Bradford-White Corp EFR160T120 manual

- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance - WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor’s phone. Follow the gas suppl[...]

2 SECTION I: IMPO RTANT INFORMATION NOTICE This water heater has a limited wa rranty. The warranty for this wa ter heater is valid only if the water heater has been installed, maintained and operated in acco rdance with these instructions. TABLE OF CONTENTS I IMPORTANT INFORMATION .............. 2 VII GAS CONNECTIONS ...............................[...]

3 DANGER DO NOT store or use gasoline or other flammabl e, combustible, or corrosive vapors and/or liquids in the v icinity of this or any other appliance. DO NOT install any damaged venting system co mponents. If damage is evident then please contact the supplier where the water heater was purchas ed or the manufactur er listed on the rating plate[...]

4 WARNING This water heater nee ds fresh air f or safe operation an d must be installed so there are provisions for adequate combustion and ventilation air. Insufficien t air supply will cause a recirculation of combus tion products resulting in contamination that may be hazardous to life. This will result in carb oning or sooting of the combustion[...]

5 SECTION II: SPECIFICATIONS Figure 1. Dimensional Layout Recovery GPH At Degree Rise DIMENSIONS ( INCHES ) Model No. Input Rate BTU/h 1st Hr. Del. Gal. At 100°F Rise 40°F 100°F 140°F Stg. Cap. U.S. Gal. Therm. Eff. % A Ht. B Dia. C Flr to Vent Outlet D Flr to Inlet Wtr. Conn E Flr to T&P Valve Conn F Fl. to Outlet Wtr. Conn G Fl. to Air In[...]

6 SECTION III: GENERAL INFORMATION FEATURES This water heater contains t he following feat ures: MAIN POWER ON/OFF SWITCH – The front panel of th is water heater has a lig hted ON/OFF switch, which is illuminated when the main power is turned on to indicate power to the water heater. COMBUSTION SYSTEM – This water heater is equipped with a sel [...]

7 LATCHES – The latches allow easy access for servicing the water heat er from the top. Simply remove the two latches for servicing and re-latch upon completion. No tools are required to obtain access to the top of the water heater. MIXING VALVE – This water heater is su pplied with an ASSE approved mixing valve to reduce the poten tial for sca[...]

8 CONDENSA TE DRAIN – The water heater should either be raised several in ches above the floor on a concrete sla b or use a low profile condensate pump to allo w free drainage of condensate from the elbow drain fitting. This water heater is a condensing t ype unit and requires a drain to be located in close proximity to allow the conden sate to d[...]

9 SECTION IV: INSTALLATION INSTRUCTIONS WARNING INSTALLATION OF THIS WATE R HEA TER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMA N IN THE FIELD. PLUMBING, AIR SUPPLY, VENTING, GAS SUPPLY AND ELECTRICAL WORK ARE REQUIRED. DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE FOLL OWING: • Liquefied pet roleum gases/[...]

10 S acrificial anode rods have been installed in the tank head of th e water heater to extend t ank life. The removal of these anode s for any reason will nullify the warranty. In areas where water is un usually active, an odor may occur at the hot water faucet due to a reaction between the sacrificial anod e and the impurities in the wate r. If t[...]

11 Figure 3a. Minimum Clearance To Combustible Material Figure 3b. Recommended Minimum Clearances For Service Access M ain Powe r[...]

12 REMOVE CRATE 1. Remove all banding an d pry off c r ate sides caref ully so as not to dam age the water heat er. 2. Carefully roll/lift the water heater from the crate base. CAUTION Do not drop wat er heater. Do not bum p water heater jacke t against floor. Do not bump exhaust vent pipe against crate or other objects. This will damage the water [...]

13 MECHANICAL EXHA US TING OF ROOM AIR 1. Where an exhaust fan is installed in the same ro om with th is water heat er and combust ion air is drawn from insi de the room, sufficient ope nings for air must be provided in the walls. UNDERSIZED O PENINGS WILL CAU SE AIR TO BE DRAWN INTO THE R OOM THROUGH THE WATER HEATER’S VE NTING SYSTEM, CAUSING P[...]

