Bradford-White Corp POWERED DIRECT VENT SERIES GAS-FIRED COMMERCIAL WATER HEATER manual

238-47707-00E REV 7/12 POWERED DIRECT VENT SERIES GAS-FIRED COMMERCIAL WATER HEATER (INDEPENDENT PVC VENTING) INSTALLATION/OPERATION MANUAL WITH TROUBLESHOOTING GUIDE PLACE THESE INSTRUCTIONS ADJACENT TO WATER HEATER AND NOTIFY OW NER TO KEEP FOR FUTURE REFERENCE - Do not store or use gasoline or other flammable vapors and liquids in the vicinity o[...]

2 SECTION I: IMPORTANT INFORMATION This water heater has a limited warranty. The warranty for this water heater is valid only if the water heater has been installed, maintained and operated in accordance with these instructions. The warranty does not cover damage or injury caused by the use of any energy-saving devices (other t han those authorized[...]

3 DANGER DO NOT store or use gasoline or other flammable, combustible, or corrosive vapors and/or li quids in the vicinity of this or any other appliance. This water heater is equipped with an adjustable thermostat to control water temperature. Hot water temperatures required for automatic dishwasher and laundry use can cause scald burns resulting [...]

4 WARNING This water heater needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air. Insufficient air supply will c ause a recirculation of combustion products resulting in contamination that may be hazardous to life. This will re sult in carboning or sooting of the combustion cha[...]

5 SECTION II: SPECIFICATIONS Figure 1. Dimensional layout Model Description Dimensions for Figure 1 Capacity Input (BTU/hr) A B C D E (Gal) Nat. LP (In.) (I n.) (In.) (In.) (In.) 100 199,999 199,999 72.13 60. 31 77.19 56.81 74.13 100 150,000 150,000 72.13 60. 31 77.19 56.81 74.13 100 250,000 225,000 72.13 60. 31 82.13 56.81 74.13 80 250,000 225,000[...]

6 SECTION III: GENERAL INFORMATION FEATURES 1. Porcelain enamel lined tank provides corrosion protecti on with a tough glass lining on the interior of the tank. 2. Magnesium anodes provide an extra measur e of protection and extends tank life. 3. Direct Vent design with an induced draft blower. Flue gases are exhausted and combustion air is taken f[...]

7 DISHWASHING MACHINE REQUIREMENTS All dishwashing machines meeting the National Sanitati on Foundation requirements are designed to operate with water flow pressures between 15 and 25 pounds per square inch. Fl ow pressures above 25 pounds per square inch, or below 15 pounds per square inch, will result in improperly sanitized dishes. The National[...]

8 SECTION IV: INSTALLATION INSTRUCTIONS INSTALLATION OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE FIELD INVOLVED. PLUM BING, 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 FOLLOWING:  Liquefied petroleum gases/pro[...]

9 Minimum Clearances The location of this water heater is of the utmost import ance. Before installing this water heater, you should read the Installation section of these instructions. After reading these Installation and Operat ing Instructions, select a location for the water heater where the floor is level and is easily accessi ble to water lin[...]

10 LOCATE WATER HEATER in front of final position before removing crate. 1. LOCATE so that venting c onnections will be short and direct. 2. THIS WATER HEATER IS SUITABLE FO R INSTALLATION ON COMBUSTIBLE FLOOR. 3. Proper venting practices must be considered when select ing a location for this water heater. For exact venting specifications, please c[...]

11 SECTION V: VENTING WARNING Risk of carbon monoxide poisoning or fire due to joint separation or pipe breakage. This water heater must be properly vented and connect ed to an approved vent system in good condition. DO NOT operate water heater with the absence of an approved vent system. A clean and unobstructed vent system is necessary to allow n[...]

12 NOTICE For installations in Canada, field supplied vent piping must comply with CAN/CGA B149.1 (latest edition) and be certified to the Standard For Type BH, Class II, 65°C, Gas Venting Systems, ULC S636. Components of this list ed system must not be interchanged with other vent systems or unlisted pipe/fittings. All components and specifi ed p[...]

