Bradford-White Corp ULTRA HIGH EFFICIENCY COMMERCIAL GAS WATER HEATER manual

238-48384-00F REV 7/12 - 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 pho[...]

2 SECTION I: IMPORTANT INFORMATION This gas-fired water heater is de sign certified by CSA In ternational under the Ame rica n Natio nal Standard, Z21.10.3 (as indicated on the rating plate) and CA N/CGA 4.3-M (as i ndicate d on the rating plate) available from CSA Standards Association, 5060 Spectrum Way, Missi ssaug a, Ontario, CANADA L4W 5N6. Th[...]

3 DANGER DO NOT store or use gasoline or othe r flammabl e, combustible, or corrosive vapors a nd/o r liquids in the vicinity of this or any other appliance. DO NOT install any damaged venting system compo nents. If damage is evident then please conta ct the supplier where the water heater was pu rch ased or the manufacture r li sted on the rating [...]

4 WARNING This water heater needs fresh air for safe operation a nd must be installed so there are provisi ons for adequate combustion and ventilation air. Insuffi cient air supply will cause a recirculati on of combustion product s resulting in contamination that may be hazardo us to life. This will result in carboning or sooting of the combus tio[...]

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 the following feature s: MAIN POWER ON/OFF SWITCH – The front panel of this wate r he ater has a lighted ON/OFF switch, which is illuminate d when the main power is turned on to indicate po wer to the water heater. COMBUSTION SYSTEM – This water heater is equip ped with a se[...]

7 TEMPERATURE AND PRESSURE RELIEF VALVE – CONDENSATE DR AIN - The water heater should ei ther be raised several inches above the floor on a concrete slab or use a low profile conden sa te pump to allow free drainage of conde nsate from the elbow drai n fitting. This water heater is a condensing type unit and requi res a drain to be located in clo[...]

8 Figure 2. Condensate Elbo w With Trap CLEANOUT – All models are eq uipped with a cleanout openin g to aid in removal of hard water deposits from the tank bottom. If this water heater operates under hard water condi tions, the following should b e performed at least every 3 months: Turn off water supply and drain the water heater. Remove the cle[...]

9 SECTION IV: INSTALLATION INSTRUCTIONS Sacrificial anode rods have been install ed in the tank head of t he water heater to extend tank life. The removal of these anodes for any reason will nullify the warr anty. In areas where water is unusual ly active, an odor may occur at the hot water faucet due to a reaction between t he sacrificial anode an[...]

10 UNPACKING INSPECT SHIPMENT carefully for any signs of damag e. 1. All equipment is carefully manufactured, inspecte d and packed. 2. Any claims for damage or shortage in shipment must be filed immediately with the shipper, and noted on the Bill of Lading. 3. Remove all venting components from the combusti on assembly compartme nt by removing the[...]

11 Figure 3b. Recommended Minimum Clearances For Service Access REMOVE CRATE 1. Remove all banding and pry off crate sides carefully so as not to damage the water heater. 2. Carefully roll/lift the water heater from the crate base. CAUTION Do not drop water heater. Do not bump water heater jacket against floor. Do not bump exhaust vent pipe against[...]

12 CAUTION If the building cold water supply has a back-flow preventer, c heck valve or wate r meter with check valve, provisions for thermal expansion of water in the hot water syste m must be provided. LOCATION KEEP APPLIANCE AREA CL EAR AND FREE OF COMBUSTIBLE MA TERIALS, GASOLI NE AND OTHER FLAMMABLE VAPORS AND LIQUIDS. This water heater must b[...]

13 CHEMICAL VAPOR CORROSION Corrosion of the flue ways and vent system will occu r if ai r for combustion contains certain chemical vapors. Such corrosion may result in poor combu stion and create a risk of as phyxiation, as well as reducing the life of the water heater. Spray can propellants, cleaning solvent s, refrigerator and ai r conditioning [...]

