SINGLE-WALL INDIRECT
WATER HEATER
A Spanish language version of these instructions is available by contacting the
manufacturer listed on the rating plate.
La version espanola de estas instruccions se puede obtener al escribirle a la
fábrica cuyo nombre aparece in la placa de especificaciones.
To avoid damage or injury,
there must be no materials
stored against the indirect
water heater and proper care
shall be taken to avoid
unnecessary contact (especially
by children) with the indirect
water heater.
q Do not store or use
WARNING
gasoline or other
flammable liquids in
the vicinity of this
water heater or any
other appliance.
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INSTALLATION/OPERATING MANUAL
WITH PARTS LISTING AND TROUBLESHOOTING GUIDE
238-43480-00B REV 12/03
For your family’s comfort, safety, and convenience, we
recommend this water heater be installed and serviced by
a plumbing professional.
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2
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 indirect 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 if 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
back of this manual.
This manual should be kept with the water heater.
We’re committed to providing you with the finest water
heater made.
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3
SECTION I
IMPORTANT INFORMATION
The equipment must be installed in accordance with those
installation regulations required in the area where the installation is
to be made. Thes e regulations must be carefully followed in all
cases. Authorities having jurisdiction shall be consulted before
installations are made.
All wiring on water heaters installed in the USA must be in
accordance with the National Electrical Code and/or local
regulations; or in Canada, installed in accordance with the Canadian
Electrical Code and/or local regulations.
The following terms are used throughout this manual to bring attention
to the presence of hazards of various risk levels, or to important
information concerning product life.
DANGER
Indicates an imminently
hazardous situation,
which, if not avoided, will
result in death, serious
injury, or substantial
property damage.
WARNING
Indicates a potentially
hazardous situation,
which, if not avoided,
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could result in death,
serious injury, or
substantial property
damage.
-READ CAREFULLY-
Indicates a potentially
hazardous situation,
which, if not avoided, may
result in moderate, or
minor injury or property
damage.
Indicates special
instructions on
installation, operation or
maintenance, which are
important but not related
to personal injury hazards.
CAUTION
NOTICE
4
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5
DANGER
DO NOT touch any electric switch; do not use any
DO NOT store or use gasoline or other flammable,
combustible, or corrosive vapors and/or liquids in the
vicinity of this or any other appliance.
IF YOU SMELL GAS:
q DO NOT try to light any appliance.
q
telephone in your building.
q Immediately call your gas supplier from a telephone in
another building. Follow the gas supplier’s
instructions.
q If you cannot reach your gas supplier, call the fire
department
DO NOT OPERATE THE APPLIANCE UNTIL THE
LEAKAGE IS CORRECTED!
Liquefied petroleum gas/propane gas is heavier than air
and will remain at floor level if there is a leak. Basements,
crawl spaces, closets, and areas below ground level will
serve as pockets for accumulation of leaking gas.
This water heater is supplied with an adjustable thermostat
to control water temperature. Hot water temperatures
required for automatic dishwasher and laundry use can
cause scald burns resulting in serious personal injury
and/or death. The temperature at which injury occurs
varies with the person’s age and the time of exposure.
The slo wer response time of disabled persons increases
the hazards to them. NEVER allow small children to use a
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hot water tap or to draw their own bath water. NEVER
leave a child or disabled person unattended in a bathtub or
shower.
6
WARNING
Installation is not complete unless a pressure and
temperature relief valve is installed into the side of the water
heater. See the Water Connections section of this manual
for details.
This water heater contains very hot water under high
pressure. Do not unscrew any pipe fittings or attempt to
disconnect any components of this water heater without
positively assuring the water is cool and has no pressure.
Always wear protective clothing and equipment when
installing, starting up, or servicing this water heater to
prevent scald injuries. Do not rely on the pressure and
temperature gauges to determine the temperature and
pressure of the water heater. This water heater contains
components that become very hot. Do not touch any
components unless they are cool.
Improper installation, adjustments, alteration, service or
maintenance can cause property damage, personal injury or
loss of life. Failure to follow all instructions in the proper
order can cause personal injury or death. Read and
understand all instructions, including all those contained in
component manufacturer’s manuals, which are provided with
the appliance before installing, starting -up, operating,
maintaining, or servicing this appliance. Keep this manual
and literature in legible condition and posted near the
appliance for reference by owner and service technician.
This water heater requires regular maintenance and service
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to operate safely. Follow the instructions contained in this
manual.
Installation, maintenance, and service must be performed
only by an experienced, skilled, and knowledgeable installer
or service agency.
7
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9
WARNING
It is the responsibility of the installing contractor to see that
all controls are correctly installed and are operating properly
when the installation is complete.
DO NOT operate the water heater with jumpered or absent
controls or safety devices.
DO NOT tamper with or alter the water heater and/or
controls.
DO NOT operate the water heater if any external part has
been under water. Immediately call a qualified service
technician to inspect the appliance and to replace any part of
the control system that was under water.
