Bradford-White PE-2-XR504T6FBN User Manual

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PE MODEL WATER HEATERS

SUPPLEMENT TO INSTRUCTION MANUAL

P/N 238-44219-00

(Replaces pg. 2 in instruction manual.)

CONGRATULATIONS!

You have just purchased one of the finest water heaters on the market today!

This installation, operation and instruction manual will explain in detail the installation and maintenance of your new Programmable Flammable Vapor Ignition Resistant Gas Water Heater. We strongly recommend that you contact a plumbing professional for the installation of this water heater.

We require that you carefully read this manual, as well as the enclosed warranty, and refer to it when questions arise. If you have any specific questions concerning your warranty, please consult the plumbing professional from whom your water heater was purchased. For your records, we recommend that you write the model, serial number and installation date of your water heater in the maintenance section in the back of this manual.

Special Flammable Vapor Ignition Resistant System:

This water heater is equipped with a Flammable Vapor Ignition Resistant System. In the event of improper usage or storage of gasoline or other flammable materials in the location where the water heater is installed, the technology will resist ignition of the flammable vapors outside the confines of the water heater.

The Flammable Vapor Ignition Resistant System Features:

Advanced Flame Arrestor Design

Re-settableThermal Switch to prevent burner/pilot operation with restricted airflow

Flammable Vapor Sensor

Automatic Ignition Device

Sight Window to observe operation of pilot and burner

FOR YOUR SAFETY: Activation of the Flammable Vapor Ignition Resistant System occurs when flammable vapors are drawn into the water heater and are combusted. If flammable vapors are detected:

Do not try to light any appliance.

Do not touch any electrical switch; do not use any phone in your building.

Leave the premises and immediately call the fire department from a neighbor’s phone. Follow the fire department’s instructions.

Once the flammable vapor has been evacuated, contact your plumbing professional or the manufacturer for further instructions. Replacement of a Flammable Vapor Ignition Resistant System equipped water heater due to a flammable vapor shutdown is not covered under the terms of the limited warranty.

238-48248-00A10/09

Minimum Clearances

(Replaces pg. 9 in instruction manual.)

WARNING

Failure to adhere to these installation and operating instructions may create a hazard to life and property and will nullify the warranty.

This installation must allow access to the front of the water heater and adequate clearance must be provided for servicing and operating this water heater. The water heater may be installed on either a combustible or non-combustiblefloor. If the water heater is to be installed directly on carpeting, it must be installed on top of a metal or wood panel (or equivalent) extending beyond the full width and depth of the water heater by at least 3 in.(7.6 cm) in any direction or, if the appliance is to be installed in an alcove or closet, the entire floor must be covered by the panel. If the rating plate or the label on the front of the heater specifies minimum clearances less than those listed in the below table, the water heater must be installed in accordance with the minimum clearances listed on the rating plate or the label on the front of the heater.

If it is necessary to install this water heater in an alcove, use the clearances listed in Figure 1.

Figure 1. Minimum Clearances for an Alcove Installation.

2

Lighting and Shutdown Instructions

(Replaces pg. 18 in instruction manual.)

FOR YOUR SAFETY READ BEFORE

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A.This appliance is equipped with an ignition device which automatically lights the pilot. Do not try

to light the pilot by hand.

B.BEFORE OPERATING smell all around the ance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle to the

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 phone. Follow the gas supplier's instructions

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

C.Use only your hand to slide the gas control switch. Never use tools. If the switch cannot be moved by hand, do not try to repair it, call a service technician. Force or attempted repair may result in a fire or

D.Do not use this appliance if any part has been under water. Immediately call a qualified technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

OPERATING INSTRUCTIONS

1.STOP! Read the safety information above.

2.Turn off all electric power to the appliance

3.Set the thermostat to lowest setting.

4.This appliance is equipped with an ignition device which

lights the pilot. Do not try to light the pilot by hand.

SWITCH SHOWN

IN "ON" POSITION

STATUS

Honeywell ON

6.Wait five (5) minutes to clear out any gas. Smell for gas, including near the floor.

If you the smell gas, STOP! Follow "B" in the safety information at left on this label. If you don't smell gas, go to the next step.

7.Slide the switch on the right side of the gas valve up to the "ON" position.

8.Set thermostat to desired setting.

OFF

VERY

HOT

B

C

A

 

HOT

 

 

LOW

THERMOSTAT

DIAL

5.Slide the switch on the right side of the gas valve down to the "OFF" position

9.Turn on all electric power to the appliance.

10.If the appliance will not operate, follow the instructions "To Turn Off Gas To Appliance" and call your

technician or gas

TO TURN OFF GAS TO APPLIANCE

1.

Turn off all electric power to the

3. Slide the switch on the right side of the

 

appliance if service is to be

gas valve down to the "OFF" position.

