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Internet Version for Reference Only
Installation and Operation Instructions Document 2144
C O R P O R A T I O N
B WRADFORD HITE
®
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,
qualied in hot water heater installation and maintenance. Improper installation and/or operation could
create carbon monoxide gas in ue gases which could cause serious injury, property damage, or death.
Improper installation and/or operation will void the warranty.
WARNING
If the information in this manual is not followed exactly, a re or explosion may result
causing property damage, personal injury or loss of life.
Do not store or use gasoline or other ammable 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 re department.
Installation and service must be performed by a qualied installer, service agency, or gas
supplier.
H2317100-
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B4 Volume Water Heater
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BRADFORD WHITE
TABLE OF CONTENTS
SECTION 1.
General Information
1.1 Introduction.................................................... 3
1.2 Heater Identication.......................................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-Temperature System............................ 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
3.3.2 To 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
Page 3
SECTION 1.
General Information
1.1 Introduction
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 led 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 modication to the water heater,
its gas controls, gas orices, wiring or
draft diverter may void the warranty. If eld
conditions require such modications, consult
factory.
1.2 Heater Identication
Consult rating plate on the heater. The following
example simplies the heater identication.
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).
1.3 Flow Requirements
For proper operation, all low volume hot water
heaters must have continuous ow through the heat
exchanger when ring. The system pump must be
capable of developing sufcient pressure to overcome
the resistance of the heater plus the entire circulating
system at the designed ow rate.
12
(311)
A
Pump
Front
Gas
Conn.
Top
58
V
(1473)
10
(260)
B
17
(432)
295/
8
(752)
Out In
17
(197)
28
(718)
Side
C
Rear
29
(737)
Pump
30
19
Gas
(483)
Inlet
12
(305)
Figure 1. Heater Conguration.
A
Front
(781)
7
(197)
Out In
41
(1060)
Side
14
(356)
4
(102)
61
(1549)
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B4 Volume Water Heater
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BRADFORD WHITE
1.4 Water 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-ve
percent 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-out and 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-nickel tubes in the exchanger.
Damage From Scaling, Corrosion, or Erosion is
Not Covered by the Warranty.
SECTION 2.
Installation
2.1 Heater Placement
The heater must be placed to provide specic
clearances on all sides for maintenance and inspection.
There must also be minimum distances maintained
from combustible surfaces. These clearances also
apply to non-combustible materials because the heater
requires air circulation for proper operation.
Heater should be mounted on a level surface.
An integral combustible ooring base is provided
as standard equipment on outdoor models. Indoor
models can be installed on a combustible oor 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 oors
other than non-combustible when the installation
complies with the American Insurance Code.
Figures 2, 3, 4 and 5 show common installation on
combustible ooring.
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 oor with an
adequate oor 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-sectional
area 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
Concrete Slab Must Extend Out A
Base For Combustible Floors
Concrete Slab - 4
" Minimum
Minimum Of
12" On All Sides
Roof - W
ood & Steel Construction
Unit
(End
View)
Base
Rail
Base For Combustible Floors
Raised Mounting
Platform (W
ood)
Mounting Platform Must Extend Out
A
Minimum Of 12" On All Sides
Unit
(End
View)
Base
Rail
20 GA
Galvanized
Sheet Metal
Cap
Flashing
Roof
Roof
Base Must Extend Out
Min. 12" On All Sides
Of Heater Frame
Met
al Plate 20
Ga. Min.
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.
Unit
(Front
View)
20 GA
Galvanized
Sheet Met
al
Cap
Flashing
Roof
Roofing
4X4
Stringer
Base
Rail
Base
for Combustible Floors
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.
Page 5
Figure 4. Typical Heater Installation with Base for Combustible Floors, Example C.
Figure 2. Typical Heater Installation with Base for Combustible Floors, Example A.
Figure 3. Typical Heater Installation with Base for Combustible Floors, Example B.
Figure 5. Installation on Concrete Blocks or Tile.
Water
Heater
CLOSET INSTALLATION
(UNACCEPTABLE)
A closet is any 4 sided enclosure
which is less than 16* times the total
volume of all the gas red appliances
within the enclosure.
Water
Heater
When the ceiling height exceeds 8 feet, you are only allowed to consider 8
*
feet when calculating the total volume of the enclosure.
ROOM INSTALLATION
(ACCEPTABLE)
A room is any enclosure which is at
least 16* times greater than the total
volume of all the gas red appliances
within the enclosure.
