Bradford-White 500-1825 User Manual

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Installation and Operation Instructions Document 2144

Installation and Operation

Instructions for

Copper Brute

Volume Water Heaters

Model B4

Sizes 500-1825

These instructions are to be stored in the pocket provided on the heater.

FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician, qualified in hot water heater installation and maintenance. Improper installation and/or operation could create carbon monoxide gas in flue gases which could cause serious injury, property damage, or death. Improper installation and/or operation will void the warranty.

H2317100-

WARNING

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

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 nearby phone. Follow the gas supplier's instructions.

If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency, or gas supplier.

BRADFORDWHITE®

C O R P O R A T I O N

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Page 2

 

 

 

 

 

 

 

TABLE OF CONTENTS

 

SECTION 1.

 

General Information

 

1.1

Introduction....................................................

3

1.2

Heater Identification.......................................

3

1.3

Flow Requirements........................................

3

1.4

Water Chemistry............................................

4

SECTION 2.

 

Installation

 

2.1

Heater Placement .........................................

4

2.2

Installation of Indoor Heaters.........................

4

2.2.1

Combustion Air Supply..................................

4

2.2.2

Venting...........................................................

6

2.3

Installation of Outdoor Heaters......................

7

2.4

Gas Supply and Piping..................................

7

2.5

Electrical Wiring.............................................

8

2.6

Water Piping of System.................................

8

2.7

Water Expansion ...........................................

9

2.8

Pump Performance and Installation ..............

9

2.9

Water Pressure............................................

10

2.10

Tank Installation...........................................

10

2.11

Two-TemperatureSystem............................

11

SECTION 3.

 

Operation

 

3.1

Controls - General.......................................

14

3.1.1

Electronic Ignition Control............................

14

3.1.2

Operating Control........................................

14

3.1.3

High Limit Controls......................................

14

3.1.4

Flow Switch .................................................

14

3.1.5

Low Water Cut-Off(Optional)......................

14

3.2

Initial Start-Up..............................................

14

3.3

To Start Up System......................................

15

3.3.1

Start Up Heater............................................

15

3.3.2To Set Temperature and High Limit

Control....................................................

15

3.4 To Turn Off Heater.......................................

16

3.5 To Shut Down System.................................

16

SECTION 4.

 

Maintenance

 

.....................................................................

16

SECTION 5.

 

Troubleshooting and Analysis of

 

Service Problems

 

.....................................................................

17

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B4 Volume Water Heater

SECTION 1.

General Information

1.1Introduction

This manual provides information for the

installation and operation of Bradford White volume water heaters. It is strongly recommended that all application and installation procedures be reviewed completely before proceeding with the installation. Consult the Bradford White factory, or local factory representative, with any problems or questions regarding this equipment. Experience has shown that most problems are caused by improper installation.

Some accessory items are shipped in separate packages. Verify receipt of all packages listed on the package slip. Inspect everything for possible damage upon delivery, and inform the carrier of any shortages or impairments. Any such claims should be filed with the carrier. The carrier, not the shipper, is responsible for shortages and damage to the shipment whether visible or concealed.

WARNING

All volume water heaters must be installed in accordance with the procedures outlined in this manual. The warranty does not apply to heaters not installed or operated in accordance with these procedures. Consult local building and safety codes before proceeding with work. The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the latest edition of the National Fuel Gas Code; ANSI Z223.1, National Electrical Code ANSI/NFPA 70 and/or in Canada CSA B149.1 requirement.

When required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.Any modification to the water heater, its gas controls, gas orifices, wiring or

draft diverter may void the warranty. If field conditions require such modifications, consult factory.

Page 3

1.2Heater Identification

Consult rating plate on the heater. The following

example simplifies the heater identification.

1

2

3

4

5

6

B4

1670

I

N

09

C

 

 

 

 

 

 

1.Basic heater model.

2.Input rate X 1000 BTU/hr.

3.Indoor (I) or Outdoor (E) installation.

4.Gas type: Natural (N) or Propane (P).

5.Ignition system: I.I.D. (09) or continuous pilot (16).

6.Firing rate: On/Off (C), 2-stage(K),4-stage(L).

Bradford White commercial water heaters are available in two models: an indoor version and an outdoor version. Both are available from the factory (see Figure 1).

