Bradford-White Corp TGHE-160E-N(X) manual

238-48794-00C 07/11 Bradford White EverHot  Condensing Tankless Gas Water Heater For Exterior Installation TGHE-160E-N(X) and TGHE-199E-N(X) INSTALLATION AND OPERATION INSTRUCTION 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 ga soline or[...]

2 SECTION I: IMPORTANT INFORMATION TABLE OF CONTENTS I IMPORTANT INFORMATION ......... 2 V II OPERATING INSTRUCTIONS ....... 39 II SPECIFICATIONS .......................... 6 TEMPERATURE ADJUSTMENT ................................ 41 III INSTALLATION INSTRUCTIONS ............................. 9 VIII MAINTENANCE .............................. 46 IV [...]

3 DO NOT store or use gasoline or other flamm able, combustibl e, or corrosive vapors and/or liquids in the vicinity of this or any other appliance. This water heater is for outdoor installati on only. Do not install indoors. This water heater is eq uipped with an adjustable t hermostat to control water tempe rature. Hot water temperatures required[...]

4 DO NOT tamper with or alter the water h eater and/or controls. DO NOT operate water heater with jum pered or absent controls or safety devices. DO NOT operate water heater if any external part ha s been under water. Immediately call a qualified service technician to inspect the water heater and to re place any part of the cont rol system includin[...]

5 Liquefied petroleum ga ses/propane ga s is heavier than air and will remain at floor level if there is a leak. Basements, crawl spaces, cl osets and areas below gr ound level will serve as pockets for accumulation of leakin g gas. Before lighting, smell all around the appliance area for gas. Be sure to smell next to the floor. IF YOU SMELL GAS: ?[...]

6 SECTION II: SPECIFICATIONS Table 1. Specifications . Model TGHE-160E-N(X) TGH E-199E-N(X) Minimum Rate Btu/h 9,500 (Natural) / 10,300 (Propane) Maximum Rate Btu/h 157,000 199,000 Flow Rate (Min-Max) * 0.4-8.0 GPM (1.5-30 L/min) 0.4-9.8 GPM (1.5-37 L/min) Flow Rate (45°F rise) 6.6 GPM (25 L/min) 8.5 GPM (32 L/min) Default Temperature Setting 104?[...]

7 Dimensions TGHE-160E-N(X), TGHE-199E-N(X) Table 2. Water Heater Dimensions. DIM DESCRIPTION TGHE-160E-N(X) In. (mm) TGHE-199E-N(X) in. (mm) A Width 18 ½ (470) 18 ½ (470) B Depth 10 5/8 (271.9) 10 5/8 (271.9) C Height - Unit 26 3/8 (670) 26 3/8 (670) D Height - with brackets 28 3/8 (721.6) 28 3/8 (721.6) E Hot W ater Outlet - from wall 4 ½ (115[...]

8 Figure 1. Graph Showing Pressure Drop v. Water Flow Rate. Figure 2. Graph Showing Water Flow Rate v. Temperature Rise. TGHE-160E-N(X) TGHE-199E-N(X) Pressure Drop (psi) Pressure Loss (ft head) TGHE-199E-N(X) TGHE-160E-N(X) Water Flow Rate (gpm) Temperature Rise ( ° F)[...]

9 SECTION III: INSTALLATION INSTRUCTIONS CAUTION If building cold water suppl y has a back-flow prevente r, check valve or wat er meter with check va lve, provisions for thermal expansion of water in the hot water system must be p rovided. WARNING Pressure relief valve discharge piping must be pi ped ne ar ground or drain to eliminate potential of [...]

10 WARNING UNPACKING INSPECT SHIPMENT carefully for any signs of damag e. 1. All equipment is carefully manufactured, insp ected and packed. 2. Any claims for damage or shorta ge in shipment must be file d immediately with Bradford White Corporation and noted on the Bill of Lading. WATER HEATER LO CATI ON 1. This water heater must be installed outd[...]

11 MOUNT WATER HEATE R ON T HE W ALL This water heater must be in stalled outdoors. Refe r to Table 3 clearan ces under overhangs, windows, doors, etc. Also, avoid locations where there is hea vy water run-off fro m roofs. Determine the proper height and location for the water heater to b e installed. Conside r the water and gas connections. Allow [...]

12 State Regulations NOTICE BEFORE INSTAL LATIO N Bradford White direct-vent applia nce mu st be installed by a state qualifi ed or licen sed contractor. If you are not properly trained, you must not install this unit. IMPORTANT: In the State of Massachuse tts (248CMR 4.00 & 5.00) For all side wall horizontally vented ga s fueled equipment inst[...]

13 FIXED CLOSED OPERABLE FIXED CLOSED OPERABLE B B B A J B I M C F B B E D L G A H K VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED Figure 3. Installation Clearances.[...]

