Bradford-White Corp 238-47878-00B User Manual

ACCESSORY MODULE

Including Protection, Performance, and Inlet Shut-off Valve Packages

This manual must be used in
conjunction with the Installation and
Operation Manual for the water heater.

Tech. Service..........................[phone]

Service Parts ..........................[phone]

Warranty Department .............[phone]

Ambler, PA 19002

www.bradfordwhite.com

- Do not store or use gasoline or other

flammable vapors and liquids in the
vicinity of the water heater 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 neighbor phone. Follow
the gas supplier instructions.

• If you cannot reach your gas

supplier, call the fire department.

- For your family comfort, safety and

convenience, it is recommended these
packages be installed and serviced by
a plumbing professional.

- Read and understand the water heater

manual before installing or operating
the Accessory Module and its
associated packages.

INSTALLATION & OPERATION MANUAL

With Troubleshooting Guide

PLACE THESE INSTRUCTIONS ADJACENT TO WATER HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE

238-47878-00B 04/10

Important Information

CONGRATULATIONS!

You have just purchased one of the finest water heater accessories on the market today!
This Installation and Operation Manual will explain in detail how to install and operate your

new Accessory Module, as well as the packages that can be connected to the Accessory
Module. We strongly recommend you contact a plumbing professional for the installation of
this new control.

We require that you carefully read this manual and your water heater manual and refer to
them when questions arise. If you have any specific questions concerning your warranty,
please consult the plumbing professional from whom your Accessory Module was
purchased. For your records, we recommend that you write the installation date for these
accessories in the back of this manual.

This manual should be kept with the Accessory Module.

NOTICE

The Accessory Module and its associated packages are for use only with Bradford White water
heaters equipped with compatible Honeywell gas controls.

The Accessory Module is always required in order to use the Protection, Performance, and/or
the Inlet Shut-off Valve Packages.

The Protection Package is required in order to use the Inlet Shut-off Valve Package.
For easier installation, the Integrated Mixing Device and Inlet Shut-off Valve should be installed

first.

Accessory Module:

The Accessory Module is an electronic component that allows the water heater gas control to be
connected to the Protection, Performance, and Inlet Shut-off Valve Packages.

Accessory Module:
Contains:

Features:

o Accessory Module
o Plug-in transformer
o Transformer wire harness
o (2) gas control harnesses (only

o Wire holders
o Wire ties
o Installation & Operation Manual
o Screws

(1) used per water heater)

o Multi-color LED used to display status and diagnostics
o Audible alarm to sound in the event a fault occurs
o Easily mounts to the water heater or can be remote mounted
o One Accessory Module fits all diameter water heaters
o Durable construction

-2-

Important Information

Protection Package (sold separately):
Contains:

Features:

Performance Package (sold separately):
Contains:

Setback Control Features:

Integrated Mixing Device Features:

Inlet Shut-off Valve (sold separately):
Contains:

Features:

o Leak sensor (2 piece)
o Dam
o Leak sensor wire harness

o Senses a collection of water near the water heater
o Sounds the alarm to alert homeowners when a water heater leak is detected and

verified

o Alarm is re-settable and can be temporarily silenced
o Durable construction
o Easy installation – all wiring is provided
o Can be used without the need for a water heater drain pan
o Includes dam, which corrals the water in order for the leak to be detected

o Setback Control
o Setback Control Junction Box

Assembly

o Setback Control wire harness
o Wire ties
o Screws

o 7 day / 4 period programming
o Conserves energy
o Hot water capacity indicator (provides an estimate of available hot water)
o Battery back-up stores programming during a power outage
o Can be programmed to comply with Sabbath requirements
o Similar interface to furnace / air conditioning thermostats
o Precision control of water temperature

o Push to turn handle
o Thermo-strip to indicate approximate outlet water temperature
o Port to draw off tank temperature water
o Port to return recirculation water into the mixing valve
o Port on cold water tee to draw off water for use without installing a saddle valve
o Allows water in the tank to be stored at higher temperatures while controlling the hot

water outlet temperature at a safe and comfortable level

o Precision control of water temperature

o Inlet shut-off valve with

integrated wire harness

o Shuts off water supply to the water heater in the event a water heater tank leak is

detected

o Solid brass construction
o Robust design
o Easy wiring with integral wire harness
o Mounts directly to the water heater inlet
o Can be used on both 3/4” and 1” NPT inlet fittings

o Wire holders
o Wire ties
o Screws

o Integrated Mixing Device (IMD)

 Mixing valve
 Cold water tee
 (2) flexible connectors (only

(1) used per water heater)

 Thermo-strip

o (2) 3/4” to 1” NPT bushing
o Wire ties

-3-

Important Information

The following terms are used throughout this manual to bring attention to the
presence of hazards at 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.

