Bradford-White Corp ULTRA HIGH EFFICIENCY GAS WATER HEATER manual

ULTRA HIGH EFFICIENCY GAS WATER HEATER (EFR160T120 Series Models) INSTALLATION/OPERATING MANUAL WITH TROUBLESHOOTING GUIDE PLACE THESE INSTRUCTIONS ADJACENT TO WATER HEATER AND NOTIFY OWNER TO KE EP FOR FUTURE REFERENCE 238-48144-00E 7/12 - Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appli[...]

2 SECTION I: IMPORTANT INFORMATION NOTICE This water heater has a limited w arranty. The warranty for this water heater is valid only if the water heater has been installed, maintained and operated in accordance w ith these instructions . TABLE OF CONTENTS I IMPORTANT INFORMATION ............. 2 VII GAS CONNECTIONS .................................[...]

3 DANGER DO NOT store or use gasoline or other flammable, combustible, or corros ive vapor s and/or liquids in the vicinit y of this or any other appliance. DO NOT install any damaged venting s ystem components. If damage is evid ent then please contact the supplier where the water heater was purchased or the manufactur e r listed on the rating pla[...]

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. Insufficient ai r supply will cause a recirculation of combu stion products resulting in contam ination that may be hazardous to life. This will result in carboning 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 the following feature s: MAIN POWER ON/OFF SWITCH – The front p anel of this water heater has a lighte d ON/OFF switch, which is illuminated when the main power is turned on to indi cate power to the water heater. COMBUSTION SYSTEM – This water heater is equip ped with a sel[...]

7 LATCHES – The latches a llow easy access for servicing the wate r heater from the top. Simp ly remove the two latches for servicing and re-lat ch upon completion. No tools are required t o obtain access to the top of the water heater. MIXING VALVE – This water heater is supplied with an ASSE approved mixing valve to reduce the potential for s[...]

8 CONDENSATE DR AIN – The water heater should ei ther be raised several inches ab ove the floor on a concrete slab or use a low profile conden sate pump to allow free drainage of co ndensate from the elbo w drain fitting. This water heater is a condensing type unit and requires a drain to be located in close proximity to allow the condensate to d[...]

9 SECTION IV: INSTALLATION INSTRUCTIONS WARNING INSTALLATION OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN TH E FIELD. PLUMBING, AIR SUPPLY, VENTING, GAS SUPPLY AND ELECTRICAL WORK ARE REQUIRED. DO NOT ATTEMPT TO LI GHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAI N OF THE FOLLOWING:  Liquefied petroleum gase s/p[...]

10 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 anod e and the impurities in the water. If th[...]

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

12 REMOVE CRATE 1. Remove all banding and pry off crate sides carefully so as not to damage the water heate r. 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 crate or other objects . This will damage the water heater [...]

13 MECHANICAL EXHAUSTING OF RO OM AIR 1. Whe re an exhaust fan i s installed in the same ro om with this water h eater and combu stion air is drawn f rom inside the room, sufficient openings for air must be pr ovided in the walls. UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM TH ROUGH THE WATER HEAT ER’S VENTING SYSTEM, CAUSING POO[...]

14 Figure 4. Typical Front Inlet Connection Figure 5. Typical Front Inlet Connect with Storage Heater[...]

15 Figure 6. Typical Two Water Heater Connection Figure 7. Typical Three Water Heater Connectio n Figure 8. Typical Four Water Heater Connection[...]

16 SECTION V: WA TER CONNECTIONS WARNING Failure to install and maintain a new, listed temperature and pressure relief valve will release the manufacturer from any claim, which might result from excessive temperature and pressures. Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period[...]

17 By setting the thermostat on this water heater to obtain the increased temperature water required by these appliances, you might create the potential for scald injury. To protect against injury, you must install the ASSE a pproved mixing valve suppli ed with the water heater in the water system. This valve will reduce point of discharge temperat[...]

18 Figure 11. Typical Plumbing Schematic for Zoned Hea ting SECTION VI: VENTING WARNING The vent system must be prope rly installed. Failure to properly install the vent sy stem could result in pro perty damage, personal injury, or death. DO NOT install dam aged venting syste m components. If dam ag e is evident then please contact the supplier whe[...]