14 Figure 4. Typical Front Inlet Connecti on Figure 5. Typical Front Inle t Connect with Stor age Heater[...]

15 Figure 6. Typical Two Water Heater Connection Figure 7. Typical Three Water Heate r Connection Figure 8. Typical Four Water Heater Connection[...]

16 SECTION V: WA TER CONNECTIONS WARNING Failure to install and maintain a new, listed temperature and pr essure relief valve will release the manufacturer from any clai m, which might re sult from excessive tem perature and pressures. Hydrogen gas can be pro duced in an ope rating wate r heater that has not had wat er drawn from the t ank for a lo[...]

17 required by these appliances, you might create th e potential for scald injury. To protect against injury, you must install the ASSE approved mixing valve supplied with the water heater in the wate r system. This valve will reduce point of discharge temperatur e by mixing cold and hot water in branch supply lin es. Follow the instructions suppli[...]

18 Figure 11. Typical Plumbing Sc hematic for Zoned He ating SECTION VI: VENTING WARNING The vent system must be properly instal led. Failure to properly install t he vent syst em could res ult in pro perty dam age, personal injury, or death. DO NOT instal l damaged ve nting system component s. If dam age is evident t hen pleas e contact the s uppl[...]

19 CAUTION The vent shall terminate a min imu m of 12 in ch es (30.5 cm ) above ex pected snowfal l level t o prevent bl ockage of vent termination. The horizontal centerline of the exha ust vent terminal (if applicable) must not be located lower than the horizontal centerline of the air intake terminal if vented thr ough the sam e wall. A service [...]

20 VENTING The venting instructions m ust be followed to avoi d restricted com bustion or recircul ation of flue gases. Suc h conditi ons cause sooting or ris ks of fire and asphy xiation. This water heater can be installed as eith er a direct vent system or power vent (air from inside) system . If it is installed a s a direct vent sy stem, then th[...]

21 Figure 12a. Vent Terminal Clearances (Other than Direct Vent or “Power Vented” Installati ons) Canadian Installations 1 US Installations 2 Canadian Installations 1 US Installations 2 A= Clearance above grade, veranda, porch, deck or balcony 12 inches (30.5 cm) 12 inches (30.5 cm) H= Clearance to each side of center line extended above meter/[...]

22 Figure 12b. Direct Vent Terminal Clearances Canadian Installations 1 US Installations 2 Canadian Installations 1 US Installations 2 A= Clearance above grade, veranda, porch, deck or balcony 12 inches (30.5 cm) 12 inches (30.5 cm) H= Clearance to each side of center line extended above meter/regulator assembly 3 feet (.9 m) within a height 15 fee[...]

23 The vent system must terminate so that pr oper clearances are m aintaine d as cited in local codes or the latest edition of the National Fuel Gas Code , ANSI Z223.1.73.4 e and 7.8a, b as follows: 1. Do not term inate near soffit vents or crawl space or other area where c ondensate or vapor could create a nuisance or hazard or cause property dama[...]

24 2. Use the pr oper PVC cem ent to secure t he exhaust vent and ai r intake term inals provided with the water heat er to the plastic pipe s. The distance between the back edge o f the exhaust vent te rminal and t he exterior wal l (see Figure 13) must be 6 inches (12.7 cm) more for the exhaus t vent terminal than the air intake terminal. Use the[...]

25 Figure 14. Typical Vertical Di rect Vent System Installation (Note: Intake and exhaust terminals may be on different outside walls.) Through The Wal l Venting Wit h Low Ground Cleara nce: When venting cannot ex it through the wall at a he ight greater than or equal to 12 inches (30.5 cm) (and above expected snow level) from the ground, then the [...]