14 Table 4. Installation Clearan ces. Ref Description Canadian Installations US Installations A Clearance above grade, veran da, porch, deck, or balcony 12 inches (30 cm) 12 inches (30 cm) B Clearance to window or door that may be opened 36 inches (91 cm) 12 inches (30 cm) C Clearance to permanently clo s ed window * * D Vertical clearance to venti[...]

15 Local codes supersede the se clearances.  Avoid termination locations near a dryer vent.  Avoid termination locations near commercial cooking exhaust s. 2" 36" 12" INSIDE CORNER * (0.30 m) to an inside (50 mm) between termi nals at same level (0.91 m) to ventilated or unventilated soffit or eve vent or to a deck or p orch Fi[...]

16 High Altitude Installations The default setting for the water is 0-2,000 ft (0-61 0 m) with dip switch numbers 2 and 3 in the OFF position. If this water heater is i nstalled at a highe r altitude, it is necessary to modify the dip swit ch settings according to Table 5. Table 5. Dip Switch Settings for High Altitude Installations. 0-2000 ft (0-6[...]

17 SECTION IV: WATER CONNECTIONS WARNING Failure to install and maintain a new, listed pressu re relief valve will release the manufacturer from any claim, which might result from excessive temperature and pressures. Keep clear of the pressure relief valve di scharge line outlet. The discharge may be hot eno ugh to cause scald injury. The water is [...]

18 potable water. Unions should be installed on both the hot and cold water lines for future servicing and disconnection of the water heater. Install a shut -off valve in the cold water sup ply line. 2. In order to service the water heater in the event the h eat exchanger needs to be flushed of mineral deposits, tee fittings with shut-off valv es a[...]

19 Figure 5. Scald Warning . Table 7. Approximate scald time/temperatures. APPROXIMATE TIME/TEMP ER ATURE 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 1[...]

20 Figure 6. Recommended Piping for a Basic Installation.[...]

21 Figure 7. Recommended Piping for a Circulation Systems . Pump to be of bronze or stainless construction[...]

22 Recommended Piping for Po wer Failure Freeze Protection As long as electrical power a nd gas are supplied to the EverHot  water h eater, freeze protection is provided to the heat exchanger and pipi ng inside the wate r heater with ambient temperatures as cold as -4  F (-20  C), when protected from dire ct wind exposure. In the event of [...]

23 PRESSURE RELIEF VALVE Keep clear of the pressure reli ef valve di scharge line outlet. The discharge may be hot enough to cause scald injury. The water is unde r pressure and may splash. For protection against excessive pressure, insta ll pressure protective equipment req uired by local codes, but not less than a pressure reli ef valve certified[...]

24 Combination Water and Space Heating Applications – Commercial Use Water Heaters Only Commercial use water h eaters may be used for space heating or combination space heating/potable water heating applications, provided the followin g requirements and recommended piping di agrams are carefully followed. WARNING The following instructions must b[...]

25 Note: in Massachusetts, the following must be done:  Tempered  potable  water  must  meet  temperatures  in  248  CMR.   All  water  piping  must  be  insulat ed  in  accordance  with  780  CMR  (Massachusetts  energy  code ).   50  feet  maximum  distance [...]

26 SECTION V: GAS CONNECTIONS WARNING Connect this water heater only to the ty pe of gas as shown on the rating plate. Use clea n black iron pipe or equivalent material approved by local codes and ordinances. Dirt and scale from th e pipe can enter the gas valve a nd cause it to malfunctio n. The inlet gas li ne must have at least a 3 in. (7.62 cm)[...]

27 Check the type of ga s and the gas inl et pressure before connecting the EverHot ® water heater to the gas supply. If the gas su pply type does not match the type shown on the water heater rating pl ate, then DO NOT connect the water he ater. Contact your Bradford White supplier for the correct water heater. GAS METER SIZE – NATURAL GAS ONLY [...]

28 INITIAL OPERATION AN D TESTING (INSTALLER ONLY) 1. Open the gas and water supply valves to the water heater. 2. Check for water and gas le aks. Use soap solution to check for gas leaks. 3. To check inlet supply p r essure, remove the 1/8” NPT plug on the gas inlet suppl y fitting just below the bottom casing and inst all a barb fitting for att[...]

29 SECTION VI: ELECTRICAL CONNECTIONS WARNING Turn off or disconnect the electrical power supply to the water heater before servicing. Label all wires prior to disconn ection when servicing controls. Wiring erro rs can cause improper and dangerous operation. Verif y proper operation after servicing. All electrical wiring must be install ed and grou[...]

30 WARNING DO NOT adjust any dipswitch settings on PC board u nless instructed to do so. Figure 10. Ladder Diagram. WATER LEVEL DETECTING CIRCUIT WATER LEVEL ELECTRODE TWIN THERMISTOR[...]