19 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 onents are ULC S636 app roved and listed by a recognized agency and may be inst alled in the U.S. and Canada. Complete instructions for the approve[...]

20 NOTICE Before beginning installation of any vent pipe, read th e vent pipe manufacturer’s installatio n instructions. Do not install the water heater in any location wh ere the ambien t temperature may fall below freezing. Water heater must be protected from free zing downd rafts during shutdown perio ds. Provide protection of the building mat[...]

21 VENTING The venting instructions must be follo wed to avoid restri cted combustion or recirculation of flue gase s. Such conditions cause sooting o r risks of fire and asphyxiation. This water heater can be installed as eit her a dire ct vent system or power vent (air from inside) sy stem. If it is installed as a direct vent system, then t he ai[...]

22 Figure 12a. Vent Terminal Clearances (Other tha n Direct 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 (30.5 cm) 12 inches (30.5 cm) H= Clearance to each side of center line extended above meter/[...]

23 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[...]

24 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 nea r soffit vents or crawl space or ot her area where conden sate or vapor co uld create a nuisance or hazard or cause prop erty damag[...]

25 2. Use the proper cement to secure t he exhau st vent and air intake termi nals provided with the water heater to the pipes. The distance between the back edge of t he exhaust vent terminal a nd the exterior wall (see Figure 13) must be 6 inches (15.3 cm ) more for the exhaust vent terminal than the air intake terminal. Use the proper cement or [...]

26 Figure 14. Typical Vertical Direct Vent Sy stem Installation (Note: Intake and exhaust terminals may be on different outside walls.) Through The Wall Venting With Low Gro und Clearance: When venting cannot exit through the wall at a height greate r than or equal to 12 inches (30.5 cm) (and abo ve expected snow level) from the ground, then the in[...]

27 Maximum Vent Length: Direct Vent Maximum Vent Length (Combi ned Maximum Length for Intake and Exhaust) Model Number Max Vent Length in feet (meters) for 2 inch (5.1 cm) Max Vent Length in feet (meters) for 3 inch (7.6 cm) Max Vent Length in feet (meters) for 4 inch (10.2 cm) EFR60T120 60 (18) 120 (36) 170 (51) Table 3 Note: The venting distance [...]

28 CAUTION Failure to properly support the vent piping with hangers and clamp s may result in damage to the water heater or venting system. Stress levels in the pipe and fittings can be significantl y in creased by imprope r installation. If rigid pipe clamps are used to hold the pipe in pla ce, or if the pipe cannot mo ve freely through a wall pe [...]

29 Follow the following proced ure to vent through the roof: 1. Cut the necessary holes through the roof and ceili ng. 2. Install the exhaust vent and air intake plastic pipes as shown in Fig ure 17. Make sure that the installation meets the local codes and/ or The National Fuel Gas Code ANSI Z223.1 (Latest Edition) or CGA/CAN B149 Installation Cod[...]

30 Through The Wall Venting With Low Gro und Clearance: When venting cannot exit through the wall at a height greate r than or equal to 12 inches (30.5 cm) (and abo ve expected snow level) from the ground, then the in stalla tion must be modified as shown below (see Fi gure 18). Refer to Tables 3 or 4 for maximum venting lengths using 2 inch (5.1 c[...]

31 MULTIPLE INTAKE/EXHAUST TERM INAL SEPARATION DISTANCES Note: When installing multiple intake/exhaust terminals on the same wall of a building, the nearest intake terminal must be at leas t 5 feet (1.5 m) from the nearest exhaust terminal.[...]

32 CONCENTRIC VENT TERM INAL INSTALLATION PROCEDURE WARNING Improper installation, adju stment, service, or ma intenance can cause propert y damage, p ersonal injury, or death. Consult a qualified installer, service agen cy, or the gas sup plier for information or assistance. This kit must be used only for terminating this water heater. Do not use [...]

33 Figure 21. Rain Cap to Small Vent Pipe Assembly 5. Install concentric Y fitting and pipe assembly through the stru cture’s hole and field-suppl ied roof boot/flashi ng. Do not allow insulation or other mate rials to accumulate inside pipe assembly when installing through the hole. 6. Secure assembly to roof structure as shown in Fi gure 22 usi[...]