ALCOVE INSTALLATION
(ACCEPTABLE)
An alcove suitable for the installation of a water heater is a restricted
section of a room not separated from
the room by a door or partition and
which meets the minimum clearances
for the specic model water heater
listed below.
Figure 6. Alcove Installation.
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B4 Volume Water Heater
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BRADFORD WHITE
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 conned 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
oor level and one at the ceiling, so the total net
free area could be double the gures 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 and self-service laundries 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 ue 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 qualied 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 ring 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-in draft
diverters for natural draft operation and must not
be connected to any portion of a mechanical draft
system under positive pressure. The ue 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
Window
Or Grill
Indoor
Room
WRONG
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 ow. 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
ue 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-wall or insulated vent
pipe (Type B or equivalent). In cold weather,
uninsulated outside vents can chill the rising ue
products, blocking the natural draft action of the
venting system. This can create a health hazard
by spilling ue 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 ring of the heater
unless a positive draft has been established.
Page 7
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
certied for outdoor installations, such
installations are not recommended in areas
where the danger of freezing exists unless proper
precautions are taken for freeze protection.
2.4 Gas Supply and Piping
Review the following instructions before
proceeding with the installation.
1. Verify that the heater is tted 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.
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 deection 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,
Note: These gures 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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B4 Volume Water Heater
Page 9
Gas Supply
Inlet
Te
e
Fitting
3" Min.
Nipple
Cap
To
Equipment
Inlet
Page 8
Figure 8. T-Fitting Sediment Trap Installation.
BRADFORD WHITE
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
ame.
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 gures 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
water column)
Max. (inches
water column)
9 14
Per Rating Plate
Note: The heater and all other gas appliances
sharing the heater gas supply line must be ring
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 specied 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 oors 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 eld installed electrical safety devices and
all eld 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 buttery 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
Pressure
Relief
Valve
Hot
Water
Hot
Water
Storage
Tank
Floor
Automatic
Tempering
Valve
Cold
Water
Tempered Water
24"
Figure 9. Pressure Relief Valve Location.
Figure 9), must be piped, but not fastened, to a
drain or oor 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 oor 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 oor stands.
5. Check piping diagrams with local applicable
plumbing, heating and building safety codes.
6. All two-temperature systems 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 oor to the valve (see Figure 10).
Page 9
Figure 10. Tempering Valve Installation.
2.7 Water Expansion
When cold water is heated the water expands. If
no water is being used during the heat-up period 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.
Th e following suggestions may sol ve the
problem:
1. Install a properly sized expansion tank.
2. Replace the installed water pressure reducing valve
with a suitable valve having a back ow port. These
valves have a back ow port which allows water
to ow 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-tank circulation
loop (see Figures 11 and 12). If the heater-to-tank
circulating loop does not contain more than 6
elbows or 30 feet of pipe, use pipe ttings 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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B4 Volume Water Heater
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BRADFORD WHITE
If the heater-to-tank circulating loop contains
more than 6 elbows or 30 feet of pipe, use
pipe or ttings 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 ttings in heater-to-tank loop.
2. Copper Brute heaters are not suitable for heating
swimming pools or any other application where
temperature of the water owing 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.
2.9 Water 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 oor is waterproof and structurally
capable of supporting the tank when it is lled
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 a glass-lined tank 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 ttings when
heater is installed with storage tank. Pipe and ttings 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-nickel heat
exchanger tubes.
Table 4. Pump Performance Requirements.
6. Install a pipe in the tank drain tting that goes to
a oor sink, and install a drain valve. If a oor
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.
Page 11
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B4 Volume Water Heater
5
1
2
3
4
CWMU
SUPPL
Y
RECIRC
5
1
2
3
4
RECIRC.
CWMU
SUPPL
Y
Page 11
2.11 Two-Temperature System
See Figures 13 and 14 for piping schematics.
This system is designed to maintain the tempered
water circulating loop at the desired temperature
during idle periods as well as when there is a
demand for hot water. It is recommended for general
purpose water supply including shower and bathing
applications. Water at 180°F is available directly from
the tank.
With
Vertical
Tank
With
Horizontal
Tank
Figure 11. Hot Water Supply System
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B4 Volume Water Heater
Page 13
5
3
2
1
2
4
CWMU
SUPPL
Y
CIRC. RETURN
D
B
K
J
C
C
H
C
H
J
180°F
Water
To
Bldg.