1.3Flow Requirements

For proper operation, all low volume hot water

heaters must have continuous flow through the heat exchanger when firing. The system pump must be capable of developing sufficient pressure to overcome the resistance of the heater plus the entire circulating system at the designed flow rate.

 

Pump

 

 

295/8

 

 

121⁄4

 

 

 

(752)

 

C

(311)

 

 

 

 

 

 

 

Gas

 

 

 

 

 

 

Conn.

 

 

 

 

 

A

V

58

 

Out

In Rear

 

(1473)

 

 

 

 

 

Front

 

 

173⁄4

29

 

 

 

(197)

 

 

 

(737)

 

 

 

 

 

 

 

 

 

 

 

 

101⁄4

 

 

281⁄4

 

 

 

(260)

 

17

 

 

Top

(432)

(718)

Side

 

 

 

B

 

 

Pump

Out In

61

(1549)

 

 

 

303⁄4

 

 

14

 

 

 

73⁄4

 

(356)

19

 

 

(781)

 

 

Gas

 

(197)

 

 

(483)

 

 

 

 

 

Inlet

 

 

 

 

 

 

12

A

 

 

413⁄4

4

 

 

 

(1060)

(305)

Front

 

 

(102)

 

 

Side

 

 

 

 

 

Figure 1. Heater Configuration.

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1.4Water Chemistry

Bradford White equipment is designed for use in

a wide variety of water conditions. The water velocity maintained in the heat exchanger tubes is kept high enough to prevent scaling from hard water and low enough to avoid corrosion from soft water. Ninety-fivepercent of the urban areas in the country have water that is compatible with this equipment, but in some areas a water supply will contain a large quantity of scaling chemicals or the water may be extremely soft and corrosive. In rare situations the water will contain both scaling chemicals and corrosive chemicals such as calcium or sodium chloride. These conditions may be the result of a nearby well or pumping station and the particular condition may not be characteristic of the entire city water system.

If an installer observes damage from these conditions to any water handling equipment in the area, a factory representative should be contacted immediately for assistance in minimizing maintenance costs. If erosion is present, the pump impeller can be replaced to reduce water velocity. If scaling conditions are bad, tube cleaning maintenance schedules can be established to prevent tube burn-outand cracking. Neglecting the problem could mean serious damage to the heater and water system.

Scaling can be recognized as a layer deposited on the inner walls of the tube which reduces the inner diameter of the tube. Scale can be any color or texture; smooth or rough, granular or amorphous. Signs of erosion are generally pitting, cavitation, ridges and “islands” on the inner walls of the tubes. Since this condition results from extremely soft water sources, or as a result of a water softening program, the internal copper surfaces will be extremely shiny. Other chemicals, such as chlorine or chlorides in the water, will cause dark surfaces of erosion.

In areas where the water supply is extremely corrosive, it is advisable to order the heater with cupro-nickeltubes in the exchanger.

Damage From Scaling, Corrosion, or Erosion is Not Covered by the Warranty.

SECTION 2.

Installation

2.1Heater Placement

The heater must be placed to provide specific

clearances on all sides for maintenance and inspection. There must also be minimum distances maintained from combustible surfaces. These clearances also apply to non-combustiblematerials because the heater requires air circulation for proper operation.

Heater should be mounted on a level surface. An integral combustible flooring base is provided as standard equipment on outdoor models.Indoor

models can be installed on a combustible floor with a special base assembly which is available from the factory, or with a base that complies with local code requirements. See rating plate for part number of the base assembly.

Do not install a heater on carpeting.

Under the National Fuel Gas Code, ANSI Z223.1, it is permissible to place the heater on floors other than non-combustiblewhen the installation complies with the American Insurance Code. Figures 2, 3, 4 and 5 show common installation on combustible flooring.

2.2. Installation of Indoor Heaters

1.Locate the water heater to provide adequate clearance for inspection and service on all sides (see Table 1). We recommend minimums of 24" from front (for proper access to and service of controls) and 18" at water connection end. For alcove installation (see Figure 6).

2.Install the heater on a waterproof floor with an adequate floor drain and a 6" minimum curb on all four sides to protect the building if heater repairs are required. The manufacturer will not be held liable for any water damage in connection with this heater.