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

35 It is acceptable to install a 90 degree elbo w on IPEX concentric vent terminations us e with this power direct vent water heater (see Figure 23b). A short length of appropriate diamet er vent pipe should be used to transition fro m the vent terminal to the 90 degree elbow. Appro ved venting materials along with primers an d cements are listed a[...]

36 INITIAL PREPARATION 1. Make sure the solvent cement you are planni ng to use is de signed for the specifi c application you are attempting. 2. Know the physical and chemical ch aracteristics and limitations of t he 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[...]

37 Figure 24. Drip Leg The gas supply lines must meet all r equirement s of the National Fuel Gas Code ANSI Z223.1 (Latest Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.2 Pro pane Installation Code (Latest Edition). GAS METER SIZE – NATURAL GASES ONLY Be sure that the gas meter ha s sufficien[...]

38 SECTION VIII: ELECTRICAL CONNECTIONS WARNING Turn off or disconnect the electrical po wer supply to t he water heater before servici ng. Label all wires prior to disconnection when servici ng controls. Wiring errors can cause improper and dange rous operation. Verif y proper operation after servicing. All electrical wiring must be install ed and[...]

39 SECTION IX: OPERATING INSTRUCTIONS WARNING Water heaters are heat-produ cing appliances. To avoid dam age o r injury there must be no materials stored against the water heater or direct v ent system, and proper care must be taken to avoid unnece ssary contact (especially by children) with the water heater and dire ct vent system. UNDER NO CIRCUM[...]

40 LIGHTING AND SHUT-DOW N INSTRUCTIONS Figure 26. Lighting Instruction Label WARNING: above on this label. on this label if you don't smell gas, "B" in the safety 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[...]

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 SCALDIN[...]

42 Condensation does not mean your t ank is leaking. Most of reported tank leaks o n installation are proven to be condensation. To avoid unnecessary inconvenience and ex pe nse, make sure the tank is leaki ng before calling an independent servicing cont ractor or qualified service professio nal. If the water heater is to remain idle for 30 days or[...]

43 To Increase Setpoint Temperature Step 1: Depress and hold “Temperature Up” button u ntil desired setpoint temperature appears in the display. Step 2: “Setpoint” indicator begins flashing in the display after pre ssing “Temperature Up” button. Step 3: Press “SET” button for new setting to take effect immediately. “Setpoint” wi[...]

44 To Decrease Setpoint Temperature Step 1: Depress and hold “Temperature Down” butto n unt il desired setpoint temperature ap pears in the display . Step 2: “Setpoint” indicator begins flashing in the display after pre ssing “Temperature Down” button. Step 3: Press “SET” button for new setting to take effect i mmediately. The setpo[...]

45 To Change Temperature Format in Display from  F to  C or ˚ C to ˚ F: Step 1: Press “SELECT” button until  F/  C is displa yed. Step 2: Press “SET” button to change temperature format. Symbol  F/  C will flash. Step 3a: Press “Temperature Up” butt on to change tempe rature format to  C. Step 1 SELECT SET Status [...]

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

47 An automatic gas shut-off device (ECO) i s incorporated 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 ximately 120°F ( 49°C ) and call a qualified servi ce agent to place[...]

48 Figure 27. Sight Glass Location MAINTENANCE SCHEDU LE WARNING Water heaters are heat produ cing appliances. To av oid damage or injury there must be no m aterials stored against the water heater or vent -air intake system, and proper care mu st be taken to avoid unnecessary contact (espe cially by children) with the water heater and vent-air int[...]

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

50 The depth of the buildup should be measure d peri odically. Water heaters will have abou t 3 inches (7.6 cm ) of lime buildup when the level of li me has reached the bottom of the cleanout ope ning or about 1 inch (2.5 cm) of lime buildup if it has reached the drain valve opening. A schedule fo r delim ing should be set up, based on the amount o[...]

51 CAUTION Before manually operating the valve, make sure that a drain line has been attached to the valve to direct the discharge to an open drain. Failure to take this precaution could mean contact with extre mely hot water passing out the valve during this checking ope ration. If the combination temperature and pressure relief valve on the water[...]