31 Figure 11. Wiring Diagram for TGHE Models.[...]

32 TEMPERATURE CONTROLS The included temperature control a llows the end user to set the hot water supply temperature and will display certain diagnostic cod es of the water heater if there is a malfunction. All models ha ve the option of up to four controllers that can be used to conv eniently control water temperatures for bath and shower fixture[...]

33 WARNING Do not adjust this water h eater in any residential application above 120ºF. If this water heater is used in a commercial application where temperatures in excess of 120ºF are required, use an ASSE approved mixing device. WARNING This water heater is equipped with an energy cut out device to prevent overheating. Should overheating occu[...]

34 Figure 12. Remote Control and the Description of Function s on All Controls. Residential Control, p/n 239-4878 8-00 Commercial Control, p/n 239-487 89-00 Installation of Control(s) 1. The controls may be wired in parallel o nly. 2. Mark the hol es on the wall using the co ntrol mounting plate and drill two mounting h oles using a 3/32” (2.4 mm[...]

35 8. Remove the plastic cover from the PCB and ele ctrical connections. 9. Thread th e cable through the access hole at th e ba se of the water h eater and connect the wires to the control terminals on the right hand side of the PCB. 10. Secure the control cable using the cl amp provide d in the control compartment. 11. Replace the plastic cover o[...]

36 Troubleshooting – Electrical There are a number of (live) tests that are required when fault finding this product. Extre me care should be used at all times to avoid contact with energiz ed components inside the water heater. Only trained and qualified service tech nicians should attempt to repair this pr oduct. Before checking for resistance [...]

37 Table 16. (FM) Combusti on Fan Motor. Wire Color Voltage Resistance Connector No. Pin Nos. Red-Black 6-45 VDC n/a L1 1-2 White-Black 5-10 VDC 9.2-9.4k ohms L1 2-4 Yellow-Black 11-13 VDC 3.5-3.9k ohms L1 2-3 Set your meter to the hertz scale. Reading across the white and black wires at terminals 2 and 4 you should read between 60 and 420 hertz. T[...]

38 Table 21. Remote Controls. Wire Color Voltage Resistance Connector No. Pin Nos. Terminals A1 10-13 VDC 1.5-3.0k ohms A 1-3 Frost Protection: This unit has frost protection he aters mounted at diffe rent points to protect the water the water heater from freezing. The heate rs located on the hot water ou tlet line should have a resistance reading [...]

39 SECTION VII: OPERATING INSTRUCTIONS WARNING Water heaters are he at-producing app liances. To avoid damage or injury there must be no materials stored against th e water heater or direct vent sy stem, and proper care must be taken to avoid unnecessary contact (especially by children ) with the water heater a nd direct vent system. UNDER NO CIRCU[...]

40 LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFO RE OPERATING WARNING: If you do not follo w these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This water heater does not have a pilot. It is equipped with a direct ignition device, which automatically lights the burner. Do not tr[...]

41 CAUTION In climates wh ere below free zing temper atures may occ ur, the water heater must b e drained when power is off to the water heater to prev ent free ze damage to the heat exchanger. Drain sol enoids are recommended to prevent freeze damage during p ower failures in cold climate regions. TURNING OFF THE WATER HEA TER FOR AN EXTENDED PERI[...]

42 2. To set the de sired temperature on the control, all hot water faucets must be closed. If there are more remote control s installed, press t he “Priority” button on the control you want to change the setting on and the “Priority” indicator light will glow. 3. Press the “Up” o r “Down” button until the requi red temperature is d[...]

43 SCALDING Figure 17. Scalding Warning. This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot w ater to avoid scalding injury. Cer tain applianc es, such as dishwas hers and automatic clothes washers may require increased wate r temperature. By setting the thermostat on this water heate[...]

44 DIAGNOSTIC CODES ON THE TEMP ERATURE CONTROL DISPLAY The Bradford White EverHot  tankless water heate rs have the ability to monitor and display any operating faults on the control display. The diagnostic codes will display on the monitor and will assist in servicing the water heater. The following is a listing of t he d iagnostic codes, whic[...]

45 Code Code Description Remedy 16 Over Temperature Warning Check for restrictions in air flow around unit and vent terminal. Check for low water flow in a circulating system causing sh ort-cycling. Check for foreign materials in combustion ch amber and/or exhaust piping. Check for clogged heat exchanger. 25 Condensate Trap Error Condensate contain[...]

46 SECTION VIII: MAINTENANCE WARNING Always turn off the electrical power supply, the manual ga s valve, and the manual water control valve whenever servicing this applian c e. KEEP THE WATER HEATER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE, AND OTHER FLAMMABLE VAPORS AND LIQUIDS. The EverHot  water heater should b e checked annua[...]