2.

Set the thermostat to the lowest setting.

 

 

 

 

3

THERMOSTAT ADJUSTMENT

(Replaces pg. 19 in instruction manual.)

The thermostat dial is adjusted to its lowest setting when shipped from the factory. When adjusting the thermostat, it should be remembered that lower temperature settings are more energy efficient. To adjust the thermostat, turn the dial clockwise until the minimum acceptable temperature is set. It is suggested that the starting point setting not exceed the 120°F (49°C) or “HOT” setting on the thermostat.

Honeywell

SWITCH SHOWN

IN "ON" POSITION

STATUS

ON

 

 

 

 

 

 

 

 

OFF

 

 

 

R

Y

 

 

 

 

C

 

E

 

 

T

B

V

 

 

O

 

 

H

 

 

 

 

 

A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

HOT

 

 

 

 

 

 

 

 

 

 

L

 

 

 

 

 

 

O

 

 

THERMOSTAT

 

 

W

 

DIAL

Figure 2. Gas Valve.

The thermostat dial is set to its lowest temperature setting when shipped from the factory. Remember that lower temperature settings are more energy efficient. Adjust the temperature by turning the thermostat dial. It is suggested that the starting point setting not be greater than the “Hot” mark on the thermostat dial (approximately 120°F [48.9°C]). Rotate the thermostat dialcounter-clockwisetodecrease the temperature setting. Rotate the thermostat dial clockwisetoincrease the temperature setting. Adjust the dial until the minimum acceptable temperature is achieved.

DANGER

Hotter water increases the risk of scald injury. Scalding may occur within five (5) seconds at a temperature setting of 140°F (60°C). To protect against hot water injury, install an ASSE approved mixing valve in the water system. This valve will reduce point of discharge temperature by mixing cold and hot water in branch water lines. A licensed plumbing professional or local plumbing authority should be consulted.Note: This water heater is equipped with an energy cut out device to prevent overheating. Should overheating occur or the gas supply fails to shut off, turn off the manual gas control valve to the water heater, and call a qualified service technician.Note: Whenever the water heater is filled with cold water, condensate will form on the cool tank surface and drops of water will fall on the hot burner and combustion chamber surfaces producing a “sizzling” noise. Condensation is normal and does not indicate a leak. It will disappear when the tank becomes heated.

4

BURNER FLAME CHECK

(Replaces pg. 22 in instruction manual.)

Steel Burner: These models are equipped with self adjusting air mixture and do not have an adjustable air shutter (See Figure 3). At periodic intervals, a visual check of the main burner and pilot flames should be made to determine

if they are burning properly. The main burner flame should light smoothly from the pilot.

Figure 3. Burner and Pilot Assembly Used.

5

INSTALLATION FOR POTABLE WATER

(Replaces pg. 28 in instruction manual.)

Figure 4

6

PARTS LIST DRAWING

(Replaces pg. 29 in instruction manual.)

1

2

3

17 4

18

19

20

21

 

 

22

24

23

25

 

26

28

27

 

 

5

 

6

7

 

8

 

9

10

11

14

12

16 15

13

15A

Figure 5

7

PARTS LIST

(Replaces pg. 30 in instruction manual.)

PART NAME AND DESCRIPTION

1.

Draft hood

15A. Resettable Thermal Switch

 

 

 

 

2.

Setback Control Junction Box Assembly

16.

Left side inner door

 

 

 

 

3.

Jacket head

17.

Accessory Module

4.

Jacket

18.

Junction box wire harness

5.

Heat trap (outlet)

19.

Thermal well

6.

Anode Outlet Device

20.

Gas control

 

 

 

 

7.

Heat trap (inlet)

21.

FV sensor / RTS wire harness

 

 

 

 

8.

Baffle

22.

FV sensor clip

9.

Diptube

23.

FV sensor

10.

T&P valve

24.

Outer door

 

 

 

 

11.

Tank

25.

Burner

 

 

 

 

12.

Combustion chamber

26.

Orifice

13.

Pedestal base

27.

Pilot assembly

14.

Drain valve

28.

Main burner feedline

 

 

 

 

15.

Right side inner door

 

 

 

 

 

 

 

8

THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION

OF:

GAS WATER HEATERS SUITABLE FOR WATER (POTABLE)

HEATING AND SPACE HEATING

(Replaces pg. 31 in instruction manual.)

All piping components connected to this water heater for space heating applications must be suitable for use with potable water. In Massachusetts, space heating piping length must not exceed 50 feet.

1.Toxic chemicals, such as those used for boiler treatment, must not be introduced into potable water used for space heating.

2.This water heater must not be connected to an existing heating system or

component(s) previously used with a non-potablewater heating appliance.

3.When the system requires water for space heating at temperatures higher than required for other means, such as an ASSE approved mixing valve must be installed to temper the water for those uses in order to reduce the scald hazard potential.