14 Figure 7. Typical Three Water Heater Connectio n Figure 8. Typical Four Water Heater Connection[...]

15 SECTION V: WA TER CONNECTIONS WARNING Failure to install and maintain a new, listed tempe ratu re and pres sure relief valve will release the manufa cturer from any claim, which might result from excessive temperature and pressures. Hydrogen gas can be prod uce d in an operating water heater that has not had water draw n from the tank f or a lon[...]

16 Approximate Time/Temperature Scald Chart Table 2. ALTERNATE SPACE HEATING WATER CONNECTIONS DANGER Toxic chemical, such as those used for boiler treatme nt, must not be introd uced into potable water used for spa ce heating. This water heater must not be connected to an existing heating system or com ponent(s) previously used wi th a non- potabl[...]

17 Figure 10. Typical Plumbing Schematic for Zoned Hea ting SECTION VI: VENTING WARNING The vent system must be properly installed. Failure to prope rly install the vent system c ould result in property damage, personal injury, or death. DO NOT install damaged venting system comp onents. If damage is evident then please contact the supplier wh ere [...]

18 NOTICE Single Wall Polypropylene venting system s that are li sted on the Bradford Whit e website are approved for use in the water heaters covered in this instruction manual. The venting system comp one nts are ULC S636 approved and listed by a recognized agency and may be inst alled in the U.S. and Canada. Complete instru ctions for the approv[...]

19 VENTING The venting instructions must be follo we d to avoid restricted combustion or recirculation of flue gases. Such conditions cause sooting o r risks of fire and asphyxiation. This water heater can be installed a s eith er a direct ve nt sy stem or power vent (air from inside) system. If it is installed as a direct vent system, then the air[...]

20 NOTICE The air intake and exhaust terminals may be located on separate outside walls or one terminal may exit the roof while the other is through the wall. The total combined equivalent vent length m ust be within the limits specified in the venting tables and the intake length cannot exceed the exhaust by more than 30 feet. The minimum recommen[...]

21 Figure 11a. Vent Terminal Clearances (Other tha n Direc t Vent or “Power Vented” Installations) Canadian Installations 1 US Installations 2 Canadian Installations 1 US Installations 2 A= Clearance above grade, veranda, porch, deck or balcony 12 inches (30 cm) 12 inches (30 cm) H= Clearance to each side of center line extended above meter/reg[...]

22 Figure 11b. 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 cm) 12 inches (30 cm) H= Clearance to each side of center line extended above meter/regulator assembly 3 feet (91 cm) within a height 15 feet ([...]

23 The vent system must terminate so that proper clearances are maintained a s cit ed 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 other area where condensate or vapo r co uld create a n uisance or hazard or cause property damage[...]

24 Figure 12. Typical Horizontal Direct Vent Sy stem Vertical Installation: Vertical venting system must be supported every 5 feet of vertical run and every 3 feet of horizontal run of vent pipe length. CAUTION Failure to properly support the vent piping with han gers and clamps may result in damage to the water heater or venting system. Stress lev[...]

25 Figure 13. Typical Vertical Direct Vent Sy stem Installation (Note: Intake and exhaust terminals may be on different outside walls.) 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 sno w level) from the ground, then the installa[...]

26 Figure 14. Vent Termina l (Low Ground Clearance) Maximum Vent Length: Direct Vent Maximum Vent Length (Combined Maximum Length for Intake and Exhaust) Model Number Max Vent Length (feet) 2” Max Vent Length (feet) 3" Max Vent Length (feet) 4" EF60T125, EF100T150 30 120 170 EF60T150, EF100T199 30 100 150 EF60T199 30 80 130 EF100T250 N/[...]

27 POWER VENT INSTALLATION Power venting is where the indoo r air is used and the exhaust is vented to the ou tside. Venting may be run horizontally through an outside wall or vertically thro ugh a ro of through using either 2 inch (5. 1 cm), 3 inch (7.6 cm) or 4 inch (10.2 cm) diameter pipe. This water heater is sup plied with a 3 inch (7.6 cm) di[...]