READ CAREFULLY

CAUTION

Indicates potentially hazardous situation,
which, if not avoided, may result in
moderate or minor injury or property
damage.

WARNING

Indicates a potentially hazardous
situation, which, if not avoided, could
result in death, serious injury or
substantial property damage.

NOTICE

Indicates special instructions on
installation, operation or maintenance,
which are important but not related to
personal injury hazards.

DANGER

Hotter water increases the risk of scald injury. Scalding may occur within five (5) seconds at a
temperature setting of 140°F (60

°

C). To protect against hot water injury, install an ASSE
approved mixing valve in the water system. This valve will reduce point of discharge
temperature by mixing cold and hot water in branch water lines. A licensed plumbing
professional or local plumbing authority should be consulted.

NOTICE

The water heater is equipped with an energy cut out device to prevent overheating. Should
overheating occur or the gas supply fails to shut off, turn off the manual gas control valve to the
water heater and call a qualified service technician.
Whenever the water heater is filled with cold water, condensate will form on the cool tank
surface and drops of water will fall on the hot burner and combustion chamber surfaces
producing a “sizzling” noise. Condensation is normal and does not indicate a leak. It will
disappear when the tank becomes heated.

CAUTION

The water heater, when set at a lower temperature setting, is not capable of producing hot water
of sufficient temperature for sanitizing purposes.

-4-

Important Information

NOTICE

The lower the temperature setting, the greater the energy efficiency, both to heat the water and
to maintain the storage temperature during standby periods. Lower water temperatures also
extend tank life. Remember, no water heating system will provide exact temperatures at all
times. Allow a few days of operation at this setting to determine the correct temperature setting
consistent with the requirements for the installation.

WARNING

Do not operate the water heater or Accessory Module without the Accessory Module cover in
place. Do not operate the water heater or Setback Control without the Setback Control Junction
Box Assembly cover in place.

Do not operate water heater, Accessory Module, and Setback Control with jumpered or absent
controls or safety devices.

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

All electrical wiring must be installed and grounded in accordance with local codes, or in the
absence of local codes, the National Electrical Code, ANSI/NFPA 70 and/or CSA C22 Electrical
Code.

Do not use wire holders to the right of the water heater gas valve. The screws used for the wire
holders can damage the water heater internal components.

For energy efficient operation of your water heater, the suggested initial water temperature setting is
120˚F (49˚C). During the winter season, or any cold period, you may desire a higher water temperature
setting to adjust for the colder incoming water. This adjustment, however, may cause additional
condensation to form on the cooler tank surface. This does not mean the tank is leaking. During summer
months, the warmer incoming water temperatures will benefit the performance of your water heater and
reduce the amount of condensation developed.

Condensation does not mean your tank is leaking. Over 40% of reported tank leaks on installation are
proven to be condensation. To avoid unnecessary expense and inconvenience, make sure the tank is
leaking before calling a service technician.

Water temperature over 125°F
can cause se vere burn s
instantly or death from scalds.

Children, disa bled and elde r ly
are at highes t risk of being
scalded.

Review this instruction manual
before setting temperature
at wat er heater.

Feel water bef ore bathing or
showering.

Tem perat ure limi ting va lves
are available.

-5-

Table of Contents

Tools Required............................................................................................ 7

Package Components................................................................................. 8

Accessory Module........................................................................... 8

Protection Package ......................................................................... 9

Performance Package..................................................................... 10

Inlet Valve Shut-off Package........................................................... 11

Wiring Diagram ........................................................................................... 12

Accessory Module Installation..................................................................... 13

Setback Control Installation ........................................................................ 27

Integrated Mixing Device - IMD................................................................... 39

Leak Sensor Installation.............................................................................. 40

Page

Inlet Shut-off Valve Installation.................................................................... 49

Remote Mounting the Setback Control ....................................................... 56

Start-up Procedure...................................................................................... 67

Diagnostic Codes........................................................................................ 73

Notes........................................................................................................... 74

Warranty...................................................................................................... 75