26 Max imu m Ve nt Le ngt h: Direct Vent Maximum Vent Length (Combine d Maximum Length for Intake and Exhaust) Model Number Max Vent Le ngth in feet (meters) for 2 inc h (5.1 cm) PVC, CPVC, or ABS Max Vent Le ngth in feet (meters) for 3 inc h (7.6 cm) PVC, CPVC, or ABS Max Vent Le ngth in feet (meters) for 4 inch (10.2 cm) PVC, CPVC, or ABS EFR60T1[...]

27 NOTICE This unit can be vented using o nly PVC (Class 160, ASTM D-2241 Sch edule 40, ASTM D-1 785; or Cellular Core Schedule 40 DWV, ASTM F-891), Sch edule 40 CPVC (ASTM F-411), or ABS (ASTM D- 2661) pipe. The fit tings, othe r than the TERMINATI ONS shoul d be equival ent to PVC - DWV fittings meeting ASTM F-2665. (Use CPVC fittings, ASTM F-438[...]

28 Figure 16. Typical Horizo ntal Power Vent System Vertical Installation: Vertical venting must be supported ever y 5 feet (1.5 m ) of vertical ru n and eve ry 3 feet (.9 m) of horizont al run o f vent pipe length. Stress levels in the pipe and fittings can be significantly increas ed by improp er installation. If rigid pipe clamps are used to hol[...]

29 Follow the following procedure to v ent through the roof: 1. Cut the necessary holes thro ugh the roof and ceiling. 2. Install the exhaust vent and air intake plastic pipes as sho wn in Figure 17. Make sure that the installation meets the local codes and/ or The Natio nal Fuel Gas C ode ANSI Z223.1 (Latest Edition) o r CGA/CAN B 149 Installation[...]

30 Through The Wal l Venting Wit h Low Ground Cleara nce: When venting cannot ex it through the wall at a he ight greater than or equal to 12 inches (30.5 cm) (and above expected snow level) from the ground, then the installation must be modified as shown below (see Figure 18). Refer to Tables 3 or 4 for maximum venting lengths usi ng 2 inch (5.1 c[...]

31 MULTIPLE INTAKE/EXHAUST TERMINAL SEPARATION DISTANCES Note: When installing multiple in take/exhaust terminals on the same wall of a building , the nearest intake terminal must be at leas t 5 feet (1.5 m) f rom the nearest exhau st terminal.[...]

32 CONCENTRIC VENT TERMINAL IN STA LLATION PROCEDURE WARNING Improper inst allati on, adjustment, servi ce, or ma intenance can cause pr operty dam age, personal injury, or death . Consult a qualified i nstaller, service agency, or the gas supp lier for info rm ation or assistance. This kit must be used only for terminatin g this water heater. Do n[...]

33 Figure 21. Rain Cap to Small Vent Pipe Assembly 5. Install concentric Y fitting and pipe assembly th rough the struct ure’s hole and field-supplied roof boot/flashing. Do not allow insulation or other materials to accumulate inside pipe assembly when installing through the hole. 6. Secure assembl y to roof struc ture as show n in Figure 22 usi[...]

34 Horizontal Installation: 1. Become familiar with coaxial vent kit pa rt no. 239-44069-02 as shown in Figure s 19 through 21. 2. Determine the best location for the termination kit. NOTICE Position termination where vent vapors will not be adversely affected by wind condition. Position termination where it will not be damaged or be subjected to f[...]

35 INITIAL PREPARATION 1. Make sure the solvent cem ent you are planning to use is de signed for the speci fic applicat ion you are attempting. 2. Know the physical and chemi cal characteristics and limitations of the PVC, PVC cellular core, ABS or CPVC piping materials that you are about to use. 3. Know the reputation of your pipe and cement manuf[...]

36 CAUTION The water heater an d individual sh utoff valve m ust be disconnected fr om the gas supply piping system during any pressure testing of the system at test pressures in e xcess of ½ psi (3.5 kPa) . The water heater mu st be isolated from the gas supply pipi ng system by cl osing its m anual shutoff valve during any pressure testi ng of t[...]