Please refer to Figure 6 for suggested piping arrangements.

Figure 6

9

(In addition to the instruction manual.)

Do not block or in any way restrict jacket air inlet slots located at the bottom front of the water heater.

Do not operate water heater with jumpered, altered, loosely tightened or absent controls and/or components.

Do not operate water heater with replacement controls and/or components which are not exact duplicates of original equipment.

Thoroughly inspect and replace, (as needed) burner inner door gasket and/or sight window gasket any time burner inner door is removed or disturbed.

Replace water heater if involved in flammable vapor incident.

This water heater is equipped with a flammable vapor sensor. If the sensor is exposed to flammable vapor, the water heater control will shut down the water heater and display a code of 7 flashes and then a 3 second pause.

If a 7 flash error code is present, check to see if flammable vapor is present in the area. If flammable vapor is present or suspected in the area, immediately leave the area and contact a service professional.

Do not try to light any appliance.

Do not touch any electric switch; do not use any phone in your building.

If you are certain there is no flammable vapor present, check the flammable vapor sensor to make certain

it has not become disconnected from the control. See the instruction manual for troubleshooting.

CAUTION

Protect the Setback Control and Accessory Module from solder and falling water during installation.

10

Electrical Connections

(In addition to the instruction manual.)

All electrical wiring and connections must be in accordance with the National Electric Code ANSI/NFPA No. 70-LatestEdition, or the Canadian Electrical CodeC22.1-LatestEdition, and any local codes which may apply. The water heater must be electrically grounded.

If a flexible line cord and plug is permitted by local code, then provide a (3) three wire grounding type receptacle within 6 ft (1.9 m) of the water heater and use the flexible cord provided. Do not plug the line cord into a receptacle that can have its power supply interrupted by a switch that is used to turn on and off lights.

Turn off the water heater gas control and disconnect power to the water heater and Accessory Module. If wiring in conduit is required, cut the flexible line cord at least 6 in. (15.2 cm) from the bushing. Unscrew and remove the Setback Control Junction Box Assembly lid. Pull the cord into the junction box assembly housing. Cut the three wires from the line cord at the bushing inside of the housing. Enlarge the hole in the back of the junction box assembly to receive a 1” electrical conduit connector. Wire the power supply into the circuit at the appropriate locations.

Replace the Setback Control Junction Box Assembly cover and re-installthe screws previously removed. Connect power to the water heater and Accessory. Turn the water heater gas control back on.

CAUTION

Turn off or disconnect the electrical power supply to the water heater before servicing. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

11

Wiring Diagram

(In addition to the instruction manual.)

PILO GAS

Honeywell

 

 

VERY

 

 

HOT

 

B

C

 

A

 

 

HOT

 

W

 

LOW

 

W BKR

 

 

 

 

 

 

 

 

 

 

 

 

FLAMMABL

 

 

 

 

 

 

 

 

 

 

VAPOR SENSOR

 

 

 

 

 

B

 

 

B

 

 

B

 

 

 

 

B

R

B

 

 

B

W

 

 

G

W

 

Y

 

B

 

 

 

B

 

G

 

 

 

 

WATER

 

 

 

 

 

 

 

 

POWER

 

 

 

 

 

 

 

 

 

TEMPERATURE

 

 

 

 

 

 

 

 

 

 

SENSO

 

 

W

B

 

 

 

 

B

 

 

W

W

B

 

 

 

 

 

 

RE-

 

G

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

THERMAL

 

 

 

 

 

 

 

 

 

 

 

G

 

 

 

 

 

 

 

 

ACCESSOR

W

 

 

 

 

 

 

 

 

 

MODUL

B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R Y

 

 

 

 

 

 

 

 

SETBACK

 

 

 

 

 

 

 

 

 

JUNCTION

 

 

 

 

 

 

 

 

 

 

 

PLUG-IN

 

 

 

W

 

R

 

 

 

 

 

 

 

B

 

 

 

TRANSFORME

 

B

 

 

 

 

 

 

 

 

 

 

 

 

W

 

 

 

A

A

 

 

 

 

 

 

 

 

 

 

W

BK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SETBACK

ELECTRICAL RATING

115 VOLTS 60HZ LESS THAN 12 AMPS

IF ANY OF THE ORIGINAL WIRES SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH APPLIANCE WIRE MATERIAL WITH A MINIMUM TEMPERATURE RATING OF 105°C AND A MINIMUM SIZE OF NO. 18 AWG.

12

TROUBLESHOOTING

(In addition to instruction manual.)

LED Status

Control Status

 

Probable Cause

None (LED not on

Electrical pow er not

1.

Control pow er sw itch in " OFF" position

or flashing)

present

2.