-6-

Tools Required

Slotted Screwdriver
Philips Screwdriver
1/8” Drill bit
Drill
Needle nose pliers
Pipe dope
Adjustable wrench
Caulk gun
RTV sealant (silicone)
Pipe cutter
Propane torch
Solder
Flux
Wire Cutters
Wire Strippers
Fine Point Marker

-7-

Package Components Accessory Module

Table 1

Description Quantity
1A Plug-in Transformer 1
2A WV4460 Wire Harness 1
3A Transformer Wire Harness 1
4A WV8840 Wire Harness 1
5A Wire Holders 4
6A Installation & Operation Manual 1
7A Wiring Diagram Label 1
8A Diagnostic Label 1
9A Wire Ties 4

10A Screws 9
11A Accessory Module 1

Accessory Module

FOR USE WITH THE FOLLOWING GAS VALVES:

222-47463-01

222-47466-02

222-47463-02

222-46402-01

222-47464-01

222-46402-02

222-47464-02

222-46990-01

222-47465-01

222-46990-02

222-47465-02

222-46991-01

222-47466-01

222-46991-02

ACCESSORY MODULE

R1 C1 LK C2 NO NC D/1 R/2 C/3 A1 A2

BK

BK BL BKBR R WBK BK Y

W

R

*WHEN CONNECTING LEAK SENSOR, REMOVE RESISTOR
BETWEEN C1 & LK.
**WHEN CONNECTING ANODE DEPLETION SENSOR, REMOVE RESISTOR
BETWEEN A1 & A2.
SEE INSTALLATION AND OPERATION MANUAL FOR MORE INFORMATION.

FOR USE WITH THE FOLLOWING GAS VALVES:

222-45613-01

222-45614-01

222-45613-02

222-45614-02

ACCESSORY MODULE

R1 C1 LK C2 NO NC D/1 R/2 C/3 A1 A2

BK

BK BL BKBR R WBK BK Y

W

R

*WHEN CONNECTING LEAK SENSOR, REMOVE RESISTOR
BETWEEN C1 & LK.
**WHEN CONNECTING ANODE DEPLETION SENSOR, REMOVE RESISTOR
BETWEEN A1 & A2.
SEE INSTALLATION AND OPERATION MANUAL FOR MORE INFORMATION.

ACCESSORY MODULE DIAGNOSTIC CODES

ACCESSORY MODULE STATUS LED STATUS

COLOR PATTERN

LED on continuously. Power on (no fault).

GREEN

One flash and three second pause. Leak alarm fault. W ater shut-off valve open.

RED

Two flashes and three second pause. Leak alarm fault. Water shut-off valve closed.

RED

Three flashes and three second pause. Anode depletion alarm or not connected.

AMBER

Four flashes and three second pause. Leak sensor malf unction.

BK

W

R

D

R

R

BK

C

W

238-47880-00A

AMBER

Five flashes and three second pause. Gas valve missing/not connected.

AMBER

RED LED strobe (quick flashes). Hardware error.

See Installation and Operation Instruction Manual f or probable causes

associated with each control status code.

238-47879-00A

NOTICE

The WV4460 wire harness must be used w ith gas con tro ls with in term ittent p ilots. T he WV884 0
wire harness must be used with gas controls with standing pilots.

-8-

Package Components Protection Package

Table 2

Description Quantity
1B Leak Sensor Bracket 1
2B Leak Sensor Housing 1
3B Dam 1
4B Screws 6
5B Leak Sensor Wire Harness 1
6B Wire Holders 4
7B Wire Ties 4

Protection Package

-9-

Package Components Performance Package

Table 3

Description Quantity
1C Setback Control Wire Harness 1
2C Integrated Mixing Device, IMD 1

- Cold Water Tee

- Mixing Valve

- 8” Flexible Connector

- 11” Flexible Connector

- Instruction & Operation Manual

- Thermo-strip
3C Setback Control (batteries included) 1
4C Wire Ties 2
5C Setback Control Junction Box Assembly 1
6C Screws 6
7C Setback Cover Plate 1

8C

Setback Control Instruction & Operation
Manual

Performance Package

1

-10-

Package Components Inlet Shut-off Valve Package

Table 4

Description Quantity

1D Inlet Shut-off Valve with Integrated Wire

Harness
2D ¾” x 1” NPT Brass Bushings 2
3D Wire Ties 4

Inlet Shut-off Valve

1

-11-

Wiring Diagram

-12-

Accessory Module Installation

In the following section, the instructions detail how to install the Accessory Module. Properly
locating and mounting the Accessory Module is required.

