: If the gas control uses a standing pilot, the WV8840 wire harness must be u sed. The WV8840 gas control and wire harness a re shown in Figure 3. Discard the WV4460 wi re harness. Locate the Accessory Module Step 4: The Accessory Module must be mounted to [...]

Accessory Module Installation -15- Mark the Location of the Acce ssory Module Step 5: Using a marker, mark the location of the Accessory Module screw holes. This is shown in Figure 5. Set the Accessory Module Aside Step 6: Remove the Accessory Module from t he water heater jacket, as sho wn i n Figure 6. Figure 5 Figure 6 Accessory Module Marker Wa[...]

Accessory Module Installation -16- Drill the Accessory Module Scre w Holes Step 7: Using a 1/ 8” drill bit and drill, drill the (2) scre w holes that were marke d in Step 5. This is sho wn in Figure 7. Position the Accessory Module Step 8: Put the Accessory Module up again st the water heater jacket and posi tion it to the pre-drilled holes. This[...]

Accessory Module Installation -17- Mounting the Accessory Module Step 9: Using (2) of the i ncluded Philips head screws, screw the Accessory Module to th e water heater jacket, as shown in Figure 9. Apply the Necessary Labels Step 10: Apply both the wiring diagram and diagnost ic labels. The se labels should be applie d to the water heater jacket n[...]

Accessory Module Installation -18- Remove the Accessory Module Cover Step 11: Using a Philips head screwdriver, loosen both screws on the A ccessory Module cover, as shown in Figure 11. The cover screws are p ermanently retained and cannot be comple tely removed. Retain the cover for later use. Prepare the Plug-in Transformer for Assembly Step 12: [...]

Accessory Module Installation -19- Transformer wire ha rness Assemble the Transformer and its Wi re Harness Step 13: Take one end of the transformer wire ha rnes s and slide each fork terminal un der one of the screws. This is shown in Figure 13. Connect the Transformer and its Wire Harness Step 14: Tighten both screws on the transformer down, as s[...]

Accessory Module Installation -20- Prepare to Connect the Transformer Wire Harness to the Acc essory Module Step 15: Loosen the (2) Philips h ead screws on the Accessory Module, labeled “R1” and “C1. ” This is shown in Figure 15. Insert the Transformer Wire Harness into the Acce ssory Module Step 16: Insert each wire stripped e nd of the Tr[...]

Accessory Module Installation -21- Connect the Transformer Wire Harness and the Accessory Module Step 17: Tighten both screws, “R1” and “C1,” while holding the Transformer wire harness in place, as shown in Figure 17. Connect Accessory Module to WV4460 Wire Harness Step 18: If the water heater gas control has a n inte rmittent pilot (WV4460[...]

Accessory Module Installation -22- Assemble the WV4460 Wire Harness and Accessory Module Step 19: Insert the red wire, from the WV4460 wire ha rness, under the screw la beled “D/1.” This is shown in Figure 19. Connect the WV4460 Wir e Harness and Accessor y Module Step 20: Tighten the screw labeled “D/1,” as shown in Figure 20. Fi g ure 19 [...]

Accessory Module Installation -23- Assemble the WV4460 Wire Harness and Accessory Module – cont’d Step 21: Insert the black wire, from the WV4460 wire harne ss, under the screw labeled “R/2.” This is shown in Figure 21. Connect the WV4460 Wir e Harness and Accessor y Module – cont’d Step 22: Tighten the screw labeled “R/2,” as shown[...]

Accessory Module Installation -24- Assemble the WV4460 Wire Harness and Accessory Module – cont’d Step 23: Insert the white wire, from the WV4460 wire harne ss, under the screw labeled “C/3.” This is shown in Figure 23. Connect the WV4460 Wir e Harness and Accessor y Module – cont’d Step 24: Tighten the screw labeled “C/3,” as show [...]

Accessory Module Installation -25- Connect the Accesso ry Module to the WV8840 Wire Harness Step 25: Insert one end of the WV8 840 wire harness ov er the edg e of the Accessory Module circuit board. This connection point is o n the bottom right hand side of the circuit board, and it is shown in Figure 25. Proceed to Step 27 when finished. Connect t[...]