13 Figure 3. Direct Vent Terminal Clearances Canadian Installations 1 US Installations 2 A= Clearance above grade, veranda, porch, deck or balcony 12 inches (30 cm) 12 inches (30 cm) B= Clearance to widow or door that may be opened 36 inches (91 cm) 12 inches (30 cm) C= Clearance to permanently closed widow *b *b D= Vertical clearance to ventilated[...]

14 The vent system must terminate so that proper clearances are maintained as cited in local codes or the latest edition of the National Fuel Gas Code, ANSI Z223.1.73.4e and 7.8a, b as follows: 1. Do not terminate near soffit vents or crawl space or ot her area where condensate or vapor could create a nuisance or hazard or cause property damage. 2.[...]

15 Direct Vent System Installation ( 199,999 and 150,000 Btu/hr. input models) This water heater is a power direct vent appliance and is des igned to vent both its products of combustion and provide the combustion air supply through 3” (7.6 cm) or 4” (10.2 cm) diameter pipe to the outdoors. This water heater may be vented either through the wal[...]

16 Through the Wall Venting : Cut two 3 1/2” (8.9 cm) diameter holes (for 3” ( 7.6 cm ) diameter pipe) or 4 1/2” ( 11.4 cm ) diameter holes (for 4” ( 10.2 cm ) diameter pipe) in the wall with the c enterline hole distances at least 6” ( 15.2 cm ) apart, but not more than 24” ( 61 cm ) apart in the location where the exhaust vent and air[...]

17 Figure 6 Figure 7A Figure 7B[...]

18 Figure 7C Through the Wall Venting With Low Ground Clearance: When venting cannot exit through the wall at a height greater than or equal to 12” (30.5 cm) (and above expected snow level) from the ground, then the installation must be modified as shown below (see Figure 8). Refer to Tables 3 or 4 for maximum venting lengths using 3” (7.6 cm) [...]

19 Direct Vent System Installation for Mode ls with Input Ratings Over 200,000 Btu/Hr. Models w ith input ratings over 200,000 Btu/hr. must use 4” (10.2 cm) diameter pipe . Install the blower adaptor exhaust vent assembly and gasket supplied in the vent kit carton on the exhaust blower outlet flange as described in the previous section. Connect t[...]

20 SECTION VI: WATER CONNECTIONS NOTE: BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE TH E MAIN WATER SUPPLY VALVE. After shutting off the main water supply, open a faucet to relieve the water line pressure to prevent any water from leaking out of the pipes while making the water connections to the wa ter heater. After the pressure has been relieve[...]

21 This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water. By setting the thermostat on this water heater to obtain the increased temperature water [...]

22 SECTION VII: GAS CONNECTIONS The gas supply lines must meet all requirements of the Na tional Fuel Gas Code (ANSI Z223.1-Latest Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation Code (Lates t Edition) or CAN/CGA B149.2 Propane Installation Code (Latest Edition). The minimum permissible gas supply pressure for the purpose of input ad[...]

23 SECTION IX: ELECTRICAL CONNECTIONS WARNING Turn off or disconnect the electrical power supply to the water heater before servicing. Label all wires prior to disconnection when servicing controls. Wiring errors c an cause improper and dangerous operation. Verify proper operation after servicing. All electrical wiring must be installed and grounde[...]

24 TYPICAL INSTALLATION Notes: The heat trap shown above is not part of the wa ter heater, only a piping suggestion to reduce the standby heat loss. The drain pan may be purchased from your water heater supplier. Water heaters are heat-producing appliances. To avoid dam age or injury there must be no materials stored against the water heater or dir[...]

25 Lighting And Shutdow n Instructions Temperature down Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control sy stem including gas controls, w hich has been under w ater. CAUTION[...]

26 SECTION X: OPERATING INSTRUCTIONS TEMPERATURE ADJUSTMENT APPROXIMATE TIME/TEMPERATURE RELATIONSHIPS IN SCALDS 120°F (49°C) More than 5 minutes 125°F (52°C) 1½ to 2 minutes 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[...]