This water heater is suitable for installation on combustible
flooring. DO NOT install this water heater on carpeting.
DO NOT operate this water heater without first being certain
it is filled with water.
Flammable items, pressurized containers, or any other
potential fire hazardous articles must never be placed on or
adjacent to the heater. Containers of flammable gases should
not be stored or used in the same room with this water
heater.
Hydrogen gas can be produced in an operating water heater
that has not had water drawn from the tank for a long period
of time (generally two weeks or more). Hydrogen gas is
extremely flammable. To prevent the possibility of injury
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under these conditions, we recommend that the water faucet
be opened for several minutes at the kitchen sink before you
use any electrical appliance that is connected to the hot water
system. If hydrogen is present, there will be unusual sounds
such as air escaping through the pipes as hot water begins to
flow. Do not smoke or have open flame near the faucet at the
time it is open.
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CAUTION
The maximum boiler water supply temperature to the indirect
heat exchanger must not exceed 240°F (116°C).
NOTICE
Insulation blankets are not required for this water heater.
This water heater meets or exceeds the ASHRAE/IES 90.1b
standards with respect to insulation and standby loss
requirements.
I- IMPORTANT
INFORMATION…………….…..
II- SPECIFICATIONS………………………………. 8
III- GENERAL
INFORMATION…………………….
IV- PRE-
INSTALLATION……………………………
V- WATER
CONNECTIONS………………………..
VI- ELECTRICAL
CONNECTIONS………………..
VII- OPERATING
INSTRUCTIONS…………………
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VIII- MAINTENANCE………………………………
….
IX- TROUBLESHOOTING
GUIDE…………………
X- PARTS
LIST……………………………………….
NOTES…………………………………………….. 36
TABLE OF CONTENTS
3
11
14
19
24
26
29
32
34
12
SECTION II
SPECIFICATIONS
Figure 1 – Tank Layout
Table 1: Water Heater Dimension (Inches)
MODEL
SW -2-30-L 22 33-5/8 28-
SW -2-40-L 24 36 29-
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SW -2-50-L 26 36 29-
SW -2-65-L 22 59-1/4 53-
SW -65C-5 22 59-1/4 53- 60 5-3/8 47-
A B C D E F
13
1/4
3/4
3/4
1/8
34-
3/8
36-
3/4
36-
3/4
60 5-3/8 27-
5-3/8 27-
1/2
5-3/8 27-
1/2
5-3/8 27-
1/2
1/2
1/8 3/4
SW -2-80-L 24 59 52-
7/8
SW -80C-5 24 59 52-
7/8
SW -2-120-L 28-
1/4
SW -120C-5 28-
1/4
62-1/2 55-
3/4
62-1/2 55-
3/4
59-
3/4
59-
3/4
63-
1/4
63-
1/4
5-3/8 27-
1/2
5-3/8 47-
3/4
6-3/8 28-
1/2
6-3/8 48-
3/4
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Table 2: Water Heater Capacities
MODEL
SW -2-30-L 30 2.6 140 404
SW -2-40-L 40 2.6 168 514
SW -2-50-L 50 2.6 196 623
SW -2-65-L 60 2.6 196 704
SW -65C-5 58 5.0 265 768
SW -2-80-L 75 2.6 224 861
SW -80C-5 73 5.0 293 920
SW -2-120-L 116 2.6 355 1324
SW -120C-5 114 5.0 415 1370
Table 3: Water Heater Performance
MODEL
SW-2-30-L 279 429 4.2 6.7 220,000
SW-2-40-L 288 438 4.2 6.7 220,000
SW-2-50-L 297 447 4.2 6.7 220,000
SW-2-65-L 306 456 4.2 6.7 220,000
SW-65C-5 534 820 8.0 12.8 420,000
SW-2-80-L 321 470 4.2 6.7 220,000
SW-80C-5 546 834 8.0 12.8 420,000
SW-2-120-L 357 507 4.2 6.7 220,000
SW-120C-5 583 871 8.0 12.8 420,000
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NOTES: All ratings based on 200 °F boiler water
temperature and 50 °F potable water inlet temperature.
Tank
Capacity
(Gal)
Maximum First
Hour Rating
(Gal/Hr) @
140 °F 115 °F
Coil
Volume
(Gal)
Continuous
Draw Rating
(Gal/Min) @
140 °F 115
°F
Dry
Weight
(Lbs)
Wet
Weight
(Lbs)
Approximate
Boiler
Output
Needed For
Ratings
(BTU/hr)
15
Table 4: Water Heater Performance (continued)
MODEL
SW-2-30-L 5.5
SW-2-40-L 7.5
SW-2-50-L 9.0
SW-2-65-L 11.0
SW-65C-5 10.5
SW-2-80-L 13.5
SW-80C-5 13.2
SW-2-120-L 20.8
SW-120C-5 20.6
Hot Water
Availability
(Minutes)
Coil Heat
Transfer Area
(Sq Ft)
14.2
14.2
14.2
14.2
27.2
14.2
27.2
14.2
27.2
NOTICE
If the boiler takes longer to heat up from a cold start than
the water availability as noted above, hot water shortage
may occur.