Accessory Module Installation -26- Connect the WV8840 Wir e Harness to the WV8840 Gas Con trol Step 27: Push the plastic connector o n the WV8840 wire harness into th e recessed area on the botto m side of the WV8840 gas control. This is shown in Figure 27. The Accessory Module installation is complete. Proceed to the installation sections for the [...]

Setback Control Installation -27- In the following section, the instructions detail how to install the Setback Control on the water heater. The Accessory Module must be installed for the Setback Control to work with the water heater gas control. Unpack the Setback Con trol Junction Box Assembly Step 1: Remove the Setback Co ntrol Junction Box As se[...]

Setback Control Installation -28- Remove the Setback Con trol Battery Holder Step 3: Depress the top side of the battery holder and remove it. This is sho wn in Figure 30. Install the Setback Contr ol Batteries Step 4: Install the (2) supplied AAA ba tteries into the battery holder of the Setback Control, as shown in Figure 31. Figure 30 Figure 31 [...]

Setback Control Installation -29- Install the Setback Contr ol Battery Holder Step 5: Install the Setback Control Batt ery Holder, just as it was installed prior t o Step 3. This is shown i n Figure 32. Remove the Protectiv e Plate Step 6: Remove the Setback Control protective plat e from the Setback Control by pullin g these items apart. This is s[...]

Setback Control Installation -30- Locate the Setback Contr ol Junction Box Assembly Step 7: Place the Setback Control Junction Box Assembly on top of the water heater. This a s sembly mu st face the front of the water heater, an d it must be located close to the centerlin e of the water heater. This is shown in Figure 34. The Setback Control Juncti[...]

Setback Control Installation -31- Remove the Setback Con trol Junction Box Assembly Step 9: Remove the Setback Control Junctio n Box Assembly from the top of the water heat er, as shown in Figure 36. Drill the Setback Control Junction Box Assembly Mounting Ho les Step 10: Using a 1/8” drill bit and drill, drill the (2) screw holes that were marke[...]

Setback Control Installation -32- Position the Setback Control Junc tion Box Assembly Step 11: Put the Setback Control Jun ction Box Assembly back on top of the wa ter heater and position it to the pre-drilled holes. This is shown in Figure 3 8. Mount the Setback Contr ol Junction Box Assembly Step 12: Using (2) of the inclu ded Philips head screws[...]

Setback Control Installation -33- Install the Setback Contr ol Step 13: Snap the Setback Control into the backpla te on the Setback Control Jun ction Box Assembly. Align the Setback Control to the backplate, and press until it is fully seated. This is shown in Figure 40. Connect the Setback Co ntrol Wire Harness to the Setback Con trol Junction Box[...]

Setback Control Installation -34- Connect the Setback Co ntrol Wire Harness to the Accessory Module Step 15: If the water heater gas control has a n inte rmittent pilot (WV4460 gas control), the conne ction, “D/1,” is already being used. This same conne ction point is used to connect the Setback Control. Loosen the screw “D/1.” This is show[...]

Setback Control Installation -35- Connect the Setback Co ntrol Wire Harness and Accessory Module Step 17: Tighten the screw labeled “D/1,” as shown in Figure 44. Assemble the Setback Control Wire Harn ess and Accessory Module – cont’d Step 18: If the water heater gas control has a n intermittent pilot (WV4460 gas control ), the connection, [...]

Setback Control Installation -36- Assemble the Setback Control Wire Harn ess and Accessory Module – cont’d Step 19: Insert the black wire, from the Setback Control wire harness, under the scre w labeled “R/2.” If the water heater has a WV4460 gas control, the gas c ontrol wire harness bl ack wire must be retained underneath this screw also.[...]

Setback Control Installation -37- Assemble the Setback Control Wire Harn ess and Accessory Module – cont’d Step 21: If the water heater gas control has a n inte rmittent pilot (WV4460 gas control), the conne ction, “C/3,” is already being used. This same conne ction point is used to connect the Setback Control. Loosen the screw “C/3.” T[...]

Setback Control Installation -38- Connect the Setback Co ntrol Wire Harness and Accessory Module – cont’d Step 23: Tighten the screw labeled “C/3,” as sho wn in Figure 50. The Setback Control installation is complete. Proceed to the installation sections for the other purch ased packages. Or, if finished, proceed to the Start-up Procedure o[...]

Integrated Mixing Device - IMD -39- Refer to the instructions included with Integrated Mixing Device (IMD), on how to install and operate the IMD. Figure 51 shows the contents included with the integra ted mixing device. Figure 51 CAUTION The piping diagram suppli ed with the water heater must be followed.[...]

