Bradford White 6A, 12A, 20A, 30A, 40A User Manual
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COMMERCIAL ELECTRIC ENERGY SAVER
WATER HEATER
ASME SERIES IMMERSION THERMOSTAT
WITH CONTACTORS
SERVICE
MANUAL
Troubleshooting Guide and Instructions for Service
(To be performed ONLY by qualified service providers)
Models Covered
by This Manual:
6A, 12A, 20A, 30A, 40A, 50A, 80A, 120A
Manual 238-47202-00A REV 08/18 |
Save this manual for future reference |
ASME Series
Commercial Electric Water Heaters
Table of Contents
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Page |
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Service Procedure |
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Introduction ………………………………………………………………………. |
2 |
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- - - |
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Tools……………………………………………………………………………… |
2 |
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- - - |
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General Information ……………………………………………………………… |
3 |
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- - - |
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Sequence of Operation …………………………………………………………… 10 |
- - - |
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Troubleshooting ………………………………………………………………….. 13 |
- - - |
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Heating Element Testing ……………..................................................................... |
15 |
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ACE-I |
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Line Voltage Testing………………...…………………………………………… |
16 |
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ACE-II |
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Fuse Testing…......................................................................................................... |
17 |
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ACE-III |
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High Limit (ECO) Testing……………………………………………………..…. |
18 |
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ACE-IV |
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Immersion Thermostat Operation Testing………................................................... |
19 |
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ACE-V |
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Contactor Operation Testing……………………………………………………… |
20 |
ACE-VI |
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Immersion Thermostat Removal and Replacement…………….………………… |
21 |
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ACE-VII |
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High Limit (ECO) Removal and Replacement……………..…………………….. |
22 |
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ACE-VIII |
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Heating Element Removal and Replacement …………………………………….. |
23 |
ACE-IX |
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Anode Inspection and Replacement ……………………………………………… |
24 |
ACE-X |
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Generic Parts List ………………………………………………………………… 25 |
- - - |
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Glossary of Terms…………………………………………………………………. 26 |
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Introduction
This service manual is designed to aid service and maintenance professionals on the function, proper diagnosis and repair of Bradford White Commercial Electric Water Heaters.
The text and illustrations in this manual provide step by step instructions to facilitate proper operation and troubleshooting procedures. Contact the Bradford White Technical Support Group immediately if diagnosis can not be made using the methods described in this service manual.
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Tools |
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- Multi Meter. |
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- Phillips Head Screw Driver. |
- 2-1/8" Deep Well Socket. |
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- Common Screw driver. |
- 1-1/16" Deep Well Socket. |
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- Thermometer. |
- ¼" Nut Driver. |
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- Drain Hose. |
- Other Hand Tools: Pipe Wrench, Channel Locks, Pliers (common & needle nose), Wire cutters, Wire Strippers, Allen Wrench Set, Flash Light.
Page 2
2
GENERAL INFORMATION
Model Number Breakdown
120A - 24 - 3 - 108B - BBG
Pressure Gage Option.
Control Circuit Option Code.
Any combination of the following optional controls:
-Heating Element Time Delay Sequencing.
-Low Water Power Interrupt.
- Panel Door Interlock |
NOTE: Code “AA” |
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- High Pressure Power Interrupt |
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denotes no optional |
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- Low Pressure Power Interrupt |
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controls used. |
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- Alarm Horn |
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Power Circuit Code.
- Voltage
- kW Rating
- Phase
- Amp Rating
Warranty
kW Rating
Tank
In the Field, this information is obtained from the heaters rating plate
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BRADFORD WHITE CORPORATION |
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Model Number |
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200 LAFAYETTE ST. MIDDLEVILLE MI 49333 |
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Model No: 120A-24-3-108B-BBG |
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Serial No: ZB2564812 |
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Cap. |
120(gal.)/454.2(liters) |
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Press: |
Test 300(psi), Working 150(psi) |
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Volts |
240 |
Max Temp 180° |
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Electrical Characteristics |
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Phase |
Single |
Amps 100 |
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kW Each |
6 |
Total kW 24 |
4 Elements |
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Wattage Rating Based Upon 60 Hz |
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Typical Rating Plate
Located On Front Of Water Heater
Page 3
3
GENERAL INFORMATION
General Controls Layout
Control Circuit |
Control Circuit |
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Fuse Block |
Transformer |
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Terminal strip |
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Pressure |
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Terminal |
Gage |
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Block |
(optional) |
High Pressure |
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Power Circuit |
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Limit Switch |
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(optional) |
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Fuse Blocks |
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Thermostat |
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Low Pressure |
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Contactors |
Control |
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Limit Switch |
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Heating Element |
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(optional) |
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Low Water |
Time Delay |
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Sequencers |
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Level Control |
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(optional) |
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(optional) |
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Thermostat |
High Limit |
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Immersion Bulb |
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Immersion |
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High Limit |
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Bulb |
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(ECO) |
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Alarm |
Alarm |
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Horn Relay |
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(optional) |
Horn |
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(optional) |
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Heating |
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Element |
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Standard Controls
Contactor
Contactor operation is achieved by energizing a 120 volt operating coil located within the contactor in response to a call for heat from the immersion thermostat. Upon a call for heat, one or more contactors will energize all heating elements simultaneously. Optionally, time delay sequencers may be used to stage contactor activation thereby reducing the inrush of current to the water heater.