Hot water availability is based off drawing 80% of the
heated tank volume at 4 gallons per minute flow rate.
Pressure
Drop at 12
GPM
(Feet of
Head)
1.3
1.3
1.3
1.3
2.6
1.3
2.6
1.3
2.6
The maximum heat transfer through the coil (heat input) of
the water heater at 240°F boiler water supply temperature
and 210°F potable water temperature is 94,100 Btu/hr for
residential models and 180,300 Btu/hr for commercial
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models. Potable water temperature is limited to below
210 °F and nominal water-containing capacity is below
120 gallons for all single-wall indirect models.
Accordingly, per Part HLW-101.2, Section IV of the
ASME Boiler and Pressure Vessel Code, all Bradford
White Single-wall Indirect products are exempted from
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complian ce with the code.
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17
SECTION III
GENERAL INFORMATION
FEATURES
This water heater contains the following features:
HEAT EXCHANGER -- The heat exchanger (coil) has 1” NPT
female fittings.
These water heaters with single-wall heat exchangers meets the
Uniform Plumbing Code for installation in all potable water systems
provided that:
• The boiler water (including additives) is practically non-toxic,
having toxicity rating of class of 1 as listed in Clinical
Toxicology of Commercial Products.
• The boiler water pressure is limited to maximum 30 psig by
approved relief valve.
• The heat transfer medium is potable water or contains only
substances that are recognized as safe by the U.S. Food and
Drug Administration (FDA).
• The pressure of the heat transfer medium is maintained less
than the normal minimum operating pressure of the potable
water system.
• The equipment is permanently labeled to indicate that only
additives recognized as safe by the FDA shall be used in the
heat transfer medium.
ADJUSTABLE AQUASTAT – The temperature may be adjusted
from 80°F to 160°F. The aquastat (thermostat) was adjusted to
120°F before the heater was shipped from the factory. It is
recommended that lower temperatures be used to avoid the risk of
scalding. Refer to the “Warnings” and the section on SCALDING in
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“Section VII – Operating Instructions.” It is further recommended,
in all cases, that the water temperature be set for the lowest
temperature that satisfies your hot water needs. This will also
provide the most energy efficient operation of the water heater and
minimizes scale formation.
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Setting the water heater temperature at 120°F will reduce the risk of
scalds. Some states require settings to specific lower temperatures.
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TEMPERATURE AND PRESSURE RELIEF VALVE —
WARNING
Keep clear of the combination temperature and pressure
relief valve discharge line outlet. The discharge may be hot
enough to cause scald injury. The water is under pressure and may
splash.
For protection against excessive temperatures and pressure, install
temperature and pressure protective equipment required by local
codes, but not less than a combination temperature and pressure
relief valve certified by a nationally recognized testing laboratory
that maintains periodic inspection of production of listed equipment
or materials as meeting the requirements of the Standard for Relief
Valves and Automatic Gas Shutoff Devices for Hot Water
Supply Systems, ANSI Z21.22 and the Standard CAN1-4.4
Temperature, Pressure, Temperature and Pressure Relief
Valves and Vacuum Relief Valves. The combination temperature
and pressure relief valve must be marked with a maximum set
pressure not to exceed the maximum working pressure of the water
heater. The combination temperature and pressure relief va lve
must also have an hourly rated temperature steam BTU discharge
capacity not less than the hourly rating of the water heater. The
supplied combination temperature and pressure relief valve, when
properly installed and unrestricted, will discharge the ma ximum input
produced by a 240°F (116°C) boiler supply temperature. A lower
boiler supply temperature will reduce the input required to be
discharged in the event of excessive potable water temperatures.
Install the combination temperature and pressure relief valve into
the opening provided and marked for this purpose on the water
heater.
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Some models may already be equipped or supplied with a
temperature and pressure relief valve. Verify that the combination
temperature and pressure relief valve complies with local codes. If
the temperature and pressure relief valve does not comply with local
codes, replace it with one that does.
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21
WARNING
Install a discharge line so that water discharged from the
temperature and pressure relief valve will exit within six (6) inches
above, or any distance below, the structural floor and cannot contact
any live electrical part. The discharge line is to be installed to allow
for complete drainage of both the temperature and pressure relief
valve and the discharge line. The discharge opening must not be
subjected to blockage or freezing. DO NOT thread, plug, or cap
the discharge line. It is recommended that a minimum clearance of
four (4) inches be provided on the side of the water heater for
servicing and maintenance of the combination temperature and
pressure relief valve
Do not place a valve between the combination temperature
and pressure relief valve and the tank!