Leak Sensor Installation -40- In the following section, the instructions detail how to install the Leak Sensor. The Accessory Module must be installed for the Leak Sensor to work with the water heater gas control. The leak sensor can take up to 15 minutes to sense and verify a water heater tank leak. Unpack the Leak Sensor and its Com ponents Step [...]

Leak Sensor Installation -41- Connect the Leak Sensor and its Wire Harness Step 3: Connect the Leak Sensor wire harness to the Lea k Sensor (specifically the end wi th the plastic connector), as shown in Figure 54. Prepare the Accessory Module for the Leak Sensor Step 4: Loosen the screw labeled “C1,” as shown in Fi gure 55. Ensure that the Tra[...]

Leak Sensor Installation -42- Prepare the Accessory Module for the Leak Sensor – cont’d Step 5: Loosen the screw labeled “LK,” as sho wn in Figure 56. Remove the Leak Sensor Resistor Step 6: Using needle nose pliers, remove the Lea k Sensor resistor fro m the Accessory Module and discard. This is shown in Figure 57. Figure 56 Figure 57 Tran[...]

Leak Sensor Installation -43- Assemble the Leak Sensor Wire Harness and the Accessory Module Step 7: Insert the red wire, from the Leak S ensor wire harness, unde r the screw labeled “C1.” This i s shown in Figure 58. En sure that the wire from the Transfo rmer wire harness at this loca tion is retained under this screw. Connect the Leak Sensor[...]

Leak Sensor Installation -44- Assemble the Leak Sensor Wire Harness and the Accessory Module – cont’d Step 9: Insert the black wire, from the Leak Sensor wire ha rness, under the screw labeled “LK.” Thi s is shown in Figure 60. Connect the Leak Sensor Wire Harness and Accessory Module – cont’d Step 10: Tighten the screw labeled “LK , [...]

Leak Sensor Installation -45- Position the Leak Sensor Step 11: Position the Leak Sensor up against the water heater jacket, as shown in Figu re 62. The Leak Sensor must be positioned to the left of the water heat er gas control. The Leak Sensor must sit flat on the floor or in the drain pan. Mark the Location of the Leak Senso r Step 12: Using a m[...]

Leak Sensor Installation -46- Remove the Leak Sensor Step 13: Remove the Leak Sensor f rom the water heater jacke t, and set it a side. This is shown in Figure 64. Drill the Leak Sensor Mounting Hole Step 14: Using a 1/8” drill bit and drill, drill the screw hole that was ma rked in Step 12. This is shown in Figure 65. Figure 64 Figure 65 Leak Se[...]

Leak Sensor Installation -47- Position the Leak Sensor Step 15: Put the Leak Sensor back in position against th e water h eater jacket and position to the pre- drilled hole, as shown in Figure 66. Mount the Leak Sensor Step 16: Using (1) of the included P hilips head screws, screw the Leak Sensor to the water heater jacket. This is shown in Figure [...]

Leak Sensor Installation -48- Position the Dam Step 17: Position the dam aro und the water heater, so it surrounds th e water heater and corrals a water heater tank leak towards the Leak Senso r. This is shown in Figure 68. Fill in the Gaps Step 18: Fill in any gaps between the dam and the floor. This is shown in Figure 69. The Leak Sensor installa[...]

Inlet Shut-off Valve Installation -49- In the following section, the instructions detail how to install the Inlet Shut-off Valve. If installed, this device will shut off the water supply to the water heater after the Leak Senso r has sensed and verified a water heater tank leak has occu rred. The Accessory Module and Leak Sensor must be installed f[...]

Inlet Shut-off Valve Installation -50- Determine if Bushings are Necess ary Step 3: If the water heater u ses a 3/4” NPT thread water inlet, the (2) in cluded 3/4” x 1” NPT bushings must be used. Proceed to Step 4. Otherwise, proceed to Step 6. Prepare Bushings for Installation Step 4: Apply pipe dope (suitable for potable wat er use) to the [...]

Inlet Shut-off Valve Installation -51- Install the Bushings Step 5: Thread the bushings into each end of the Inlet Shut-off Valve, as shown in Figure 72. Install the Inlet Shut-off Valve Step 6: Thread the Inlet Shut-off Valve onto the wate r heater inlet (cold). Or, if an integrated mixing device is used, thread the Inlet Shut-off Valve ont o the [...]