Terminal connections of Terminal connections to the contactor operating coil.
fuse block and/or terminal block
Terminal connections to the heating elements
Page 4
4
GENERAL INFORMATION
Standard Controls (continued)
Immersion Style Thermostat Control
The thermostat will complete control circuit voltage upon a call for heat. Likewise, the control
will interrupt control circuit voltage when the water Immersion Thermostat Control temperature is sufficient to satisfy the adjustable
temperature limit of control.
Direct
Immersion
bulb
Immersion Style High Limit (ECO) Control for Contactor Models
The high limit (ECO) control will interrupt control circuit voltage causing the heater to shut down when the high temperature limit of the control is reached (196°F±4°F). Once the cause for over heated water has been determined, The control must be manually reset to restore normal operation.
Manual Reset
Buttons
Direct
Immersion
bulb
Page 5
5
GENERAL INFORMATION
Standard Controls (continued)
Direct Immersion “Screw-in” Type Heating Element
2-1/8 Hex |
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Terminal Block |
Screw-in Flange |
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Zinc Plated Copper or
Incoloy Sheath
Terminal Block |
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Screw |
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Element Rating Ink Stamped |
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on face of Terminal Block. |
Optional Controls
Certain control components are available as “Optional“. When these optional components are installed with the water
heater, the control circuit wiring diagram accordingly will include these components. The optional equipment available |
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from the manufacturer includes the following: |
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-High Water Pressure Switch |
-Heating Element Time Delay Sequencers |
-Low Water Pressure Switch |
-Electrical Door Lock |
-Low Water Level Switch |
-Alarm Horn |
High and Low Water Pressure Controls-
These controls interrupt the electrical current to the contactor coil when the pressure settings are exceeded. The operation and setting of these controls are described in the manual provided by the control manufacturer. This manual is included with the water heater Installation and Operating Instruction manual provided with the water heater.
The pressure settings for these controls are adjustable. These controls are specified for use when the installation has unique pressure requirements that must be safeguarded. Therefore, before adjusting the pressure values, it is recommended that you consult the person responsible for the facility that the water heater is servicing.
The electrical connections are referenced in the Control Circuit Wiring Diagram and in the pressure control manual provided by the control manufacturer. Refer to these instructions when servicing the controls.
Page 6
6
GENERAL INFORMATION
Optional Controls (continued)
Low Water Level Control-
This control will interrupt the electrical current to the contactor coil when a low water level condition is sensed inside the water heater tank. When the low water level condition is corrected the control will automatically sense the new situation and electrical current will again energize the contactor coil. Normal water heater operation will be resumed.
To remove the low water level control from the tank you must first loosen the control by un-threading it from the tank fitting and then rotating the control until the arrow printed on the side of the hex fitting is pointing downward. This will enable the float orientation to align itself with the opening in the tank-fitting.
When installed, refer to the direction of the arrow on the hex and insure that it is pointing upwards. If it is not pointing upward, the control switch will not activate when the tank is refilled with water. Refer to illustration below for clarification.
Heating Element Time Delay Sequencers-
Heating element sequencers are available in order to stage the activation of the heating elements thereby, reducing the inrush of electrical current to the water heater. The sequencers will control one or more contactor coils depending upon the water heater voltage, phase, and KW.
One contactor will be energized immediately when there is heating demand, the second contactor, controlled with a sequencer, will be activated approximately 20 seconds later, and the third contactor will be activated in another 20 seconds thereby, staging the three contactors over the 40 second time period. The staging occurs in a similar manner for applications having more than three contactors.
Refer to the Control Circuit Wiring Diagram for the specific application being serviced.
Note: On the occasion of servicing the water heater where frequent restarts in a short time interval are encountered (i.e. on, off, on, etc.), the timing sequences will not begin until the sequencers have experienced a time interval to reset.