37 SECTION VIII: ELEC TRICAL CONNECTIONS WARNING Turn off or disconnect the electrical power supply to the water heater before servicing. Label all wires prior to disconnectio n when servic ing controls. Wiring er rors can cause i mproper and dangero us operatio n. Verify proper operat ion after se rvicing. All electrical wiring must be installed a[...]

38 SECTION IX: OPER ATING INSTRUCTIONS WARNING Water heaters are heat-produ cing appl iances. To a void dam age or injury there must be no m aterials stored against the water heater or direct vent system , and proper care m ust be taken to avoi d unnecessary contact (especi ally by c hildren) with the wate r heater and di rect vent sy stem. UN DER [...]

39 LIGHTING AND SHUT-DOWN INSTRUCTIONS Figure 26. Lighting Instruction Label WARNING: above on this label. on this label if you don't smell gas, "B" in the safet y information above If you then smell gas, STOP! Follow 6. Wait (5) minutes to clear out any gas. may result causing property damage, personal injury or loss of life. If you[...]

40 TEMPERATURE ADJUSTMENT APPROXIMATE TIME/TEMPERATURE RELATIONSHIPS IN SCALDS 120°F (49°C) More than 5 minutes 125°F (52°C) 1½ to 2 m inutes 130°F (54°C) About 30 seconds 135°F (57°C) About 10 seconds 140°F (60°C) Less than 5 seconds 145°F (63°C) Less than 3 seconds 150°F (66°C) About 1½ seconds 155°F (68°C) About 1 second SCALDI[...]

41 Condensation do es not mean your tank is leaking. Most of repor ted tank leaks on installation are prov en to be condensation. T o avoid unneces sary inc onvenience an d expense, m ake sure the tank is leaki ng before call ing an in dependent ser vicing cont ractor o r qualified serv ice professional. If the water heater is to remain idle for 30[...]

42 To Increase Setpoint Temperature Step 1: Depress and hold “Temperature Up” button until d esired setpoint temperature appears in the display. Step 2: “Setpoint” indicator begins flashing in the display after pressing “Temperature Up” button. Step 3: Press “SET” button for new setting to take effect imme diately. “Setpoint” wi[...]

43 To Decrease Setpoint Temperature Step 1: Depress and hold “Temperature Down” button until desired setpoint te mperature appears in the display. Step 2: “Setpoint” indicator begins flashing in the display after pressing “Temperature Down” button. Step 3: Press “SET” button for new setting to take effect immediately. The setpoint w[...]

44 To Change Temperature Format in Display from ° F to ° C or ˚ C to ˚ F: Step 1: Press “SELECT” button until ° F/ ° C is displayed. Step 2: Press “SET” button to change temperature format. Symbol ° F/ ° C will flash. Step 3a: Press “Temperature Up” button to change temperature format to ° C. Step 1 SELECT SET Status idle Opera[...]

45 Step 3b: Press “Temperature Down” button to change temperature format to ° F. Step 4: Press “SET” button to confirm ˚ F or ˚ C format. ° F/ ° C will stop flashing. Setpoint display will appear in the format selected ( ˚ F or ˚ C) in 10 seconds. Step 5: Pressing “SELECT” button will return display to setpoint in format selected[...]

46 An automatic gas shut-off device (ECO) i s incorp orate d in the sensor and control board which will shut off all gas supply to the burner if the water heater temperature exceed s 200°F ( 93°C ). Should the ECO function (open), the water temperature should be reduced to appro x imately 120° F ( 49°C ) and call a qualified service ag e nt to [...]

47 Figure 27. Si ght Glass Loc ation MAINTENANCE SCHEDULE WARNING Water heaters are heat produ cing a ppliances. To av oid damage or injury there must be no m aterial s stored against the water heater or vent -a ir intake system, and proper care mu st b e taken to avoid unnecessary contact (espe cially by children) with the water heater and vent-ai[...]

48 Suggested Maintenance Schedule COMPONENT OPERATION INTERVAL REQUIRED Tank Sediment Removal Monthly Flushi ng Anode Rods Inspect At least every 2 years Replace as Required Relief Valve Check Operation At l east annually Proper Operation Ignition System Inspect Annually Check for proper operation Table 5. FLUSHING WATER HEATER 1. Turn OFF the wate[...]