2.2.1 Combustion Air Supply

1.Copper Brute water heaters must have provisions for combustion and ventilation air in accordance with section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI Z223.1, or Sections 7.2, 7.3 or 7.4 of CSA B149.1, Installation Codes, or applicable provisions of the local building codes.

A Copper Brute heater may receive combustion air from the space in which it is installed, or

it can be ducted directly to the unit from the outside. Ventilation air must be provided in either case.

2.In the United States, the most common requirements specify that the space shall communicate with the outdoors in accordance with method 1 or 2, which follow. Where ducts are used, they shall be of the same cross-sectionalarea as the free area of the openings to which they connect.

Method 1: Two permanent openings, one commencing within 12 inches (30 cm) of the top and one commencing within 12 inches (30 cm) of the bottom, of the enclosure shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors. When directly communicating with the outdoors, or when communicating to the outdoors through vertical

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B4 Volume Water Heater Page 5

Clearance

Indoor

Outdoor

From

(inches)

(inches)

Top

30

Unobstructed

Water Conn. Side

12

24

Opposite Side

6

24

Front

Alcove

Unobstructed

Rear

8

24

Vent Pipe*

6

Hot Water Pipes

Per Code

Per Code

*1" when using type B Vent (refer to Manufacturer's Instructions

Table 1. Minimum Heater Clearances

From Combustible Surfaces.

Concrete Slab Must Extend Out A

Minimum Of 12" On All Sides

Unit

(End View)

Base

Rail

Base For Combustible Floors

Concrete Slab - 4" Minimum

Roof - Wood & Steel Construction

Figure 2. Typical Heater Installation with Base for Combustible Floors, Example A.

Mounting Platform Must Extend Out A

Minimum Of 12" On All Sides

20 GA

Unit

 

(End View)

 

Galvanized

 

Sheet Metal

 

 

Cap

 

Base

 

 

Rail

 

Base For Combustible Floors

Flashing

Roof

Raised Mounting

Roof

 

 

 

Platform (Wood)

 

Figure 3. Typical Heater Installation with Base for Combustible Floors, Example B.

 

Unit

 

(Front View)

Base

20 GA

Galvanized

Rail

Sheet Metal

 

Cap

Roofing

Base for Combustible Floors

 

Roof

Flashing

4X4 Stringer

Figure 4. Typical Heater Installation with Base for Combustible Floors, Example C.

Base Must Extend Out

Metal Plate 20

Min. 12" On All Sides

Ga. Min.

Of Heater Frame

Under Entire

 

Heater

Concrete Blocks Or Tile

Min. 7" High With 3" Min.

Air Openings

Blocks must provide solid base and be braced so they cannot slip out of place. Air openings in blocks must be arranged to provide unobstructed opening through entire width or length of base.

Figure 5. Installation on Concrete Blocks or Tile.

Water

Heater

CLOSET INSTALLATION

ROOM INSTALLATION

 

(UNACCEPTABLE)

(ACCEPTABLE)

A closet is any 4 sided enclosure

A room is any enclosure which is at

which is less than 16*times the total

least 16*times greater than the total

volumeofallthegasfiredappliances

volumeofallthegasfiredappliances

within the enclosure.

within the enclosure.

 

 

 

 

 

 

ALCOVE INSTALLATION

 

 

 

 

 

 

 

 

 

 

 

 

(ACCEPTABLE)

 

 

 

 

 

 

 

 

 

 

 

 

An alcove suitable for the installa-

 

 

Water

 

 

 

 

 

 

 

 

tion of a water heater is a restricted

 

 

Heater

 

 

 

sectionofaroomnotseparatedfrom

 

 

 

 

 

the room by a door or partition and

 

 

 

 

 

 

whichmeetstheminimumclearances

 

 

 

 

 

 

for the specific model water heater

 

 

 

 

 

 

listed below.

 

 

 

 

 

 

 

* When the ceiling height exceeds 8 feet, you are only allowed to consider 8 feet when calculating the total volume of the enclosure.

Figure 6. Alcove Installation.

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ducts, each opening shall have a minimum free area of 1 square inch per 4000 Btu/hr (5.5 square cm/kW) of total input rating of all equipment in the enclosure. When communicating to the outdoors through horizontal ducts, each opening shall have a minimum free area of not less than 1 square inch per 2000 Btu/hr (11 square cm/ kW) of total input rating of all equipment in the enclosure. Table 2 shows data for this sizing method, for each Copper Brute model.