Inlet Shut-off Valve Installation -52- Connect the Cold Water Supply Step 7: Pipe the cold water supply piping to the Inlet Shut-off Valve inlet, as shown in Figure 74. Connect the Inlet Shut-off Valv e Harness to the Accessory Module Step 8: Loosen the (3) screws on the Accessory Module lab eled “C2,” “NO,” and “N C.” This is shown in [...]

Inlet Shut-off Valve Installation -53- Assemble the Inlet Shut-off Valve Wire Harn ess and the Accessory Module Step 9: Insert the blue wire, from the Inlet Shut-off Valv e wire harness, under t he screw labeled “C2,” as shown in Figure 76. Connect the Inlet Shut-off Valv e Wire Harness to the Accessory Module Step 10: Tighten the screw labeled[...]

Inlet Shut-off Valve Installation -54- Assemble the Inlet Shut-off Valve Wire Harn ess and the Accessory Module – cont’d Step 11: Insert the brown wire, from the Inlet Shut-off Valve wire harn ess, under the screw labeled “NO,” as shown in Figure 78. Connect the Inlet Shut-off Valv e Wire Harness and the Acces s ory Module – cont’d Step[...]

Inlet Shut-off Valve Installation -55- Assemble the Inlet Shut-off Valve Wire Harn ess and the Accessory Module – cont’d Step 13: Insert the black wire, from the Inlet Shut-off Va lve wire harness, under the screw la beled “NC,” as shown in Figure 80. Connect the Inlet Shut-off Valv e Wire Harness to the Accessory Module – cont’d Step 1[...]

Remote Mounting th e Setback Control -56- In the following section, the instructions detail how to Remote Mount the Setback Control. Remove the Setback Con trol from the Backplate Step 1: Remove the Setback Co ntrol from the back plate attach ed to the Setback Control Junction Box Assembly. Some force may be requir ed. This is show n in Figure 82. [...]

Remote Mounting th e Setback Control -57- Mount the Protective Plate Step 3: Mount the Setback Control Protective Plate in a de sired location. Be sure that the Setback Control will not be direct sunlight, as the display may be difficult to read. This is shown in Figure 84. Measure Wire for Remote Mounting Step 4: Measure and cut (3) pie ces of 18 [...]

Remote Mounting th e Setback Control -58- Label the Wires for Rem ote Mounting Step 5: Label the (3) cut wires (A), (B ), and (C) respectively. Label both en ds of the wires. This is shown in Figure 86. Masking tape can be used to label the wires. Prepare the Wires for Installation Step 6: Strip approximately 1/4” of the wire’s insulation from [...]

Remote Mounting th e Setback Control -59- Install Wire (A) – Backplate Step 7: Using wire (A), insert one end into the top terminal locat ion on the backplate (located on the Setback Control Junctio n Box Assembly). This is s hown in Figure 88. Be sure that the wire already located in this location is not dislodged. Fasten Wire (A) into its Desig[...]

Remote Mounting th e Setback Control -60- Install Wire (B) – Backplate Step 9: Using wire (B), insert one end into the mi ddl e terminal location on the backplate (l ocated on the Setback Control Junctio n Box Assembly). This is s hown in Figure 90. Be sure that the wire already located in this location is not dislodged. Fasten Wire (B) into its [...]

Remote Mounting th e Setback Control -61- Install Wire (C) – Backplate Step 11: Using wire (C), insert one end into the bot tom terminal location on th e backplate (located on the Setback Control Juncti on Box Assembly). This is shown in Figure 92. Be sure that the wire already located in this location is not dislodged. Fasten Wire (C) into its D[...]

Remote Mounting th e Setback Control -62- Route Wires to Protectiv e Plate Step 13: Route all three wires to t he Setback Control Protective Plate. Install Wire (A) – Protective Plate Step 14: Using wire (A), insert on e end into the top terminal location on the Protective Plate. This is shown in Figure 94. Figure 94 Protective Plate Wire (A)[...]

Remote Mounting th e Setback Control -63- Fasten Wire (A) into its Designa ted Location – Protec tive Plate Step 15: Tighten the slotted screw in the top terminal lo cation on the Protective Plate. Thi s is shown in Figure 95. Install Wire (B) – Protective Plate Step 16: Using wire (B ), insert one end into th e middle terminal location on the [...]