SACRIFICIAL ANODES—Three sacrificial anode rods have
been installed in the tank head to extend tank life. The anode rods
should be inspected annually to determine the amount of sacrificial
decay and replaced when necessary to prolong tank life. Water
conditions in your area will influence the time interval for inspection
and replacement of the anode rod. The use of a water softener may
increase the speed of anode consumption. More frequent inspection
of the anode is needed when using softened (or phosphate treated)
water. Contact the plumbing professional who installed the water
heater or the manufacturer listed on the rating plate for anode
replacement information.
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22
SECTION IV
PRE-INSTALLATION
UNPACKING
INSPECT SHIPMENT carefully for any signs of damage. If
damage is noted, do not install the product. Contact the shipper or
manufacturer listed on rating plate. All equipment is carefully
manufactured, inspected, and packed. Our responsibility ceases
upon delivery of the packaged heater to the carrier in good
condition.
NOTE: Any claims for damage or shortage in shipment must
be filed immediately against the carrier by the consignee.
IMPORTANT DECISIONS REQUIRED
BEFORE INSTALLATION
SIZING
1. Boiler DOE Heating Capacity – The Single-wall
Indirect water heater will provide the rated performance
only if used in conjunction with a boiler with a DOE
heating capacity (Boiler Output) at least as much as the
minimum noted in Table 3. If the boiler has less
capacity, the output of the tank will be reduced. To
determine the approximate reduction in output from the
tank use the following formula:
New Rating = (maximum first hour rating) x
Actual Boiler Output Capacity
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For example, what would the 140°F first hour rating be
if model SW-2-50-L was installed with a boiler having a
DOE heating capacity of 180,000 BTU/h?
Minimum Boiler Output Capacity
23
Answer:
New Rating
= 297 gal/hr x (180,000 BTU/h)/(220,000 BTU/h)
= 297 gal/hr x 0.818 = 243 gal/hr
NOTICE
Increasing the boiler DOE heating capacity above the
values listed in Table 3 will not increase the rating of the
water heater.
Ratings are based on 200°F boiler water. If 180°F boiler
water is supplied, First Hour and Continuous Draw ratings
will be reduced by approximately 27%.
2. Circulator Sizing – Refer to Table 4 for the
corresponding pressure drop through the coil for the
given model. Calculate the pressure drop of all straight
pipe and fittings on the supply and return of the water
heater at the selected flow rate. Add the piping/fitting
pressure drop to the pressure drop through the water
heater coil.
Sel ect a circulator that will provide an appropriate flow
rate at the combined pressure drop.
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SYSTEM ZONE CONTROL
The Single-wall Indirect water heater must be installed as a zone
separate from the space heating system. The domestic hot water
zone’s piping and circulator must be sized for a minimum flow rate
with all zones in use and a maximum flow rate with only the water
24
heater in use. For this reason, the preferred method of zone
control is with circulators.
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25
1. Circulators – With space heating zones using circulators,
the Single-wall Indirect should be added as an additional
zone with a circulator.
2. Zone Valves – Select a valve with a low-pressure drop
to assure adequate flow through the water heater.
3. Hybrid – The space heating zone can be zoned using zone
valves and the Single-wall Indirect zoned with a circulator.
DOMESTIC HOT WATER PRIORITY
Two options are available, Priority and Non-Priority.
1. Priority – Demand for space heating is interrupted or
postponed until the domestic hot water demand is
satisfied. This option provides maximum delivery of
domestic hot water. Priority is recommended when:
a) Boiler net output is 100,000 Btu per hour or less, or
b) When boiler output required to satisfy domestic hot
water demand is at least 50% of the boiler output
required to satisfy space heating demand, or
c) When an interruption in space heating can be
tolerated during a long domestic hot water draw.
2. Non-Priority – Boiler output is divided between space
heating and domestic hot water heating. Delivery of
domestic hot water can be reduced during simultaneous
space and domestic hot water heating operations,
depending on such factors as boiler output, boiler oversizing, number of space heating zones calling for heat, and
the ratio of domestic hot water load to space heating load.
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26
Component Location
CAUTION
This water heater must be located in an area where leakage of the
tank, water line connections, or the temperature and pressure relief
valve will not result in damage to the area adjacent to the water
heater or to lower floors of the structure. When such locations
cannot be avoided, a suitable drain pan must be installed under the
water heater. The drain pan depth must be suitable for draining and
collecting water, and have a minimum length and width of at least
four (4) inches measured from the jacket of the water heater. The
drain pan, as described above, can be purchased from your plumbing
professional. The drain pan must be piped to an adequate drain.
The piping must be at least ¾ inc h in diameter and pitched for
proper drainage.
Clearance from Combustible Materials
Top Sides Front Rear
0” 0” 0” 0”
Table 5 – Combustible Material Clearances
Recommended Service Clearances
Non-Piping
Side
4” 16” 0” 4”
Front
(Aquastat)
Table 6 – Service Clearances
Rear
T & P Relief
Valve Side
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CAUTION
Do not drop water heater. Do not bump water heater jacket against
floor.