27 Water Heater Display and Control Buttons SELECT SET Status Set button Select button Temperature Down Button Temperature Up Button °F idle setpoint Operational Sequence o f operation Indicato r Reads "Idle” or “Heating" Status Indicato r Read "Operational" or "Service Needed" Shown flashing in dis p la y onl y w[...]

28 TO INCREASE SETPOINT TEMPERATURE Step 1: Depress and hold “Temperature Up” button until des ired setpoint temperature appears in the display. Step 2: “Setpoint” indicator begins flashing in t he display after pressing “Temperature Up” button. Step 3: Press “SET” button for new setting to take effect imm ediately. “Setpoint” w[...]

29 To Decrease Setpoint Temperature Step 1: Depress and hold “Temperature Down” button until desired setpoint temperature appears in the display. Step 2: “Setpoint” indicator begins flashing in t he display after pressing “Temperature Down” button. Step 3: Press “SET” button for new setting to take effect imm ediately. The setpoint [...]

30 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. SELECT SET Status °C idle O[...]

31 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 selec[...]

32 An automatic gas shut-off device (ECO) is incorporated in the sensor and control board which will shut off all gas supply to the burner and pilot if the wate r heater temperature exceeds 200°F ( 93°C ). Should the ECO function (open), the water temperature should be reduced to approximately 120°F ( 49°C ) and follow Lighting Instructions to [...]

33 SECTION X: MAINTENANCE Burner Flame Check At the time of installation and at periodi c intervals (about every 3 months), a vis ual check of the pilot and burner flames should be made to determine if they are burning properly. No adjustment to the air shutter should be required for this heater . The burner flames should be blue with yellow tips. [...]

34 A qualified service technician should perform the following maintenance at the minimum periodic intervals suggested below. In some installations, the maintenance interval may be more frequent depending on the amount of use and the operating conditions of the water heater. Regular inspection and maintenance of the water heater will help to insure[...]

35 To reinstall the burner rack, reverse the above procedure. Alternate method for removing the burner rack, when there is at least 20” (50.8 cm) clearance on the left front side: a) Shut off the gas and electrical supply to the water heater. b) Disconnect both pilot tube fittings at the combustion box bulkhead fitting. c) Disconnect wires to gas[...]

36 13. The induced draft blower motor used in this model seri es has sealed bearings and does not have provisions for oiling the bearings. 14. The vent system must be ins pected at least once a year to ens ure against leakage of exhaust products. Contact your supplier, plumbing professi onal or contact the company at the addre ss given on the ratin[...]

37 SECTION XI: DIAGNOSTIC AND TROUBLESHOOTING GUIDE DIAGNOSTIC GUIDE FOR HONEYWELL INTEGRATED CONTROL SYSTEM SEQUENCE OF OPERATION FOR PDV AND INDUCED DRAFT MODELS 1. When the tank temperature drops below the temperature setpoint on the disp lay, the control sends power to the induced draft blower to start the ignition sequence. 2. When blower reac[...]

38 ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY (FOR SERVICE PERSONNEL ONLY) The display has a “service mode” for changing the maximum setpoint and accessing information in aiding servicing of the water heater. This procedure is for service and installation per sonnel only. To enter the Service Mode, follow the steps illustrated below: St[...]

39 The follow ing is the sequence of modes available in “Serv ice Mode” by pressing the “Select” button: Error Code Number (Display/Reset). This is only shown if there is an operating error in the “User Mode”. 1. Max Setpoint (Display/Change) 2a. Water Temperature Average (Displays average if there are two sensors – sens or temperatur[...]

40 2b. Water Temperature - Upper Sensor (Displays if there is an upper sensor – some models) 2c. Water Temperature - Lower Sensor (Displays if there are two sensors) 3. Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle) SELECT SET Status °F idle Operational Lower Senso r  SELECT SET Status °F idle Operational Upper Sens[...]

41 4. Setpoint (Display/Change) 5. ˚ F/ ˚ C (Display/Change) 6. Differential (Display only – shows the differential of the thermostat) SELECT SET Status °F idle Differe ntia l Operational  SELECT SET Status °F/C° idle Operational °F  SELECT SET Status °F idle setpoint Operational [...]

42 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. To change the Maximum Setpoint Limit (Max Setpoint) for the temperature setpoint: Step 1: In service mode press the “Select” button until “Max [...]