Page 7
7
GENERAL INFORMATION
Optional Controls (continued)
Electrical Door lock-
An electrical door lock is offered in order to secure the access to the water heater control cabinet. This device will lock the control cabinet door when the 120VAC control circuit voltage is applied to it.
Note: Once the door is opened, the water heater can be re-energized, if necessary, for service diagnosis.
Alarm Horn-
The Alarm Horn is an option specified when the installation desires an audible signal to immediately sound an alert when the water heater operation is interrupted for certain faults. Referring to the control circuit wiring diagram, the alarm will activate when any one of the following events occur:
The Hi-Limit control has been tripped
The High Water Pressure Control senses excessive pressure
The Low Water Pressure Control senses insufficient pressure
The Low Water Level Control senses an insufficient quantity of water
The alarm will sound only for the options specified (i.e. if a low water level control is not specified then the alarm will not recognize a low water level condition).
Horn Relay
Internal Wiring
Horn Relay
Combination Temperature and Pressure Gage-
A non-electrical device to visually reference water temperature and internal tank pressure.
Page 8
8
GENERAL INFORMATION
Commonly Used Formulas
(Single phase) |
(balanced 3 phase) |
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2 |
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Watts |
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Watts |
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Amps = |
Amps = |
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Watts = Amps x Volts |
Ohms = |
Volts |
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Volts x 1.732 |
Watts |
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Volts |
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Common Service Wire
Configurations
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208 3Ph |
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Neutral |
A |
B |
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C |
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120 |
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120 |
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120 |
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208 |
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208 |
208 |
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RED |
BLACK |
RED |
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240V 1Ph |
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BLACK |
GREEN |
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Ungrounded |
Grounding |
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RED |
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Ungrounded |
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240 |
120 |
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120 |
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240 3Ph |
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Neutral |
A |
B |
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C |
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120 |
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120 |
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120 |
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240 |
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240 |
240 |
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RED |
BLACK |
RED |
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480 3Ph/277 1Ph |
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Neutral |
A |
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B |
C |
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277 |
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277 |
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277 |
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480 |
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480 |
480 |
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RED |
BLACK |
RED |
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Full Load Current Amps
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208 Volt |
240 Volt |
277 Volt |
380 Volt |
415 Volt |
480 Volt |
600 Volt |
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kW |
1 Ph |
3 Ph |
1 Ph |
3 Ph |
1 Ph |
3 Ph |
3 Ph |
1 Ph |
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3 Ph |
3 Ph |
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- |
3 |
14.4 |
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12.5 |
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10.8 |
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6.3 |
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6 |
28.8 |
16.6 |
25.0 |
14.4 |
21.6 |
9.1 |
8.3 |
12.5 |
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7.2 |
5.7 |
9 |
43.2 |
25.0 |
37.2 |
21.6 |
32.4 |
13.6 |
12.5 |
18.7 |
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10.8 |
8.66 |
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12 |
57.6 |
33.3 |
50.0 |
28.9 |
43.3 |
18.2 |
16.7 |
25.0 |
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14.4 |
11.5 |
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13.5 |
64.9 |
37.5 |
56.2 |
32.5 |
48.7 |
20.5 |
18.8 |
28.1 |
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16.2 |
13.0 |
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72.1 |
41.6 |
62.5 |
36.1 |
54.1 |
22.7 |
20.9 |
31.2 |
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18.0 |
14.4 |
15 |
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86.5 |
50.0 |
75.0 |
43.4 |
64.9 |
27.3 |
25.0 |
37.5 |
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21.6 |
17.3 |
18 |
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24 |
115.4 |
66.7 |
100.0 |
57.8 |
86.6 |
36.4 |
33.4 |
50.0 |
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28.9 |
23.1 |
27 |
129.8 |
75.0 |
112.5 |
65.0 |
97.4 |
41.0 |
37.5 |
56.2 |
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32.5 |
26.0 |
30 |
144.2 |
83.3 |
125.0 |
72.2 |
108.3 |
45.6 |
41.7 |
62.5 |
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36.1 |
28.8 |
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173.0 |
100.0 |
150.0 |
86.7 |
129.9 |
54.7 |
50.1 |
75.0 |
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43.3 |
34.6 |
36 |
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45 |
216.3 |
125.0 |
187.5 |
108.3 |
162.4 |
68.4 |
62.6 |
93.7 |
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54.1 |
43.3 |
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54 |
259.6 |
150.0 |
225.0 |
130.0 |
194.9 |
82.0 |
75.1 |
112.5 |
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65.0 |
52.0 |
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81 |
389.4 |
224.8 |
337.5 |
194.8 |
292.4 |
123.1 |
112.6 |
168.7 |
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97.4 |
78.0 |
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Page 9
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