Method 2: One permanent opening, commencing within 12 inches (30 cm) of the top of the enclosure, shall be permitted. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that directly communicate with the outdoors and shall have a minimum free area of 1 square inch per 3000 Btu/hr (7 square cm/kW) of the total input rating of all equipment located in the enclosure. This opening must not be less than the sum of the areas of all vent connectors in the confined space.

Other methods of introducing combustion and ventilation air are acceptable, providing they conform to the requirements in the applicable codes listed above.

In Canada, consult local building and safety codes or, in absence of such requirements, follow CSA B149.1.

Heater

Each Opening*

Model

(Square Inches)

 

 

500

125

600

150

715

179

850

213

1010

253

1200

300

1430

358

1670

418

1825

457

 

 

*Net Free Area in Square Inches

Area indicated is for one of two openings; one at floor level and one at the ceiling, so the total net free area could be double the figures indicated.

For special conditions refer to the latest edition of ANSI Z223.1. or CSA B149.1

Consult factory if not communicating directly through the walls with the outdoors.

Note: Check with louver manufacturers for net free area of louvers. Correct for screen resistance to the net free area if a screen is installed. Check all local codes applicable to combustion air.

IMPORTANT: In beauty shops, barber shops, cleaning establishments andself-servicelaundries with dry cleaning equipment, it is important that the water heater be installed in a location where combustion and ventilation air is received from a source outside the building. Please refer to the most recent edition of the National Fuel Gas Code, ANSI Z223.1, or in Canada, CSA requirements.

3.(a) In the United States: Exhaust Fans or Vents: Any equipment which exhausts air from the heater room can deplete the combustion air supply or reverse the natural draft action of the venting system. This could cause flue products to accumulate in the heater room. Additional air must be supplied to compensate for such exhaust. The information in Table 2 is not applicable in installations where exhaust fans or blowers of

any type are used. Such installations must be designed by qualified engineers.

(b) In Canada: Follow Canadian standard, CSA B149.1 or local codes.

4.If a blower or fan is used to supply air to the heater room, the installer should make sure it does not create drafts which could cause nuisance shutdowns of the pilot. If a blower is necessary to provide adequate combustion air to the heater, a suitable switch or equivalent must be wired into the heater control circuit to prevent the heater from firing unless the blower is operating.

5.The heater must be completely isolated and protected from any source of corrosive chemical fumes such as trichlorethylene, perchlorethylene, chlorine, etc.

2.2.2 Venting

1.Bradford White heaters have built-indraft diverters for natural draft operation and must not be connected to any portion of a mechanical draft system under positive pressure. The flue outlet must be connected to a clear, unobstructed vent of adequate capacity ending above the highest point of the building with an approved vent cap. The venting system should be installed according to the latest edition of ANSI Z223.1 and/or, in Canada, CSA B149.1 requirement and any local codes having jurisdiction.

IMPORTANT NOTE: Do not use sheet metal screws at the snap lock joints of Type B gas vents.

2.Do not weld or fasten the vent pipe to the heater draft hood. The weight of the stack must not rest on the heater. The draft hood and heater top must be easily removable for normal heater service and inspection.

Table 2. Minimum Recommended

Air Supply to heater.

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B4 Volume Water Heater Page 7

3.Avoid using long horizontal runs of the vent pipe, and too many 90° elbows, reductions or restrictions. Horizontal runs should have at least a 1/4" rise per foot in the direction of flow. A vent connector should be supported for the design and weight of the material used to maintain clearances and prevent physical damage and separation of joints.

4.Avoid ending heater vents near air conditioning or air supply fans. The fans can pick up exhaust flue products from the heater and return them inside the building, creating a possible health hazard. A minimum of 4 feet horizontal distance must be maintained from electrical meters, gas meters, and relief equipment.

5.Always use double-wallor insulated vent pipe (Type B or equivalent). In cold weather,

uninsulated outside vents can chill the rising flue products, blocking the natural draft action of the venting system. This can create a health hazard by spilling flue products into the heater room.