27
Appliance Location
1. Boiler Location – Locate the Single-wall Indirect as close to
the boiler as practical.
2. Fixture Locations – For fastest delivery of hot water, place
the Single-wall Indirect close to points of use.
Additional Recommended Components
1. Shut-off Valves – Allows isolation of water heater from
domestic water system and/or boiler system during service.
2. Unions – Allows water heater movement during service if
adequate clearance cannot be provided.
3. Thermal Expansion Tank – If the water heater is installed in
a closed water supply system, such as one having a back-flow
preventer in the cold water line, provide thermal expansion
control. Contact the water supplier or local plumbing
inspector for additional information.
WARNING
Do not plug the inlet and outlet tappings of tankless heater left
installed in the boiler.
MOVE THE WATER HEATER TO A PERMANENT
POSITION BY SLIDING OR WALKING.
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28
SECTION V
WATER CONNECTIONS
WARNING
FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED
TEMPERATURE AND PRESSURE RELIEF VALVE WILL
RELEASE THE MANUFACTURER FROM ANY CLAIM
WHICH MIGHT RESULT FROM EXCESSIVE
TEMPERATURE AND PRESSURES.
Hydrogen gas can be produced in an operating water heater that
has not had water drawn from the tank for a long period of time.
HYDROGEN GAS IS EXTREMELY FLAMMABLE. To
prevent the possibility of injury under these conditions, we
recommend the hot water faucet be opened for several minutes
at the kitchen sink before you use any electrical appliance that is
connected to the hot water system. If hydrogen is present,
there will be an unusual s ound such as air escaping through the
pipes as hot water begins to flow. Do not smoke or have open
flame near the faucet at the time it is open.
Keep clear of the temperature and pressure relief valve
discharge line outlet. The discharge may be hot eno ugh to
cause scald injury. The water is under pressure and may splash.
CAUTION
If sweat fittings are to be used, DO NOT apply heat to the
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nipples on top of the water heater. Sweat the tubing to the
adapter before fitting the adapter to the water connections. It is
imperative that heat is not applied to the nipples containing a
plastic liner.
29
INSTALL TEMPERATURE AND PRESSURE RELIEF
VALVE (if not factory installed)
WARNING
Temperature and pressure relief valve discharge piping must be
piped near the floor to eliminate potential of severe burns. Do
not pipe in any area where freezing could occur. Do not install
any shut-off valves, plugs or caps to the temperature and
pressure relief valve or piping.
INSTRUCTIONS FOR POTABLE CONNECTIONS
1. BEFORE PROCEEDING WITH THE INSTALLATION,
CLOSE THE MAIN WATER SUPPLY VALVE. After
shutting off the main water supply, open a faucet to relieve the
water line pressure to prevent any water from leaking out of
the pipes while making the water connections to the water
heater. After the pressure has been relieved, close the faucet.
The COLD water inlet and HOT water outlet are identified
on the top of the water heater. Make the proper plumbing
connections between the water heater and the plumbing
system to the house. Install a shut-off valve in the cold water
supply line.
2. If this water heater is installed in a closed water supply
system, such as one having a back-flow preventer in the cold
water supply, provisions must be made to control thermal
expansion. DO NOT operate this water heater in a closed
system without provisions for controlling thermal expansion.
Warranties do not cover damages from thermal expansions
such as pressure bulges and/or deformities. A properly sized
expansion tank will alleviate most problems. Your water
supplier or local plumbing inspector should be contacted on
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how to control this situation.
3. After installation of the water lines, open the main water
supply valve and fill the water heater. While the water heater
is filling, open several hot water faucets to allow air to escape
from the water system. When steady
30
streams of water flow through the faucets, close them and
check all water connections for possible leaks.
4. NEVER OPERATE THE WATER HEATER
WITHOUT FIRST BEING CERTAIN THAT IT IS
FILLED WITH WATER.
INSTRUCTIONS FOR BOILER CONNECTIONS
The Single-wall Indirect connection labeled “To Boiler Return”
should be piped to the boiler return piping as close to the boiler as
possible and especially after any flow control or check valves in the
space heating return piping. The use of a union and a shut-off valve
is recommended. The use of a flow control or check valve is
required to prevent back flow through the water heater during
operation of the space heating system. Pipe and fittings between
the boiler and Single-wall Indirect should be ¾” diameter or larger.
CAUTION
Maximum boiler water supply temperature to the indirect
heat exchanger must not exceed 240°F (116°C).
CONNECT WATER BOILER SUPPLY PIPING
1. For a space heating system that utilizes ZONE VALVES, refer
to Figure 2. The Single-wall Indirect connection labeled
“FROM BOILER SUPPLY” should be piped to the boiler
supply piping. Mount the circulator making sure the flow arrow
points toward the water heater. The use of shut-off valves and
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unions are recommended for future service convenience. The
use of an air separator and vent is recommended to eliminate air
in the system. Pipe and fittings between the boiler and Singlewall Indirect must be ¾” diameter or larger.