49 The depth of the buildup shou ld be measured period ically. Water heaters will have abou t 3 inches (7.6 cm ) of lime buildup when the level of lime has reache d the bottom of the cleanout opening or about 1 inc h (2.5 cm) of lime buildup if it has reached the drain valve openin g. A schedule f or deliming sh ould be set up , based on the a moun[...]

50 CAUTION Before manually operating the valve, make sure that a drain lin e has been attached to the valve to direct the discharge to an open drain. Failure to take this precaution could m ean contact with extrem ely hot water passing out the val ve during t his checkin g operatio n. If the combination temperature and press ure relief valve on the[...]

51 SECTION XI: DIAGNOSTIC AND TROUBLESHOOTING GUIDE DIRECT SPARK HONEYWELL INTE GRATED CONTROL SYSTEM SEQUENCE OF OPERATION 1. When the t ank temperature drops below the temperat ure setpoint on the display, the co ntrol sends po wer to the com bustion blower for a 30 second pre -purge pe riod. 2. At the end of the pre-purge period, the c ontrol se[...]

52 ACCESSING SERVICE MODE ON THE WATER HEATER DISP LAY (FOR SERVICE PERSONNEL ONLY) The display has a “Se rvice Mode” for changing t he maximum setpoi nt and accessing inform ation in aiding servicing of the water heater. This procedure is for service and installation person nel on ly. To enter the Service Mode, follow the steps illustrate d be[...]

53 The following is the sequence of modes available in “Service Mode” by pressing the “Select” button: Error Code Number (Display/Reset). This is only show n if there is an operating error in the “User Mode”. 1. Max Setpoint (Display/Change) 2. Water Temperature Sensor Reading. SELECT SET Status °F idle Wat er Te mp Operational & S[...]

54 3. Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle) 4. Setpoint (Display/Change) 5. ˚ F/ ˚ C (Display/Change) SELECT SET Status °F/C° idle Operational °F & SELECT SET Status °F idle setpoint Operational & SELECT SET Status Heating Operational Flame Current µA &[...]

55 6. Differential (Display only – shows the differential of the thermostat) 7. Software Version (Display only) 8. Error Code History (Displays if there are present error codes or up to 10 previous error codes). Water Heater Display will show -- if there are no error codes. SELECT SET Status °F idle Differe ntia l Operational & & SELECT [...]

56 To change the Maximum Setpoint Limit (M ax Setpoint) for the te mperature setpoint: Step 1: In service mode press the “Select” button until “Max Setpoint” is displayed. Step 2: Press “Set” button to enter setting mode. “Max Setpoint” will flash to indicate setting m ode. WARNING Setting the water temperature to the maximum set po[...]

57 Step 3: Press the “UP” or “DOWN” buttons to change the ma ximum setpoint value. This will limit the maximum setpoint the user can select. Note: The maximum setpoint is approximately 180 ˚ F (82 ˚ C) . Step 4: Press “Set” button to confirm new “Max Setpoint” value and stop setting mode. Step 5: 30 Seconds after the last button p[...]

58 Display of Water Temperature: Step 1: In Service Mode, Press the “Select” button until “Water Temp” is displayed in the upper right section of the water heater display. This is the reading for the tank sensor. To Display Flame Sense Current of the Pilot Flame Sensor: The pilot flame sense current is available only when the burners are in[...]

59 To Display and Change Temperature Setpoint: Step 1: In “Service Mode” press the “Select” button un til “Setpoint” is shown in the water heater display. Step 2: Press the “Set” button to enter the setting mode . “Setpoint” will flash in the water heater display. NOTICE Note: The maximum temperature that can be set in the Water[...]

60 Step 4: To lower the temperature setpoint, press the “Tempe rature Down” button until the desired temperature is shown on the water heater display. Step 5: When the desired setpoint is reached on the wate r heater display, press the “Set” button to confirm the new setpoint. “Setpoint” stops flashing in the water heater display. To Di[...]