28 Vertical Installation: Vertical venting must be supported every 5 feet of vertic al run and every 3 feet of horizontal run of vent pipe length. Stress levels in the pipe and fittings can be significa ntly incr ease d by improper installation. If rigid pipe clam ps are used to hold the pipe in place, or if the pipe cannot move freely th rough a w[...]

29 Figure 17. Vent Terminal (Lo w Ground Clearance) Maximum Vent Length Determination Power Vent Maximum Vent Length Model Number Max Vent Length (feet) 2” Max Vent Length (feet) 3" Max Vent Length (feet) 4" EF60T125, EF100T150 30 120 170 EF60T150, EF100T199 30 100 150 EF60T199 30 80 130 EF100T250 N/A 80 130 EF100T300 N/A 60 110 Table 4[...]

30 MULTIPLE INTAKE/EXHAUST TERM INAL SEPARATION DISTANCES Figure 18 Note: When installing multiple intake/exhaust terminals on the same wall of a building, the nearest intake terminal must be at least 5 f eet from the nearest exhaust terminal.[...]

31 CONCENTRIC VENT TERM INAL INST ALLATION PROCEDURE WARNING Improper installation, adjustment, service, or maintenanc e can cau se property damage, personal injury, or death. Consult a qualified installer, service age ncy, or the gas su pplie r for information or assistan ce. This kit must be used only for terminating this water h eater. Do not us[...]

32 2. Determine the best location for the termination kit. 3. Cut the recommended 5” (12.7 cm) diameter hole (for 3” vent termination) or 4 inch (1 0.2 cm) for 2” vent termination kit. 4. Partially assemble vent ki t by performing the following: a. Cement concentric Y fitting to larger diameter pipe. (See Figure 20). b. Cement rain cap to sma[...]

33 9. Operate heater through one cycle to ensure combustion-air and vent pipes are properly connected and sealed to concentric ven t termination connections. Horizontal Installation: 1. Become familiar with coaxial vent kit part no. 239-44069-01, as shown in Figures 19 through 21. For venting 4 inch (10.2 cm) or 2 inch (5.1 cm) diameter pipe, use t[...]

34 It is acceptable to install a 90 degree elbow on IPEX concentric vent terminations use with this power direct vent water heater (see Figure 23b). A short length of appropriate diameter vent pipe should be used to transition from the vent terminal to the 90 degree el bow. Approved venting materials along with primers and cements are listed at the[...]

35 INITIAL PREPARATION 1. Make sure the solvent cement you are planni ng to use is designed for the specific application you are attempting. 2. Know the physical and chemical characteristics and limi tations of the PVC, PVC cellula r core, ABS or CPVC piping materials that you are abou t to use. 3. Know the reputation of your pipe and cement manufa[...]

36 SECTION VII: GAS CONNECTIONS WARNING Connect this water heater only to the type of gas as sho wn on the rating plate. Use clean black i ron pip e o r equivalent material approved by local codes and ordin ances. (Dirt and scal e from the pipe can enter the gas valve and cause it to malfunction). The inlet gas line must have at least a 3 inch (7.6[...]

37 GAS METER SIZE – NATURAL GASES ONLY Be sure that the gas meter has sufficient cap acity to su pply the full rated gas input of the water heater as well as the requirements of all other ga s fired eq uipment supplied by the me ter. If the gas meter is too small, ask the gas comp any to install a larger meter having adequate capacity. GAS PRESSU[...]

38 SECTION VIII: ELECTRICAL CONNECTIONS WARNING Turn off or disconnect the electrical p ower su pply to t he water heater before servicing. Label all wires prior to disconnection when servi cing controls. Wiring erro rs can cause improper a nd dangerous ope ration. Verify prope r operation after servicing. All electrical wiring must be installe d a[...]