43 Step 2: Press “Set” button to enter setting mode. “M ax Setpoint” will flash to indicate setting mode. Step 3: Press the “UP” or “DOWN” buttons to change the maximum setpoint value. This will limit the maximum setpoint the user can select. Note: The maximum setpoint is approximately 180 ˚ F. Step 4: Press “Set” button to con[...]

44 Step 5: 30 Seconds after the last button press, the Water Heater Display will go back to “User Mode”. It will read “Max Setpoint” without showing a temperature va lue if the temperature setpoint is at the maximum setting. The Water Heater Display can be set back to the “User Mode” immediately by pressing both the “Temperature Up”[...]

45 Step 2: For water heaters using two temperature sensors, pr essing the “Select” button again displays the Upper Sensor temperature reading. “Upper Sensor” will be displayed in the lower right side of the status window of the water heater display. Step 3: For water heaters using two temperature sensors, pr essing the “Select” button a[...]

46 To Display and Change Temperature Setpoint: Step 1: In “Service Mode” press the “Select” button until “Setpoint” is shown in the water heater display. Step 2: Press the “Set” button to ent er the setting mode. “Setpoint” will flash in the water heater display. Step 3: To raise the temperature setpoint, press the “T emperatu[...]

47 Step 4: To lower the temperature setpoint, press the “T emperature Down” button until the desired temperature is shown on the water heater display. Step 5: When the desired setpoint is reached on the water heat er display, press the “Set” button to confirm the new setpoint. “Setpoint” stops flashi ng in the water heater display. To D[...]

48 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° "[...]

49 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 Senso r  Setpoint shown in °F SELECT SET Status °F idle Operational °F °F/C°  &q[...]

50 How to reset the control from Lockout Conditions: If an error code is displayed (except for #4, low flame sense cu rrent), the water heater will be in a “lockout condition” with the water heater display showing the error code number and “S ervice Needed” in the status section of the display window. Error codes 62 (maximum number of retri[...]

51 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. T he error code label is located below the water heater display and the following section in this Installation and Oper[...]

52 Step 2: Press the “Temperature Down” button to select the error c ode index, starting with the most recent 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 c ode number. If [...]

53 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 [...]

54 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. The water heater display will store up to 10 error codes with the oldest code st arting in code index #1 with[...]

55 Error Code Definition of Code Cause of Problem and Actions Taken to Correct 23 Flame Detected Before Ignition Check to make sure gas valve has clos ed. No voltage should be present at the gas valve before the ignition cycle. Make sure wire positions on the wire harness are correct. If gas valve is stuck open, replace. 24 Flame Detected After Hea[...]

56 Procedure for Checking Thermostat Sensors Set the thermostat above water temperature (See temperat ure adjustment section) and observe system through one (1) complete cycle. Make sure system operates as desired. To check the upper sensor or lower sensor assembly, compar e the resistance of the sensor terminals (blue leads for upper sensor, yello[...]

57 SECTION XII: PARTS LIST REPLACEMENT PARTS LIST FOR POWERED DIRECT VENT MODELS Contact your supplier, plumbing professi onal or the company listed on the rating plate of the water heater for replacement parts. Provide the part name as well as the m odel and serial number(s) of the water heater(s) when ordering parts. When applicable, the followin[...]

58 VENT KIT COMPONENTS AND OPTIONAL CONDENSATE TEE 150,00 AND 199,999 BTU/HR. MODELS: 3” VENT KIT MODELS OVER 200,000 BTU/HR.: 4” VENT KIT COMMON: 3” AND 4” VENT KIT 3” OR 4” EXHAUST TERMINAL 3” OR 4” INTAKE TERMINAL[...]

59 SECTION XIII: INSTALLATION FOR POTABLE WATER AND SPACE HEATING THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION OF: GAS WATER HEATERS SUITABLE FOR WATER (POTABLE) HEATING AND SPACE HEATING 1. All piping components connected to this water heater for space-heating applications must be suitable for use with potable water. In Massachusetts, space hea[...]

60 SECTION XIV: NOTES[...]