Supply voltage interrupted

One short flash

Stand-bymode,

Temperature demand is satisfied (no call for

every four

Thermostat is satisfied (no

seconds

faults)

heat)

 

 

Alternates bright

Thermostat calling for heat

Tank temperature below setpoint of

and dim

(no fault)

thermostat

(heartbeat)

 

 

 

 

 

1.

Unstable pilot

Short flash once

Weak pilot signal on last

2.

Pilot tube block or restricted

3.

Oxidation build-upon pilot electrode

every second

call for heat

4.

Wire damage to pilot assembly or bad

 

 

 

 

connection at gas valve

Tw o flashes,

 

 

 

three second

Relay not w orking

Faulty relay

pause

 

 

 

Three flashes,

 

 

 

three second

Relay not w orking

Faulty relay

pause

 

 

 

Four flashes,

Excessive tank

1.

Thermal w ell sensor out of calibration

three second

temperature, system must

pause

be reset

2.

Faulty gas valve

 

 

Five flashes,

False pilot flame present

Pilot valve stuck in open position

three second

pause

 

 

 

Six flashes, one

 

1.

Unstable pilot

Failed to light pilot,

2.

Pilot tube block or restricted

flash, three

system resets after (5)

3.

Oxidation build-upon pilot electrode

second pause

minutes

4.

Wire damage to pilot assembly or bad

(Soft Lockout)

 

connection at gas valve

 

 

13

Troubleshooting continued-

 

LED Status

Control Status

 

Probable Cause

 

Six flashes, tw o

Relay not w orking properly

 

 

 

 

flashes, three

during burner operation,

Faulty relay

 

second pause

system auto resets after

 

(Soft Lockout)

(5) minutes

 

 

 

 

 

 

 

1.

Unstable pilot

 

Six flashes, three

Pilot flame extinguished,

2.

Pilot tube block or restricted

 

flashes, three

system auto resets after

3.

Oxidation build-upon pilot electrode

 

second pause

(5) minutes

4.

Wire damage to pilot assembly or bad

 

(Soft Lockout)

connection at gas valve

 

 

 

 

 

 

 

5.

Insufficient combustion air

 

Six flashes, four

Undesired false pilot flame

 

 

 

 

flashes, three

sensed, system auto

Pilot valve stuck in open position

 

second pause

resets

 

 

 

 

 

 

 

1.

Flammable vapor present

 

Seven flashes,

Flammable vapor sensor or

2.

Flammable vapor sensor exposed to

 

resettable thermal sw itch

excessive moisture

 

three second

 

fault detected, see

3.

Flammable vapor sensor exposed to

 

pause

 

w arning label

extreme ambient temperature

 

 

 

 

 

 

4.

Resettable thermal sw itch open

 

Eight flashes, one

Flammable vapor sensor

1.

Flammable vapor sensor out of

 

flash, three

out of specification,

specification

 

2.

Possible short in flammable vapor sensor

 

second pause

possible short

 

or resettable thermal sw itch w iring

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.

Damage to thermal w ell w ires

 

 

 

 

2.

Thermal w ell sensor resistance out of

 

Eight flashes,

Thermal w ell sensor

range

 

3.

Replace thermal w ell

 

three flashes,

damaged or unplugged or

 

three second

gas valve electronics fault

4.

Verify control is not w et or physically

 

pause

detected

damaged

 

5.

Reset control on/off sw itch

 

 

 

 

 

 

 

 

6.

Replace electronic module if 8-3error

 

 

 

 

persists

 

Eight flashes, four

 

 

1.

Verify control is not w et or physically

 

 

 

damaged

 

flashes, three

Gas valve fault detected

 

2.

Reset control on/off sw itch

 

second pause

 

 

3.

Replace gas control if 8-4error persists

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fault

 

 

Probable Cause

 

 

Resettable Thermal Switch Tripped (Open)

 

1.

Insufficient combustion air

 

 

 

2.

Flammable vapors present

 

 

 

 

 

 

14

Troubleshooting continued-

Control Sequence of Operation

Start up Sequence

Upon powering up, the control checks for the presence of the flammable vapors, if the resistance is in the expected range the control will begin normal operation after 5 to 8 seconds.

Normal Heating Sequence

1.The thermostat senses a call for heat.

2.The control checks that the relay contacts are open.

3.The control sends power to the relay, which then closes the relay contacts.

4.The control starts the ignition process by providing a spark at the pilot electrode and allowing gas to flow to the pilot.

5.When the pilot is lit, the gas control senses the pilot flame and opens the main gas valve.

6.The main burner is lit.

7.The main burner continues to operate until the thermostat is satisfied.

8.When the thermostat is satisfied, the main and pilot gas valves close.

9.The relay contacts remain closed for a short period before opening.

The water heater remains in the stand-bymode until the next call for heat.

15

Notes

16