31
Figure 2 - Water Boiler Piping with Zone Valves
2. For a space heating system that utilizes CIRCULATORS, refer
to Figure 3. The Single-wall Indirect connection labeled
“FROM BOILER SUPPLY” should be piped to the boiler
supply piping. Mount the circulator making sure the flow arrow
points toward the water heater. The use of shut-off valves and
unions are recommended for future service convenience. The
use of an air separator and vent is recommended to eliminate air
in the system. Pipe and fittings between the boiler and Singlewall Indirect must be ¾” diameter or larger.
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Figure 3 - Water Boiler Piping with Circulators
32
CONNECT STEAM BOILER SUPPLY PIPING
hout connections available below the water line is not
F lower than the
Figure 4 represents a typical steam boiler connection diagram.
Refer to the boiler installation manual or contact the boiler
manufacturer for an appropriate piping diagram. The use of a
union, shut-off valves, and a drain valve is recommended for future
service convenience. The use of an in-line “Y”-style strainer is
required to prevent accumulation of sludge in the water heater’s
coil.
Figure 4 – Typical Steam Boiler Connections (connections available
below the water line)
NOTICE
Typical steam boiler wit
recommended due to insufficient water temperature, especially during
warmer months when the space heating system is not operational. Boiler
water temperature at the bottom of a steam boiler can be 50°
boiler’s water temperature limit setting during such periods.
FILL BOILER SYSTEM
1. On new boiler installations, do not purge the boiler or space
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heating system through the water heater. During any boiler or
space heating system flushing, cleaning, or purging, the water
heater should be isolated to avoid possible attack on the
carbon steel coil by chemical additives.
2. Purge air from boiler/water heater piping.
3. Check system for leaks. Repair as necessary.
33
SECTION VI
ELECTRICAL CONNECTIONS
Install electric wiring in accordance with National Electric Code or
the Canadian Electrical Code and local regulations. See the
boiler’s installation manual for wiring diagrams.
DANGER
Positively assure all electrical connections are unpowered before
attempting installation or service of electrical components or
connections of the water heater or building. Lock out all
electrical boxes with padlock once power is turned off.
WARNING
When installed, the water heater must be electrically grounded in
accordance with local codes or, in the absence of local codes,
with the National Electrical Code, ANSI/NFPA 70, and /or the
CSA C22.1 Electric Code.
Failure to properly wire electrical connections to the water heater
may result in serious physical harm.
Electrical power may be from more than one source. Make sure
all power is off before attempting any electrical work.
The Single-wall Indirect is supplied with an aquastat temperature
control. This aquastat must be installed in the aquastat well
location of the water heater. Refer to Figure 5. Remove the cover
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and loosen the clamping screws. Insert the aquastat capillary bulb
to the well bottom as shown and screw the aquastat clamp securely
in the well groove. The aquastat acts as a thermostat for zone
control and should be wired accordingly. Refer to the boiler or
zone control manufacturer’s instructions if any additional wiring is
required. The control is factory set at 120°F and care should be
34
made to not rotate this dial while wiring the control. Once electrical
connections are
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35
complete, secure the aquastat cover back in place. AT NO TIME
SHOULD WATER HEATER OPERATION TAKE PLACE
WITHOUT THE COVER ON THE CONTROL.
Figure 5 - Aquastat Control
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36
SECTION VII
OPERATING INSTRUCTIONS
WARNING
Water heaters are heat-producing appliances. To avoid damage
or injury there must be no materials stored against the water
heater, and proper care must be taken to avoid unnecessary
contact (especially by children) with the water heater.
UNDER NO CIRCUMSTANCES SHALL FLAMMABLE
MATERIALS, SUCH AS GASOLINE OR PAINT THINNER
BE USED OR STORED IN THE VICINITY OF THE
WATER HEATER OR IN ANY LOCATION FROM WHICH
FUMES COULD REACH THE WATER HEATER.
Installation or service of this water heater requires ability
equivalent to that of a licensed tradesman in the field
involved. Plumbing and electrical work are required.
SYSTEM START-UP
Follow boiler installation instructions to place boiler in operation.
SEQUENCE OF OPERATIONS
1. Aquastat senses stored water temperature drops below
desired setting.
a. Domestic hot water priority only: Normally closed
contacts open to interrupt space heating.
2. Aquastat satisfied.
a. Aquastat contacts open, turning off domestic hot water
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circulator and de-energizing relay.
b. Normally open contacts open, stopping boiler operation.
c. Domestic hot water priority only: Normally closed
contacts close, returning boiler control to space
heating.
37
WATER TEMPERATURE ADJUSTMENT
ure water at any
heater to obtain an increased water temperature, you may create
Such valves are available from the manufacturer of
1. The aquastat controls the maximum water temperature in the
tank. The differential is a fixed 5°F with a 160°F maximum
setting, set at the factory to 120°F.