6.Avoid oversize vent piping or extremely long runs of the pipe which may cause excessive cooling and condensation. Rule of Thumb: The total length of the vent, including the connector and any offset, should not exceed 15 feet for every inch of vent diameter. Longer total lengths shown in venting tables are based on maximum capacity, not condensation factors.

7.When the installation of a draft fan is necessary in connecting a venting system to a the heater, the installation should be engineered by competent personnel following good engineering practices. The draft fan supplier should be consulted for correct size. The installation should be in accordance with the latest edition of ANSI Z223.1 and/or, in Canada, CSA B149.1 requirement and any local codes having jurisdiction. When a draft fan is installed, a suitable draft switch must be wired into the heater control circuit at terminal designated “Field Interlock” to prevent firing of the heater unless a positive draft has been established.

2.3 Installation of Outdoor Heaters

1.Locate the heater to provide the minimum clearances as listed in Table 1, “Placement of Heater”.

2.Do not place the heater in an enclosure or wall recess. Avoid locations where wind deflection off structures might cause down draft. When such wind conditions are possible, place the heater at least three (3) feet from the structures.

3.Never install the heater under any kind of roof overhang. Do not place the heater below or adjacent to any doors, windows, louvers, grills,

Window

Or Grill

WRONGIndoor

Room

Figure 7. Incorrect Outdoor Installation.

etc. which connect in any way with an inhabited area of a building. This includes other structures such as garages or utility rooms (see Figure 7).

4.Although these models are CSA designed certified for outdoor installations, such installations are not recommended in areas where the danger of freezing exists unless proper precautions are taken for freeze protection.

2.4Gas Supply and Piping

Review the following instructions before

proceeding with the installation.

1.Verify that the heater is fitted for the proper type of gas by checking the rating plate. Bradford White heaters are normally equipped to operate below a 2000 foot altitude. Heaters equipped to operate at higher altitudes have appropriate stickers or tags attached.

Note: These figures are for Natural Gas (.65 Sp. Gr.), and are based on 1/2" water column pressure drop. Check supply pressure with a manometer, and local code requirements for variations.For LPG, reduce pipe diameter one size, but maintain a 1" minimum diameter. A normal number of Tees and elbows have been taken into allowance.

Table 3. Gas Piping Sizes.

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Gas Supply

To

 

Inlet

Equipment

 

 

Inlet

 

Tee

 

 

 

 

Fitting

 

Nipple

3" Min.

 

 

 

Cap

 

Figure 8. T-FittingSediment Trap Installation.

8.Before operating the heater, the complete gas supply system and all connections must be tested for leaks using a soap solution. Do not use raw flame.

Caution

Since some leak test solutions (including soap and water) may cause corrosion or stress cracking, the piping must be rinsed with water after testing, unless it has been determined that the leak test solution is noncorrosive.

2.Use the figures in Table 3 to provide adequate gas piping from the gas meter to the heater.

3.A trap (drip leg) must be provided ahead of the gas controls (see Figure 8 ). A manual gas shutoff valve must also be provided for service convenience and safety. Check the local codes.

4.The heater and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig. The heater must be isolated from the gas supply piping system by closing its individual manual gas shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig.

5.Provide gas supply pressure to the heater as follows:

 

Natural Gas

 

LPG

 

 

 

 

Min. (inches

Per Rating Plate

 

water column)

 

 

 

 

 

 

 

 

Max. (inches

9

 

14

water column)

 

 

 

 

 

 

 

 

Note: The heater and all other gas appliances sharing the heater gas supply line must be firing at maximum capacity to properly measure the inlet supply pressure. Low gas pressure could be an indication of an undersized gas meter and/or obstructed gas supply line.

6.The correct burner manifold gas pressure is stamped on the rating plate. The regulator is preset at the factory and normally requires no further adjustment.

7.The gas manifold and control assembly was tested and conform to the safe lighting and other performance criteria specified in the latest editions of ANSI Z21.13, Low Pressure Boiler Standard.

2.5 Electrical Wiring

WARNING

The heater must be electrically grounded in accordance with the most recent edition of the National Electrical Code, ANSI/NPA 70. In Canada, all electrical wiring to the heater should be in accordance with the Canadian Electrical Code, CSA C22.1 Part 1. Do not rely on the gas or water piping to ground the metal parts of the heater. Oftentimes, plastic pipe or dielectric unions isolate the heater electrically. Service and maintenance personnel who work on or around the heater may be standing on wet floors and could be electrocuted by an underground heater.