Conventional
Tank
140°F Water
To Bldg.
To
Drain
To Drain
Cold
Water
To
Drain
Pump
140°F
Water
Return From
Bldg.
180°F
Water
Return From
Bldg.
Cold
Water
Pump
BRADFORD WHITE
Figure 12. Hot Water Supply System with Dual Tanks, Building Loop Return and Circulating Pump.
Legend
B - Check Valve
C - Check Valve
D - Tempering Valve
H - Throttling Valves in Building Loop Returns
J - Circulating Pump for Return Loop
K - Service Valves to Isolate Heater and Pump
for Service
Figure 13. Two-Temperature Hot Water Supply System with Vertical Tank.
Page 13
Internet Version for Reference Only
B4 Volume Water Heater
Cold
Water
180°
Water
To
Bldg.
Conventional
Tank
To
Drain
24" Min.
To Drain
Pump
140°
Water
To
Bldg.
140°
Water
Return
From Bldg.
180°
Water
Return
From Bldg.
H
H
C
C
B
D
K
K
E
J
Cold
Water
180°
Water
To
Bldg.
Conventional
Tank
To Drain
140°
Water
To
Bldg.
To
Drain
Pump
180°Water
Return
From Bldg.
140°Water
Return
From Bldg.
B
D
E
K
J
I
H
H
C
C
Page 13
With
Horizontal
Tank
Legend
B - Check Valve in Hot Water Supply
to Tempering Valve
C - Check Valve in Return Line from
Building Loop
D - Tempering Valve
E - Venturi (Suction) Tee
H - Throttling Valves in Building Loop
Returns
I - Circulating Pump for 180° Building
Loop
J - Circulating Pump for 140° Building
Loop
K - Service Valves to Isolate Heater
and Pump for Service
With
Vertical
Tank
Legend
B - Check Valve in Hot Water Supply
to Tempering Valve
C - Check Valve in Return Line from
Building Loop
D - Tempering Valve
E - Venturi (Suction) Tee
H - Throttling Valves in Building Loop
Returns
I - Circulating Pump for 180° Building
Loop
J - Circulating Pump for 140° Building
Loop
K - Service Valves to Isolate Heater
and Pump for Service
Figure 14. Two-Temperature Hot Water Supply System.
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Page 14
B4 Volume Water Heater
Page 15
Rating Plate
Ignition Control
Pressure Relief
Valve
Flow Switch
In
Out
Transformer
Terminal Strip
Operating Control
(Aquast
at)
Hi-Limit
Operating
Gas Valve
Manual
Pilot
Valve
Manual
Main
Gas
Valve
Safety
Gas
Valve
BRADFORD WHITE
SECTION 3.
Operation
3.1 Controls - General
See Figure 15 for control locations.
3.1.1 Electronic Ignition Controls:
a. Intermittent Ignition:
Pilots are automatically lit when the
operating aquastat calls for heat (System
#9).
The unit performs its own safety check and
opens the main valves only after the pilot is
proven to be lit. Whenever the pilot ame
is interrupted, the main gas valve closes
within 0.8 seconds.
b. Electronically Supervised Standing Pilot
System (System #16):
When pilot ame fails, the ignition control
module responds in less than 0.8 seconds
and provides 100% safety shutdown.
3.1.2 Operating Controls:
Electrically Operating Controls:
Copper Brute units are equipped with operating
temperature. The temperature sensing bulb is
located in the heater inlet.
3.1.3 High Limit Controls:
The manual reset high limit switches are
provided as standard equipment on all heaters.
Automatic reset switches are optionally provided.
The temperature sensing bulb of the switch is
always located in the heater outlet. Burners will
automatically shut down whenever overheating
of water occurs.
3.1.4 Flow Switch:
Standard on all models, the switch is mounted
directly in the header outlet. The ow switch
shuts down all burners in case of low water
condition or pump failure.
3.1.5 Low Water Cut Off: (Optional)
The low water cut off automatically shuts off the
heater whenever the water level drops below the
probe. The probe is located at the heater inlet.
3.2 Initial Start-Up
Before placing the heater in operation, be certain
that the heater is lled with water and all air is purged
from the system. Once the heater is connected to the
gas supply, the automatic safety shutoff devices must
be checked.
1. Before beginning the tests, make sure the main
manual gas valve, and any other heater ring
valves are in the “OFF” position.
Figure 15. Control Components.