WARNING
SCALDING
This water heater can deliver scalding temperat
faucet in the system. Be careful whenever using hot water to
avoid scalding injury. By setting the aquastat on this water
the potential for scald injury. To protect against inju ry, you
should install an ASSE approved mixing valve (a device to limit
the temperature of water to protect against scald injury via
mixing hot and cold water supply) in the water system. This
valve will reduce point of discharge temperature in branch
supply lines.
this water heater or a local plumbing supplier. Please consult
with a plumbing professional.
Table 7 details the approximate relationship of water temperature and
time with regard to scald injury and may be used as a guide in
determining the safest water temperature for your applications.
RELATIONSHIPS IN SCALDS
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Figure 6 - Scald Warning
38
APPROXIMATE
TIME/TEMPERATURE
120°F More than 5 minutes
125°F 1 ½ to 2 minutes
130°F About 30 seconds
135°F About 10 seconds
140°F Less than 5 seconds
145°F Less than 3 seconds
150°F About 1 ½ seconds
155°F About 1 second
Table 7 – Scald Relationships
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39
2. For the most energy efficient operation, adjust the aquastat for
the minimum water temperature necessary to meet domestic
hot water needs. Refer to Figure 7. Use a small flat
screwdriver to rotate the temperature dial through the hole
directly below the temperature indication window. The
temperature setting is aligned with the notch in this window.
IT IS NOT NECESSARY TO REMOVE THE COVER
TO ADJUST THE TEMPERATURE SETTING. THE
AQUASTAT COVER SHOULD NEVER BE
REMOVED WITHOUT ELECTRICITY BEING
FIRST DISCONNECTED.
3. After the water heater completes a heat-up cycle, check the
water temperature at a faucet. Allow enough water to flow to
ensure that the water temperature reflects the tank
temperature. Adjust the water heater’s temperature setting as
necessary.
a. Adjusting to a lower temperature setting will not
immediately affect water temperature. Draw sufficient
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water or allow the water heater to sit until a heat-up cycle
is initiated. Repeat step 3.
b. Adjusting to a higher temperature may not immediately
affect water temperature. If a heat-up cycle begins,
return to step 3. If a heat-up cycle does not begin, draw
Figure 7 - Aquastat Control
40
sufficient water or allow the water heater to sit until a
heat-up cycle is initiated. Repeat step 3.
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41
SECTION VIII
MAINTENANCE
The Single-wall Indirect is intended to provide a service life of many
years. Components that require service, however, may be subject
to failure. Failure to use the correct procedures or parts in these
circumstances may make the water heater unsafe.
The owner should arrange to have the following inspections and
simple maintenance procedure performed by qualified service
personnel at the frequencies suggested.
1. Boiler and Domestic Water Piping (Annual) – Check all
piping for signs of leakage at joints, unions, and shut-off
valves. Repair as needed.
2. Temperature-Pressure Relief Valve (Annual)- The
temperature-pressure relief valve should be checked to ensure
that it is in operating condition. To check the relief valve, lift
the lever at the end of the valve several times. The valve
should seat properly and operate freely. If water does not
flow, remove and inspect for obstructions or corrosion.
Replace with a new valve of the recommended size as
necessary. Do not attempt to repair the valve, as this could
result in improper operation and a tank explosion. In areas
with poor water conditions, it may be necessary to inspect the
temperature-relief valve more often than once a year.
CAUTION
Before manually operating the valve, make sure that a
drain line has been attached to the valve to direct the
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discharge to an open drain. Failure to take this
precaution could mean contact with extremely hot water
discharging from the valve during this checking
operation.
42
If the temperature–pressure relief valve on the heater discharges
periodically or continuously, it may be due to thermal expansion of
water in a closed water supply system, or it may be due to a faulty
relief valve.
Thermal expansion is the normal response of water when it is
heated. In a closed system, thermal expansion will cause the
system pressure to build until the relief valve actuation pressure is
equaled. Then the relief valve will open, allowing some water to
escape, slightly lowering the pressure. Contact your water supplier
or local plumbing inspector on how to control this situation.
ABOVE ALL, DO NOT PLUG THE TEMPERATURE AND
PRESSURE RELIEF VALVE. THIS IS NOT A SOLUTION
AND CAN CREATE A HAZARDOUS SITUATION.
3. Anode Inspection and Replacement - This water heater is
equipped with multiple sacrificial anodes. Anodes protect the
glass-lined tank from corrosion by sacrificing themselves
through electrolysis. When the anode material is consumed,
there is no more protection and corrosion of the tank
accelerates.
Inspection of the anode every year allows you to identify a
spent anode and replace. Replace the anode when its
diameter is 3/8 of an inch, or every other year, which ever is
first. Aggressive, very hot and softened water causes rapid
consumption of the anode, requiring frequent inspections.
Anodes are available from your distributor or from the
manufacturer listed on the rating plate.
To inspect or replace an anode:
The anodes on this water heater are easily accessible from the
top of the heater making replacement simple and quick.