39 SECTION IX: OPERATING INSTRUCTIONS WARNING Water heaters are heat-produ cing a ppliances. To avoid dam age or injury there must be no m aterial s stored against the water heater or direct v ent system, and proper care must be taken to avoid unnece ssary contact (esp ecially by children) with the water heater and dire ct vent system. UNDER NO CIR[...]

40 LIGHTING AND SHUT-DOW N INSTRUCTIONS Figure 26. Lighting Instruction Label WARNING: above on this l abel. on this label i f you don't smell gas, "B" in the sa fety information above If you then smell gas, STOP! Follo w 6. Wait (5) minu tes to clear out any gas. may result causing property damag e, personal injur y or loss of life.[...]

41 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°F (68°C) About 1 second CAUTI[...]

42 WARNING If the water heater display does not sh ow “Operational” in t he “Status” indicator, there may be an operating malfunction with the water heater. If this is the case, a numeric code will be displayed. Refer to the label next to the display for the definition of the error code and call your plumbing p rofessional or service agent [...]

43 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 the display after pressing “Temperature Up” button. Step 3: Press “SET” button for new setting to take effect immediately. “Setpoint” wil[...]

44 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 the display after pressing “Temperature Down” button. Step 3: Press “SET” button for new setting to take effect immediately. The setpoint wi[...]

45 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 idl[...]

46 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[...]

47 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 age nt to p[...]

48 SECTION X: MAINTENANCE DANGER DO NOT ATTEMPT TO REPAIR GAS VALVE. DO NOT ATTEMPT TO REPAIR IGNITION MODULE. DO NOT ATTEMPT TO REPAIR VENTURI. DO NOT ATTEMPT TO REPAIR THERMOSTAT BOARD. DO NOT ATTEMPT TO REPAIR TRANSFORMER. DO NOT ATTEMPT TO REPAIR PRESSURE SWITCH. GENERAL KEEP APPLIANCE AREA CLEAR AND FREE FROM COMBUS TIBLE MATERIALS, GASOLINE A[...]

49 MAINTENANCE SCHEDU LE Following are the instructio ns for performing some of t he recommended maintenance. Unit inspection a nd adjustment should be performed by a competent technician. Suggested Maintenance Schedule COMPONENT OPERATION INTERVAL REQUIRED Tank Sediment Removal Monthly Flushing Anode Rods Inspect Semi-Annually Replace as Required [...]

50 The usage of water softening equi pment greatly reduces the ha rdne ss of the water. Ho wever, this equipment does n ot always remove all of the hardness (lime). For this reas on it is recommended that a regul ar schedule of deliming be maintained. The depth of the buildup should be measured perio dically. Water heaters will h ave about 3 i nche[...]

51 DRAIN VALVE AND TANK ACCESS PANEL The water heaters are equi pped with a ¾ inch drain valve. An access panel covers the cleanout op ening in the tank, which is seal ed by a g asket and cover. RELIEF VALVE At least twice a year, the temperature and pressure relief valve should be ch ecked to ensure that it is in operating condition. To check the[...]

52 SECTION XI: DIAGNOSTIC AND TROUBLESHOOTING GUIDE DIRECT SPARK HONEYWELL IN TEGRATED CONTROL SYSTEM SEQUENCE OF OPERATION 1. When the tank temperature drops below the temperature setpoint on the displ a y, the control sends power to the combustion blower for a 30 second pre-purge peri od. 2. At the end of the pre-purge period, t he control sends [...]

53 Step 1: Press “Select” and “Temperature Up” buttons together and hold for 3 seconds until “Max Setpoint” is shown in the display. Step 2: Pressing “Select” button will change display to next mode The following is the sequence of modes av ailable in “Servi ce Mode” by pressing the “Select” button: Error Code Number (Displa[...]

54 1. Max Setpoint (Display/Change) 2. Water Temperature Sensor Reading. 3. Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle) SELECT SET Status Heating Operational Flame Current µ A  SELECT SET Status °F idle Wat e r Te mp Operational  SELECT SET Status idle Operational Max Setpoint value in Water Heater Display Max S[...]