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B4 Volume Water Heater
Pilot Valve
ON POSITION
ON
ON
OFF
OFF
ON
ON
OFF POSITION
Main Gas Valve
Main Gas
Valve
Pilot
Valve
OFF
ON
ON
2. Make sure the heater’s power switch is in the
“ON” position. After placing the manual pilot
gas valve in the open position and resetting all
safety devices, (high limit, pressure switch, lowwater cutoff, etc.) pilot(s) can be lit following the
procedure located on the heater rating plate.
3. Once the pilot(s) is lit and has been established
for ve minutes, the ame failure response time
should be checked as follows:
System 9 - (Intermittent ignition): With this
system pilots are automatically lit when the operating
controls call for heat. If the pilot ame fails for any
reason, the main valve is shut off within one second
and the pilot spark ignition is initiated until the pilot
ame has been reestablished. On propane systems, unit
locks out for safety. This sequence should be checked
by turning off the manual pilot gas valve, and, at the
same time, monitoring the audible sparking at the pilot
burner and signal interruption to the main valve.
Caution
Propane gas is heavier than air and sinks to
the ground. Exercise extreme care in lighting
the heater when so equipped.
Page 15
Figure 16. Gas Manual Valves.
System 16 - (Electronically supervised standing
pilot system): Extinguish the pilot ame by placing
the manual pilot valve in the closed position, and at
the same time, begin recording the time it takes for the
output signal from the electronic ignition control to
be interrupted. The signal interruption can be detected
either with a test light or a voltmeter. The response
time should never exceed one second.
4. With the pilots lit, initial activation of the main
burners can be achieved by slowly opening
the main manual valve. The result should be a
smooth lighting of the main burners.
Hi-Limit Checkout:
After running the heater for a long enough
period, bring the water temperature within the range of
the hi-limit and slowly back off the high limit setting
until the heater shuts off. The main burners should
reignite when the hi-limit is reset and turned back up
to its original setting. The heater should now run until
it shuts off automatically on operating aquastat.
3.3 To Start Up System:
3.3.1 Start Up Heater
Be certain system pump is running, then proceed
as follows:
1. Turn off main electrical switch.
2. Turn off all manual gas valves and wait ve
3. Set operating control to lowest setting.
minutes (see Figure 16).
4. Slowly turn manual gas valve to “ON”.
5. Reset all safety valve switches (manual reset high
limit and low water cut off).
6. Open manual pilot valve. Turn on main electrical
switch.
7. Set temperature controller to desired temperature.
Pilot will light automatically to ignite main
burners whenever the aquastat calls for heat.
For standing pilot system, press on pilot relay
knob, see Figure 17, light pilot and keep relay knob
depressed for one minute then release. Once the pilot
is lit, the power is supplied through the aquastat to the
main gas valve.
3.3.2 To set the temperature and high-
limit controls:
When using a tank aquastat:
Set the tank aquastat to the desired tank
temperature. Set the heater temperature control 20°F
higher than tank aquastat. Set the manual reset high
limit 50°F higher than tank aquastat. Example: If
desired temperature is 140°F, set the tank aquastat at
140°F, set the heater temperature control at 160°F, and
set the manual reset high limit at 190°F. If the heater
is equipped with a pump time delay, the three-position
switch on the side of the heater can be put into the
“Auto Pump” position, so that the pump will only run
when the tank aquastat calls for heat. Then, when the
call for heat is satised, the heater will turn off, but
the pump will run for the set amount of delay time
(adjustable between 0.1 and 10 minutes).
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B4 Volume Water Heater
Page 17
Pilot Reset
Page 16
Figure 17. Pilot Safety Relay.
When a tank aquastat is not used:
The pump on the heater must run continuously,
so the heater's temperature control will sense the tank's
water temperature. Set the heater temperature control
to the desired tank temperature. Set the manual reset
high limit 50°F higher than the heater temperature
control. Example: If desired temperature is 140°F, set
the heater temperature control at 140°F, and set the
manual reset high limit at 190°F.
BRADFORD WHITE
3.4 To Turn Off Heater:
1. Turn off main electric switch.
2. Close all manual gas valves.
3.5 To Shut Down System:
To shut down heater, turn off all manual gas
valves and electrical disconnect switches. Whenever
danger of freezing exists, shut off water supply and
remove drain plug in the bottom of front header
cover. Drain every part of system subject to freezing
temperature.
SECTION 4.
Maintenance
1. Lubricate the water circulating pump (see
instructions found on the pump).