Remote Mounting th e Setback Control -64- Fasten Wire (B) into its Designa ted Location – Protec tive Plate Step 17: Tighten the slott ed screw in the middle terminal location on the Protective Plate. This i s shown in Figure 97. Install Wire (C) – Protective Plate Step 18: Using wire (C), i nsert one end into the bottom terminal location on th[...]

Remote Mounting th e Setback Control -65- Fasten Wire (C) into its Designa ted Location – Protec tive Plate Step 19: Tighten the slotted screw in the bottom terminal location on the Protective Plate. This is shown in Figure 99. Install Setback Control Step 20: Snap the Setback Control into the Protective Plate. Align the Setback Control to the Pr[...]

Remote Mounting th e Setback Control -66- Install Cover Plate Step 21: Snap the Setback Cover Plate onto the back plate (located on the Setback Control Junction Box Assembly). This is shown in Figure 101. Figure 101 Remote Mounting the S etback Control is compl ete. Proceed to the installation sections for the other purchased packages. Or, if finis[...]

Start-up Procedure -67- In the following section, the instructions deta il the Start-up Procedure for the Accessory Module, once any or all of its packages are completely installed. Route the Wire Harn ess es in the Accessory Module Step 1: Route all of the wire harnes ses out of the openi ngs in the bottom and left side of the Acce ssory Module. A[...]

Start-up Procedure -68- Fix the Accessory Module Cov er in Place Step 3: Tighten both Accessory Module co ver screws, as sho wn in Figure 104. Route the Various Wire Harnesses Step 4: Route the wire ha rnesses along the jacket and group th em using the included wire ties. This is shown in Figure 105. Figure 104 Figure 105 Accessory Module Philips h[...]

Start-up Procedure -69- Fix the Wire Harnesses Step 5: Using the include d wire holders, fix the wi re harn esses to the water heater jacket only to the left of the water heater gas cont rol, as shown in Figure 106. Wire holders can be use d to fix the wire harnesses to the water heater jacket only to the left of the water heater gas control. Route[...]

Start-up Procedure -70- Plug in Transformer Step 7: Plug in the Transformer that powers the A ccessory Module, as well as its components. This is shown in Figure 108. Observe Accessory Module Start-up Sequence Step 8: Watch the LED on the Accessory M odule, and observe as it prog resses through the Start-up Sequence. This i s shown in Figure 109. I[...]

Start-up Procedure -71- Action Required for Improper Start-u p Sequence Step 9: If the Start-up Sequence results in a red LE D strobe, the internal ele ctronics on the Accessory Module failed. The Accessory Modul e must be repl ac ed. This is shown in Figure 110. Faulty Component / Improper Assembly of Components Step 10: If another LED sequence is[...]

Start-up Procedure -72- Verify Inlet Shut-off Valve Operation (if installed) Step 11: If the Inlet Shut-off Valve is installed, t he valve will open during the Start-up Sequence. Verify that the valve is open by drawing water from a faucet (s pecifically hot water). This is shown in Figure 111. Program the Setback Control (if insta lled) Step 12: R[...]

Diagnostic Codes -73- LED Status Accessory Module Status Probable Cause None No LED. Power not on. 1. No power at outlet. 2. Transformer bad, replace transformer. 3. Transformer wire ha rne ss not properly connected. Check all wire connectio ns. Green LED on continuously. Power on (no fault). n/a Red One flash and three second paus e . Leak alarm f[...]

Notes -74-[...]

LIMITED PARTS WARRANTY -75- WHAT DOES THIS LIMITED WARRAN TY COVER? This limited warranty covers compon ent parts for malfunction caused by defects in materials and/or workmanship. It extends to the first buyer and to any subsequent owner(s) at the original pl ace of installation. WHAT DOES THIS LIMITED WARRANTY NOT COVER? h 1. This limited warrant[...]

Ambler, PA For U.S. and Canada field service, contact your professional installer or local Bradford White sa les representative. Sales / 800-523-2931 Fax / 215-641-1670 Parts Fax / 215-641-2108 Technical Support / 800-334-3393 Fax / 269-795-1089 Warranty / 800-531-2111 Fax / 269-795-1089 International: Telephone / 215-641-9400 Telefax / 215-641-975[...]