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a. Turn the water heater electricity off for the zone
containing the Single-wall Indirect. Flow water until
the discharge is cool or allow enough time for the
potable water to cool naturally. Connect a hose to the
drain valve. Locate the hose’s
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discharge in an area where any remaining hot water
will not cause any damage or injury.
b. Open the drain valve to flush any sediment out of the
bottom to the heater.
c. Shut off the cold water supply. Make sure all hot
water fixtures and circulating pumps are turned off.
d. Wait for water flow from the hose to stop. Remove
the anode using a socket of the appropriate size. Do
not use an impact wrench.
e. Inspect and replace the anode as required. Use pipe
tape or sealant when reinstalling the anode.
f. Close the drain valve. Open a hot water fixture to
allow air to escape. Open the cold water supply to
the heater and allow the tank to fill.
g. Check your anode and drain valve for leaks.
h. Turn the water heater electricity on for the zone
containing the Single-wall Indirect.
4. Sediment (Annual, but harsh water quality may
dictate more frequent service)- Depending on water
conditions, a varying amount of sediment may collect in the
tank. Levels requiring service are indicated by a small
temperature difference in the supply and return lines (See
also “Scale” below). Repeated flushing usually clears such
material. As a preventive measure, water should be drawn
from the tank at the drain valve until it runs clear.
5. Scale (Annual)- Hard water may cause scale to build-up
on the outside of the heat exchanger coil. A water softener
will prevent this problem (See also “Sediment” above).
Symptoms would be reduced recovery capacity or reduced
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temperature differential between boiler supply and return
lines. Repeated flushing should resolve the problem.
44
SECTION IX
TROUBLE SHOOTING GUIDE
PROBLEM
No hot water at
faucet
Water at faucet
too hot
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CAUSE SOLUTION
Boiler does not
operate
operate
Improper aquastat
setting or calibration
open (if used)
Electrical problem
(relay, wiring, etc.)
Scale build-up If boiler, circulator, and tank
Clogged cold water
filter or boiler
supply strainer (if
used)
Aquastat set too
high
Improper system
plumbing
Improper system
wiring
Refer to boiler installation
instructions
Check main service switch
Check fused disconnect
Check power supply Circulator does not
Replace as necessary
Turn tank aquastat to
appropriate setting
Check power supply Zone valve does not
Replace as necessary
Check fuse and replace
Check circuit breaker and
reset (if applicable)
Check power supply
are operating satisfactorily,
coil may have scale coating.
See Section VIII:
Maintenance
Clean or replace filter or
strainer
Lower aquastat setting. See
Section VII
Compare plumbing to
Section V: Water
Connections
Compare wiring to Section
VI: Electrical Connections
45
TROUBLE SHOOTING GUIDE (CONT.)
PROBLEM
Insufficient hot
water
Boiler cycles
more than 5
times per day in
summer Boiler high limit set
CAUSE SOLUTION
Aquastat setting too
low
Undersized boiler
with no priority to
domestic hot water
Peak use of hot
water is greater than
tank storage
capacity
Faulty tank aquastat Replace aquastat
Excessive demand Reduce demand or
Faulty aquastat Replace aquastat
too low
Adjust aquastat to higher
setting. See Section VII
Rewire for priority
Determine peak usage and
compare to tank capacity
consider larger tank
Increase boiler high limit
setting
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46
SECTION X
PARTS LIST
PART NAME & DESCRIPTION
1. Aquastat Control 7. Drain Valve
2. Aquastat Well 8. Jacket Head Pan
3. Anode 9. Hole Closure
4. Diptube 10. Heat Exchanger Escutcheon
5. Outlet Nipple 11. Escutcheon
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6. T & P Relief Valve 12. Finish Flange
47
Contact your supplier or plumbing professional for replacement
parts or contact the company at the address given on the rating
plate of the water heater.
Provide the part name, model, and serial numbers of the water
heater when ordering parts.
READ THE WARRANTY FOR A FULL EXPLANATION OF THE
LENGTH OF TIME THAT PARTS AND THE WATER HEATER ARE
WARRANTED.
Manufactured under one or more of the following U.S. Patents: 4,416,222;
4,628,184; 4,669,448; 4,672,919; 4,808,356; 4,829,983; 4,861,968; 4,867,106;
4,904,428; 5,000,893; 5,023,031; 5,052,346; 5,081,696; 5,092,519; 5,115,767;
5,199,385; 5,277,171; 5,341,770; 5,372,185; 5,485,879; 5,660,165; 5,574,822;
5,596,652; 5,682,666; 5,943,984. Other U.S. and Foreign patents applications
pending. Current Canadian Patents: 1,272,914; 1,280,043; 1,289,832; 2,045,862;
2,107,012; 2,108,186; 2,112,525.
Complete the following information and retain for future reference:
Model No:
Serial No:
Service Phone
Days: Nights:
Address:
Supplier:
Supplier Phone No:
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48
Notes
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49
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