2. If a strainer is employed in a pressure reducing
valve or in piping, clean it every six (6) months.
3. At start-up and every six (6) months thereafter,
the pilot and main burner ame should be
observed for proper performance (see Figure 18).
See attached lighting and shut-down instructions
for proper pilot ame pattern). If ame has the
appearance of “sooting” tips, check for debris
near orices. Call serviceman.
4. Inspect the venting system for obstruction,
leakage and corrosion at least once each year.
Figure 18. Main Burner Flame Pattern.
5. Keep heater area clear and free from combustible
material, gasoline and other ammable
vapors and liquids (see Table 1 for minimum
clearances).
6. Be certain all combustion air and ventilation
openings are unobstructed.
7. Check for fouling on the external surfaces of
the heat exchanger every six months. (NOTE:
After installation and rst start-up, check the heat
exchanger for fouling after the following periods
of operation: 24 hours, 7 days, 30 days, 90 days,
and once every six months thereafter).
Fouling on the external surfaces of the heat
exchanger is caused by incomplete combustion
and is a sign of combustion air and/or venting
problems. As soon as any fouling is observed,
the cause of the fouling should be corrected (see
Section 5, Troubleshooting Guide). The heat
exchanger can be checked by locating a mirror
under the burners with a ashlight. An alternate
method is to remove the venting and top panel as
necessary to inspect from above. Also check the
vent system for defects at this time.
a. If cleaning is required, shut off all electrical
and gas supply to the heater.
b. To expose the heat exchanger:
Indoor Models:
Remove ue pipe, top of unit, rear upper jacket,
ue collector rear panel and heat exchanger
bafes.
Outdoor Models:
Remove vent top assembly, rear upper jacket,
ue collector rear panel and heat exchanger
bafes.
c. Remove all burners:
It is usually more convenient to remove
the burner tray assembly. Disconnect
sensor wire, ignition cable (or thermocouple
generator) and pilot gas line. Disconnect
manifold inlet union(s). Remove the four
(4) retaining screws. Grasp burner/pilot
assembly rmly at the front. Push it back,
disengaging it from the gas orice. Lower
the front of the burner (to avoid damaging
pilot shield) then remove the burner tray.
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B4 Volume Water Heater
Caution
Black carbon or green soot on a dirty heat
exchanger can, under certain conditions, be
ignited by a random spark or open ame. To
prevent this unlikely occurrence, dampen the
soot deposits with wet brush or ne water
spray before servicing or cleaning the heat
exchanger.
With a wire brush, remove soot and loose scale
from heat exchanger. Clean fallen debris from
bottom of heater. Make sure burner ports are
clear and pilot assembly is free of debris.
d. Reassemble in reverse order: Be sure the
heat exchanger bafes are replaced.
8. The gas and electric controls installed on heaters
are engineered for both dependable operation
and long life, but the safety of this equipment
completely depends on their proper functioning.
It is strongly recommended that the basic items
be checked by a competent serviceman every
year and replaced when necessary. The basic
controls are:
a. Water temperature controls.
b. Pilot safety system.
c. Automatic electric gas valve(s).
d. Flow sensing safety device.
9. Low water cutoffs should be inspected every six
(6) months, including ushing of oat types.
NOTE: Warranty does not cover any damage
caused by lack of required maintenance or improper
operating practices.
10. Both modulating and stage valve are adjusted at
the factory for minimum permissible rates and
should not be readjusted.
Page 17
c. Tube cleaning kit consisting of reamer,
stainless steel brush, speed handle and
handle extensions.
d. Heater thermometer (with 1/2" NPT well)
100-240°F.
2. In addition, the heater should be equipped with
a system pressure gauge with proper ranges for
heater operation.
I. HEATER WILL NOT FIRE.
Possible Cause What To Do
A. Electric power is off A. Check to see that main power
switch is “ON.” Use testing
device to trace power to
heater junction box.
B. Operating or safety control B. Turn off power. Use continuity
has opened circuit to electric across terminals of each
gas valve. operating and safety control
switch up to the electric gas
valve. Replace effective
control.
C.Pilot ame is out. C.Relight pilot per instruction.
D.Manual reset device has D. Follow instructions for start tripped. up. Reset Pilot safety and all
manual reset safety switches
and reset manual safety gas
valve.
E. No gas pressure to burners. E.Trace gas line to service
shutoff cock. If service cock is
open, trace gas line to meter.