1.Check heater wiring and pump for correct voltage, frequency and phase. If the pump circuit is other than 115V, check to see that the heater is provided with an appropriate transformer.

2.Wire the heater and pump exactly as shown in the wiring diagram supplied with the heater.

3.The pump and heater must be electrically interlocked so the heater cannot come on unless the pump is running.

4.All field installed electrical safety devices and all field installed devices (draft switches, relays, timers, outdoor temperature reset devices, etc.) can be connected to the heater wiring at points shown in the wiring diagram designated “Field Interlock”.

2.6 Water Piping of System

1.Be sure to provide valves at the inlet and outlet of the heater so it can be readily isolated for service. A butterfly or similar type of valve is recommended.

2.The pressure relief valve installed in the tapped opening provided in the outlet header (see

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B4 Volume Water Heater Page 9

Pressure

Relief

Valve

Figure 9. Pressure Relief Valve Location.

Figure9), must be piped, but not fastened, to a drain or floor sink. The drain pipe must be the same size as the valve outlet and must pitch downward from the valve.

Special attention must be given to relief valve settings in installations where the heater is located on the ground floor of a tall building. The static pressure of the system is elevated and could cause the relief valve to leak. Where no special setting of the relief valve is ordered, the factory will furnish a 125 psi setting. Never reduce the relief valve openings.

3.Pressure relief valve lever must be tripped at least once a year to insure that waterways are clean. When manually operating lever, water will discharge through drain line. Precautions must be taken to avoid contact with hot water and water damage.

4.The weight of all water and gas piping should be supported by suitable hangers or floor stands.

5.Check piping diagrams with local applicable plumbing, heating and building safety codes.

6.All two-temperaturesystems using temperature valves must have forced recirculation in the low temperature building loop.

7.A check valve installed at the hot water inlet to the tempering valve will prevent cold water from being drawn in reverse through the tempering valve into the hot water.

8.When installing a tempering valve, place at bottom of antithermosyphon loop at least 24" high to prevent excessive hot water from entering mixed water supply. Bring the cold water supply up from the floor to the valve (see Figure 10).

Hot

 

 

Tempered Water

 

 

 

 

 

 

 

Water

 

 

24"

 

 

 

 

 

 

 

 

 

 

Hot

 

 

 

 

Cold

 

 

 

 

 

Water

 

 

 

 

 

Water

 

 

 

Automatic

Storage

 

Floor

 

Tank

 

 

Tempering

 

 

 

 

 

Valve

 

 

Figure 10. Tempering Valve Installation.

2.7Water Expansion

When cold water is heated the water expands. If

no water is being used during the heat-upperiod the expanded water will normally back up into the city mains.

A water pressure reducing valve installed in the incoming cold water line may act as a check valve and prevent the expanded water from moving backward.

This will cause pressure to rise in the heater, which will be relieved by the pressure relief valve.

If the relief valve pops frequently a mineral deposit may build up on the valve seat, causing it to leak.

The following suggestions may solve the problem:

1.Install a properly sized expansion tank.

2.Replacetheinstalledwaterpressurereducingvalve withasuitablevalvehavingabackflowport.These valves have a back flow port which allows water to flow backwards when the pressure in the system exceeds the pressure in the mains.

3.Install an auxiliary small relief valve set at 25 psi less than the main relief valve. The valve must be piped to a drain and may require occasional cleaning. It will bleed off the expanded water and protect the main pressure relief valve from becoming fouled.

2.8 Pump Performance and Installation

1.The factory provided pumps on all Copper Brute heaters are sized to provide proper circulation through the heater and heater-to-tankcirculation loop (see Figures 11 and 12). If theheater-to-tankcirculating loopdoes not contain more than 6 elbows or 30 feet of pipe, use pipe fittings in the loop no smaller than the following:

Model

Pipe Size

 

 

500 through 850

2"

1010 through 1825

2-1/2"

 

 

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If the heater-to-tankcirculating loop containsmore than 6 elbows or 30 feet of pipe, use pipe or fittings in the loop no smaller than the following:

Model

Pipe Size

 

 

500 through 850

2-1/2"

1010 through 1825

3"

 

 

Pump performance requirements are provided in Table 4 for reference purposes.