52 SECTION XI: DIAGNOSTIC AND TROUBLESHOOTING GUIDE DIRECT SPARK HONEYWELL IN TEGRATED CONTROL SYSTEM SEQUENCE OF OPERATION 1. When the tank tem perature drops belo w the temperature setpoin t on the display, the control se nds power to the combustion blower for a 30 second pre-purge peri od. 2. At the end of the pre-purge period, the control sends[...]

53 ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY (FOR SERVICE PERSONNEL ONLY) The display has a “Service Mode” for ch anging the maximum setpoint and accessing informa tion in aiding servicing of the water heater. This procedure is for service and in stalla tion personnel only. To enter the Service Mode, follow the steps illustrated below:[...]

54 The following is the sequence of modes available in “Service Mode” by pressing the “Select” button: Error Code Number (Displ ay/Reset). This is only show n if there is an operating error in the “Use r Mode”. 1. Max Setpoint (Display/Change) 2. Water Temperature Sensor Reading. SELECT SET Status idle Operational Max Setpoint value in [...]

55 3. Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle) 4. Setpoint (Display/Change) 5. ˚ F/ ˚ C (Displa y/Change) SELECT SET Status °F/C° idle Operational °F  SELECT SET Status °F idle setpoint Operational  SELECT SET Status Heating Operational Flame Current µ A [...]

56 6. Differential (Display only – shows the differential of the thermo stat) 7. Software Version (Display only) 8. Error Code History (Display s if there are present error cod es or up to 10 previous error codes). Water Heater Display will show -- if there are no error codes. SELECT SET Status idle Operational Soft SELECT SET Status °F idle Dif[...]

57 To change the Maximum Setpoint Limit (M ax 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. “M ax Setpoint” will flash to indicate setting mode. WARNING Setting the water temperature to the maximum set poi[...]

58 Step 3: Press the “UP” or “DOW N” buttons to change the maximum setpoint valu e. This will limit the maximum setpoint the user can select. Note: The maximum setpoint is app roximately 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[...]

59 Display of Water Temperature: Step 1: In Service Mode, Press the “Select” button until “Wate r Temp” is displ ayed 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 th e burners are[...]

60 To Display and Change Temperature Setpoint: Step 1: In “Service Mode” press the “Se lect” 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. NOTICE Note: The maximum temperature that can be set in the Wate[...]

61 Step 4: To lower the temperature setpoint, press the “Tem pe rature Down” b utton until the desired temperature is shown on the water heater displa y. Step 5: When the desired setpoint is re ached on the water heater display, press the “S et” button to confirm the new setpoint. “Setpoint” stops flashi ng in the water heater display. [...]

62 Step 2: Press “Set” button to change temperature format. “ ˚ F/ ˚ C” symbol will flash in the water heater di splay. Step 3a: Press “Temperature Up” button to change temperature format to ˚ C. Step 3b: Press “Temperature Down” butt on to change temperature format to ˚ F. SELECT SET Status idle Operational  °F °F/C° &quo[...]

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 cu rrent), the water heater will be in a “locko ut condition” with the water heater display showing the error code number an d “Service Need ed” in the status section of the display window. Error codes 62 (m aximum number of r[...]

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 Do wn” button to se lect the error code index, starting with the most recent error code “10”. Step 3: Press the “Select” button to view the error code for “co de 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[...]

67 Step 4: Press the “Temperature Do wn” button to change to the previous cod e index, code #9. Step 5: Press the “Select” button for code index #9 to view if there are any cod e numbers. SELECT SET Status idle Operational Error Code Index  SELECT SET Status idle Operational Stored Error Code For Code Index #9 [...]

68 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 starting in code inde x #1 with[...]

69 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 ntac ts have opened. Check to make sure the venting system is not blocked. Check to make sure the condensate drain i s not clogged and is sloping towa rd the drain. Make sure the vent length does not[...]

70 Procedure for Checking Thermostat Sensors Set the thermostat above water temperat ure (Se e temperature adjustment secti on) and ob serve system through one (1) complete cycl e. Make sure system operates a s desired. To check the sen sor assembly, compa re the resistan ce of t he sensor wires (either out side black to center wire with yellow mar[...]

71 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[...]

72 Customer must specify complete model number and serial number when 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[...]

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

74 NOTES[...]

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76 NOTES[...]