If no pressure is present at
meter, call for public utility
service. If gas is present in
heater inlet, check pressures
in following sequence:
(1) downstream from pressure
regulator. (2) downstream
from electric gas valve.
Replace or adjust as
necessary.
SECTION 5.
Troubleshooting and Analysis of
Service Problems
1. For proper service and problem diagnosis of the
heater and heater system, the following tools are
required:
a. Gas pressure test kit with range from zero
to 14 W.C. Either a slack tub manometer or
an accurate gas pressure gauge is acceptable
with proper adapters which will connect to
the available ttings in the line and on the
gas valve.
b. Multi-meter with the following ranges:
0 to 500 volts A.C.
0 to 1000 ohms continuity.
F. Electric gas valve operator is F. Disconnect wiring harness at
burned out or shortened. gas valve terminals. Check
continuity to actuator coil. If
open circuit or short is
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B4 Volume Water Heater
Page 19
BRADFORD WHITE
II. HEATER IS POUNDING, KNOCKING OR EMITTING STEAM FROM RELIEF VALVES.
Possible Cause What To Do
A. Low or no water ow. A. This condition is usually
caused by lack of adequate
water ow through heater.
Check the following:
1. Is the heater wired into the
pump circuit so that the heater
cannot re unless the pump is
running?
2. Check to see that all valves
in system are open to be
sure that water can circulate
through the heater and the
system.
3. If the system has automatic
water valves (2-way or 3-way)
that can cut off the water ow
through the heater check to
see that they are equipped with
end-switches which shut the
heater down when the water
ow through the heater is
reduced by 70% from full ow.
4. Examine pump for clogged
impeller.
B. Low or no system pressure. B. Clean strainer in pressure
reducing valve. Look for closed
valve water line or a leak in the
system.
C.Clogged “Y” strainer. C. Remove strainer element and
clean screen.
D.Debris from system piping D. Remove header covers.
is blocking tubes. Examine all tubes and
waterways. Use new gaskets
when reassembling. Clean
out tubes.
E. Scale has formed in tubes. E. This is always caused by the
inow of raw water into the
system. Clean tubes with tube
cleaning kit. Determine
hardness. Check water ow,
replace pump for modied
ow if necessary.
III. WATER DRIPPING
IN FIREBOX.
Possible Cause What To Do
Tube in heat exchanger has A tube failure is almost always
overheated and ruptured. caused by (a) scale formation
in the tube or (b) inadequate
water ow through the heater.
IV. PRESSURE RELIEF VALVES LEAKING INTERMITTENTLY OR STEADILY.
Possible Cause What To Do
A.Static pressure in system A. Calculate height of water in
exceeds setting of relief valve. system above heater. Install
new valve with psi setting 25%
above required static system
working pressure. Do not
exceed 160 psi.
B. Expansion tank is water- B. Drain expansion tank, then
logged (if installed). reopen it to the system. Look
for leaks in expansion tank
or ttings. Calculate required
volume of expansion tank in
relation to system to determine
if tank is adequate.
V. SOOT IN FLUEWAYS OR IN TUBES, OR NOXIOUS FUMES INDICATIVE OF BAD COMBUSTION.
Possible Cause What To Do
A. Combustion air supply to A. Check air supply opening.
heater room is inadequate. Look for debris in screen or
louvre which covers combus-
tion air opening, or for material
blocking the opening.
B. Stack or vent is blocked or B. Look for blocked stack and
restrictive. excessive number of elbows in
stack or excessive length of
horizontal runs.
C.Severe down draft is causing C.Check for (1) proper vent cap
spillage of ue products into on stack; (2) adequate height
room. of stack above roof;
(3) equipment exhausting air
from inside of building; and
(4) proper installation of draft
diverter.
D.Gas pressure to burners is D.Check gas pressure with
excessive. nanometer, and adjust with
heater ring at full rate.
E. Heater not tted for the fuel E. See nameplate for correct fuel.
supplied.
F. Heater installed at high F. Installations at altitudes in
altitude without proper excess of 2000 ft. above sea
derating. level are subject to jurisdiction
of the local inspection
authorities.
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C O R P O R A T I O N
B W
RADFORD HITE
®
BRADFORD WHITE
®
Ambler, PA 19002
Tech. Service (800) 334-3393
Service Parts (800) 538-2020
Warranty Service (800) 531-2111
H2317100-
www.Bradford White.com
Litho in U.S.A. © Bradford White 0602 Document 2144
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