To assure free circulation, do not use globe valves, side outlet tee connections or other restrictive fittings in heater-to-tankloop.

2.Copper Brute heaters are not suitable for heating swimming pools or any other application where temperature of the water flowing through the heater remains below the dew point (110°F).

In applications requiring the rapid use of measured volumes of water, the recovery of the heater between the time intervals of use must equal the volume used.

2.9Water Pressure

It is very important that water pressure in the

system be maintained above 30 psi. If the system pressure should drop below this, the vapor pressure of water in the suction side of the pump can cause hammer and cavitation in the pump and damage the heater through lack of water circulation.

2.10 Tank Installation

1.Be sure the floor is waterproof and structurally capable of supporting the tank when it is filled with water.

2.The tank should be placed so that manholes, inspection covers, nameplates and drain valves are accessible.

3.Be sure the tank is suitable for the water in the system. Some water is corrosive and requires a protected tank with a special lining.

4.If the tank is glass-lined,it should be equipped with a suitable magnesium anode. It is good practice to replace the anode when it is approximately 50% used. The factory warranty on aglass-linedtank will be void if a satisfactory anode is not in place at the time of a failure or if it is consumed by cathodic action.

5.Make sure the tank connections in the heatertank circulating loop are the proper size as listed in Section 2.8. If tappings are smaller than the recommended pipe size, a larger pump may be required. Consult the factory if in doubt.

 

 

 

Flow

Head*

Temp. Rise

 

 

 

Water

Rate

Loss

Across

 

 

Model

Category

(GPM)

(ft.)

Heater, (°F)

 

 

 

 

 

 

 

 

 

 

Soft

45

5.0

17

 

500

Normal

68

9.9

11

 

 

 

Hard

90

15.7

8

 

 

 

 

 

 

 

 

 

 

Soft

45

5.1

20

 

600

Normal

68

10.0

14

 

 

 

Hard

90

15.9

10

 

 

 

 

 

 

 

 

 

 

Soft

45

5.3

24

 

715

Normal

68

11.0

16

 

 

 

Hard

90

17.8

12

 

 

 

 

 

 

 

 

 

 

Soft

45

5.4

30

 

850

Normal

68

11.1

20

 

 

 

Hard

90

18.1

15

 

 

 

 

 

 

 

 

 

 

Soft

45

3.9

35

 

1010

Normal

68

7.5

23

 

 

 

Hard

90

11.7

18

 

 

 

 

 

 

 

 

 

 

Soft**

68

7.8

27

 

1200

Normal

68

7.8

27

 

 

 

Hard

90

12.2

21

 

 

 

 

 

 

 

 

 

 

Soft**

68

8.1

32

 

1430

Normal

68

8.1

32

 

 

 

Hard

90

12.6

24

 

 

 

 

 

 

 

 

 

 

Soft**

68

8.3

37

 

1670

Normal

68

8.3

37

 

 

 

Hard

90

13.0

28

 

 

 

 

 

 

 

 

 

 

Soft**

90

13.5

30

 

1825

Normal**

90

13.5

30

 

 

 

Hard

90

13.5

30

 

 

 

 

 

 

 

 

Water Category

Grain Hardness per Gal.

Soft

1 through 7.5

Normal

7.6 through 17

Hard

Over 17

* Pressure drop includes loss through 30 feet of pipe and normal fittings when heater is installed with storage tank. Pipe and fittings are assumed to be 2" on Models (500-850)and 2 1/2" on Models(1010-1825)

** To prevent erosion, these models must be ordered with cupro-nickelheat exchanger tubes.

Table 4. Pump Performance Requirements.

6.Install a pipe in the tank drain fitting that goes to a floor sink, and install a drain valve. If a floor sink is not available, install a hose bib.

7.Hot water tanks in an existing installation are likely to have a deposit of silt on the bottom. Therefore, it is important to extend the pump suction pipe in the tank to a position near the top. Pipe the return from the heater to the bottom of the tank.

8.Incorrect installation can cause rapid failure of water tanks due to electrolysis. Tanks must be installed with dielectric connections to electrically isolate the tank from stray current. Note that the use of brass or bronze connectors does not replace the need for dielectric connections.