61 Step 2: Press “Set” button to change temperature format. “ ˚ F/ ˚ C” symbol will flash in the water heater display. Step 3a: Press “Temperature Up” button to change temperature format to ˚ C. Step 3b: Press “Temperature Down” button to change temperature format to ˚ F. SELECT SET Status idle Operational % °F °F/C° "°[...]

62 Step 4: Press “Set” button to confirm ˚ F or ˚ C format. ˚ F/ ˚ C will stop flashing. Step 5: Pressing “Select” button will return display to setpoint in format selected ( ˚ F or ˚ C) immediately. SELECT SET Status °F idle Operational Lower Sensor & Setpoint shown in °F SELECT SET Status °F idle Operational °F °F/C° % &qu[...]

63 How to reset the control from Lockout Conditions: If an error code is displayed (except for #4, low flame sense current), the water heater will be in a “lockou t condition” with the water heater di splay showi ng the error c ode num ber and “Service Ne eded” in the status section of the display window. Error cod es 62 (maxim um number of[...]

64 Error Codes and Error History Display: If there is an operating problem with the water heater, an e rror code number will appear on the water heater display with “Service Needed” to the right of the “Status” indicator. The error code label is located below the water heater display and the following section in this Installation and Operat[...]

65 Step 2: Press the “Temperature Do wn” b utton to se lect the error code index, starting with the most re cent error code “10”. Step 3: Press the “Select” button to view the error code for “code 10”. If there is a number displayed, note what the number is. The label next to the water heater display will identify the code number. I[...]

66 Step 4: Press the “Temperature Down” button to change to the previous code index, code #9. Step 5: Press the “Select” button for code index #9 to view if there are any code numbers. SELECT SET Status idle Operational Error Code Index % SELECT SET Status idle Operational Stored Error Code For Code Index #9 &[...]

67 Step 6: Continue pressing the “Temperature Down” button to change to the next error code index and press “Select” to view the error code number, if any, for that index number. Continue on to index #1, the oldest error code index. T he water heater display will store up to 10 error codes with the oldest code st arting in code index #1 wit[...]

68 Error Code Definition of Code Cause of Problem and Actions Taken to Corre ct 29 Pressure Switch Failed to Close The blocked vent pressure switch co nta c ts have opened. Check to make su re the venting system is not blocked. Check to make sure the condensate drain i s not clogged and is sloping towa rd the d rain. Make sure the vent length does [...]

69 Procedure for Checking Thermostat Sensors Set the thermostat above water temperat ure (Se e temperature a djustment secti on) and ob serve system through one (1) complete cycl e. Make sure system operates a s de sired. To check the sen so r assembly, compa r e the resistance of t he se nsor wires (either outside bl ack to center wire with yellow[...]

70 SECTION XII: PARTS LIST Customer must specify complete model number and serial number when ordering service parts. EF™ – Series Water Heater 1 Combustion Surround Assembly 2 Burner Assembly (Specify model) 3 2nd Pass Top Collector Cover 4 Screw 10-16 x ¾ 5 Vent Termination Elbow 6 Thermostat Sensor Probe 7 Baffle 4” Flue (Specify Model) 8[...]

71 Customer must specify complete model number and serial number wh en ordering service parts. 1 Combustion Surround Assembly AA Keeper Latch & Catch BB Screw 8-32 x ½ RHCR CC Control Panel Assembly DD Jacket Head 28 ¼" Grey EE Switch Main Power FF Control Display GG Combustion Surround JJ Surround Bas/Jacket Head[...]

72 CC Ignition Control Assembly 1C Control Mounting Panel 9C Secondary Transformer Harness 2C Thermostat PC Board 10C Blower Harness 3C Transformer – 120/24 VAC 11C Power Switch Harness 4C Terminal 12C Powered Anode Harness (399 on ly) 5C Terminal Strip 13C Black Powered Anode Wire Assembly (399 only) 6C Powered Anode Control (399 only) 14C Whit [...]