47 CAUTION Before manually operating the valve, make su re t hat a drain line has been attached to the valve to direct the discharge to a n open drain. Failure to take this precaution could mean contact with extremely hot water passing out the valve during this checking operation. FLUSHING PROCEDURE FOR MINE RAL SCAL E REMOVAL FROM HEAT EXCHANGER T[...]

48 Figure 19. Piping for Mineral Scale Flushing. Rinnai Wa ter Heater Ga s Su ppl y V1 V3 V2 V4 H1 H2 H3 Ci rc u la t i ng Pu m p 5 g all on pail o f vi r gin, fo od g r ad e , w h i t e v ine g a r (o r vir gin, fo od gr a d e , cit ri c a c i d) . Co l d W a te r L in e Ho t W ater Li ne n-l i ne Fi l te r I Ev e r H o t®[...]

49 Common Troubleshooting Commen ts on the Operation of the EverHot ® Tankless Water Heater Comment: I don’t have any hot water when I open the tap! Make sure the gas and electricity is turned on to t he water heater. The temperature display should have the green light lit when a hot wate r tap is open and th e water heater is operating. Ma ke s[...]

50 SECTION IX: PARTS LIST TGHE-160E and TGHE-199E Models[...]

51 TGHE-160E TGHE -199E No. Description Quantity 001 Main Body 1 1 002 Wall Bracket 2 2 003 Rubber Bushing 1 1 004 Connection Reinforcement Panel 1 1 005 Heat Protection Plate 1 1 006 Front Panel 1 1 007 Gasket - Top and Bottom 2 2 008 Gasket - Side 2 2 011 Screw Cover 2 2 012 Screw Cover Lid 4 4 013 Cable Access Assembly 1 1 014 Rubber Bushing 1 1[...]

52[...]

53 TGHE-160E TGHE -199E No. Description Quantity 103 Burner Unit Assembly LPG 1 1 Burner Unit Assembly NG 1 1 104 Burner Case Cover 1 - 106 Burner Packing 1 - 107 Burner 16 - 108 Burner Case Back Cove r 1 - 109 Damper LPG 1 1 Damper NG 1 1 110 Manifold Assembly NG 1 1 Manifold Assembly LPG 1 1 111 Manifold Packing 1 - 112 Manifold Packing 1 - 114 C[...]

54[...]

55 TGHE-160E TGHE -199E No. Description Quantity 100 Gas Controller Assembly 1 1 101 Test Port Set Screw 2 2 102 Gas Connection 3/4" NPT 1 1 400 Water Inlet 3/4" NPT 1 1 401 Water Flow Servo and Sensor A ssembly 1 1 402 Rectifier 1 1 403 By-pass Flow Assembly 1 1 404 Stop Bracket 2 2 408 Hot Water Outlet 3/4" NPT 1 1 409 Stop Bracket[...]

56[...]

57 TGHE-160E TGHE-199E No. Description Quantity 447 Connection Harness 1 1 712 Frost Sensing Switch 2 1 713 Anti-Frost Heater 120V 1 1 715 Valve Heater 120V Assembly 1 1 721 Fuse Harness 1 1 722 Power Harne s s 1 1 724 Sensor Harness 1 1 725 Thermal Fuse Harness Assembly 1 1 726 Ignitor Harness 1 1 729 Temperature Controller Harness 1 1 731 Solenoi[...]

58 SECTION X: WARRANTY What does this Limited Warr anty Cover? This limited warranty covers b o th the heat exchanger and component parts for leakage or other malfunction caused by defects in materials and/or wo rkmanship. It applies to the o riginal consumer purchaser and to any subseque nt owner as long as the wa ter heater remains installed at i[...]

59 demand recirculation is n ot incorporated. A system that incorporates a continuou s recirculation due to timer settings, excessive heat lo ss of the loop or aquastat / thermostat setting will be treated as a continuous circul ation system and hav e a reduced warranty of 3 years. On-demand recirculation i s defined as a hot water re-c ir culating[...]

60 EverHot® Limited Warranty Registration In order to confirm Limit ed Warranty coverage at 12 year s for Residential Applications 1 , complete the information below and click submit. *Consumers First Name: *Consumers Last Name: ____________________ ___________________ *Address: *City: ____________________ ____________________ *State: *Zip: ______[...]

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Ambler, PA For U.S. and Canada field service, Contact your professional installer or local Bradford White representative. Sales/ 800-523-2931 Fax/ 215-641-1670 Parts Fax/ 215-641-2180 Technical Support/ 800-334-3393 Fax/ 269-795-1089 Warranty/ 800-531-2111 Fax/ 269-795-1089 International: Telephone/ 215-641-9400 Telefax/ 215-641-9750 Mississauga, O[...]