55 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 [...]

56 7. Software Version (Display only) 8. Error Code History (Displays if there are present erro r codes or up to 10 previous error codes). Water Heater Display will show -- if there are no error codes.  SELECT SET Status idle Operational No current error codes SELECT SET Status idle Operational Soft[...]

57 To change the Maximum Setpoi nt Limit (Max Setpoint) for the temperature 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 mode. WARNING Setting the water temperature to the maximum set poin[...]

58 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 (82 ˚ C) . Step 4: Press “Set” button to confirm new “Max Setpoint” value and stop setting mode. Step 5: 12.5 minutes after the last button [...]

59 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[...]

60 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 enter the setting mode. “Setpoint” will flash in the w ater heater display. NOTICE Note: The maximum temperature that can be set in the Water [...]

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

62 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 Changes to "?[...]

63 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[...]

64 How to reset the control from Lockout Conditions: If an error code is displayed (exce pt for #4, low flame sense curr ent), the water heater will be in a “lockout condition ” with the water heater display sh owin g the error code number and “Servi ce Need ed” i n the status sect ion of the display window. Error codes 62 (maximum number o[...]

65 Error Codes and Error History Display: If there is an operating problem with the water heater, an error 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 Insta llation and Operat[...]

66 Step 2: Press the “Temperature Down” button to select the error code 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 code number. If no[...]

67 Step 5: Press the “Select” button for code index #9 to view if there are any code numbers. 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 heat[...]

68 DIAGNOSTIC ERROR CODES A ND TROUBLESHOOTING PRO CED URE S FOR EF MODELS WITH HONEYWELL INTEGRATED DIRECT SPARK IGNITON CONTROL SYSTEM Error Code Definition of Code Cause of Problem and Actions Taken to Corre ct No code – blank display Check power sup ply to the water h eater. Make sure water heater is plugged in and the breaker is on. Check if[...]

69 Error Code Definition of Code Cause of Problem and Actions Taken to Corre ct 62 Maximum Number of Retries Detected Burner is either not lighting or not stay ing lit during ignition cycle. Chec k inlet gas pressure for minimum pressure on rating label. Can you hear sparking to the burner? Check high voltage cable connections. Check inlet gas pres[...]

70 Procedure for Checking Thermostat Sensors Set the thermostat above water temperat ure (Se e temperature a djustment secti on) and ob se rve system through one (1) complete cycl e. Make sure system operates as de sired. To check the sen so r assembly, compar e the resistance of the sen sor wires (either outside black to center wire with yellow ma[...]

71 SECTION XII: PARTS LIST EF™ – Series Water Heater 1 Combustion Surround Assembly 2 Burner Assembly (Specify model) 3 2nd Pass Top Collector Cover 4 Screw 10-16 x 3/4" 5 Vent Termination Elbow 6 Thermostat Sensor Probe 7 Baffle 4” Flue (Specify Model) 8 Mag. Rod Assembly 9 Baffle 2” Flue 10 Wire Harness-Servic e Panel 11 Plastisert N[...]

72 1 Combustion Surround Assembly AA Keepe r Latch & Catch BB Scre w 8-32 x 1/2" RHCR CC Control Panel Assembly DD Jacket Head 28 1/4“ Grey EE Switch Main Power FF Control Display GG Combustion Surround JJ Surround Bas/Jacket Head KK Display Harness[...]

73 2 Combustion Ass'y (pictured previous page) 1A Combustion Ass’y (Specify model) 14A Inlet Pipe 2A Blower/Gas Valve Ass’y (Specify model) 15A Gasket Blower Transition (Specify model) 3A Burner Ass’y (Specify model) 16A Screw 8 -3 2 x 1/4" RHCR 4A Blower – EBM (Specify model) 17A Gasket Flame Sensor 5A Silicone Hose 18A Flame Sen[...]

74 NOTES[...]

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76 NOTES[...]