Unpack the Accessory Module

Step 1: Remove the Accessory Module and its components from their packaging, as shown in Figure 1.

Determine the Gas Control Wire Harness

Step 2: If the gas control uses an intermittent pilot, the WV4460 wire harness must be used. The
WV4460 gas control and wire harness are shown in Figure 2. Discard the WV8840 wire harness.
Otherwise, proceed to Step 3.

WV4460

Gas Control

Figure 1

Determine gas control

number using label on side

of control

WV4460 Wire

Harness

Figure 2

-13-

Accessory Module Installation

Determine the Gas Control Wire Harness – cont’d

Step 3: If the gas control uses a standing pilot, the WV8840 wire harness must be used. The WV8840
gas control and wire harness are shown in Figure 3. Discard the WV4460 wire harness.

Locate the Accessory Module

Step 4: The Accessory Module must be mounted to the left of the water heater gas control. Hold the
Accessory Module to the water heater jacket as high as possible and practical. Do not cover any safety
or warning labels on the water heater. This is shown in Figure 4.

WV8840

Gas Control

Figure 3

Figure 4

Determine gas control

number using label on side

of control

Accessory Module must

be mounted to the left of

this line

WV8840 Wire

Harness

WARNING

Failure to properly locate the Accessory Module may cause damage to the water heater wiring
harness.

-14-

Accessory Module Installation

Mark the Location of the Accessory Module

Step 5: Using a marker, mark the location of the Accessory Module screw holes. This is shown in
Figure 5.

Water

Heater

Accessory

Module

Marker

Figure 5

Set the Accessory Module Aside

Step 6: Remove the Accessory Module from the water heater jacket, as shown in Figure 6.

Accessory

Module

Water

Heater

Figure 6

-15-

Accessory Module Installation

Drill the Accessory Module Screw Holes

Step 7: Using a 1/8” drill bit and drill, drill the (2) screw holes that were marked in Step 5. This is shown
in Figure 7.

Position the Accessory Module

Step 8: Put the Accessory Module up against the water heater jacket and position it to the pre-drilled
holes. This is shown in Figure 8.

Accessory

Module

Water

Heater

Marked drill

locations

Drill

Figure 7

Pre-drilled

holes

Water

Heater

Figure 8

-16-

Accessory Module Installation

A

Mounting the Accessory Module

Step 9: Using (2) of the included Philips head screws, screw the Accessory Module to the water heater
jacket, as shown in Figure 9.

Apply the Necessary Labels

Step 10: Apply both the wiring diagram and diagnostic labels. These labels should be applied to the
water heater jacket near the Accessory Module. This is shown in Figure 10.

Water Heater

jacket

Accessory

Module

Philips head

screwdriver

Figure 9

ccessory Module

Apply the Wiring

Diagram and

Diagnostic labels

Water Heater

Figure 10

-17-

Accessory Module Installation

Remove the Accessory Module Cover

Step 11: Using a Philips head screwdriver, loosen both screws on the Accessory Module cover, as
shown in Figure 11. The cover screws are permanently retained and cannot be completely removed.
Retain the cover for later use.

Accessory

Module base

Accessory

Module base

Philips head

screwdriver

Wiring Diagram

label

Prepare the Plug-in Transformer for Assembly

Step 12: Loosen the (2) slotted sc rews on the transfo rmer. These screws are permanently re tained and
cannot be completely removed. This is shown in Figure 12.

Slotted head

screwdriver

Accessory Module

cover screws

Figure 11

Plug-in

Transformer

Figure 12

Slotted screws

-18-

Accessory Module Installation

Assemble the Transformer and its Wire Harness

Step 13: Take one end of the transformer wire harness and slide each fork terminal under one of the
screws. This is shown in Figure 13.

Plug-in

Transformer

Transformer

slotted screws

Transformer

wire harness

Figure 13

NOTICE

If the Transformer wire harness is not of sufficient length, move the nearest electrical box to
within reaching distance.

Connect the Transformer and its Wire Harness

Step 14: Tighten both screws on the transformer down, as shown in Figure 14.

Slotted head

screwdriver

Transformer

slotted screws

Plug-in

Transformer

Transformer

wire harness

Figure 14

-19-

Accessory Module Installation

Prepare to Connect the Transformer Wire Harness to the Accessory Module

Step 15: Loosen the (2) Philips head screws on the Accessory Module, labeled “R1” and “C1.” This is
shown in Figure 15.

Philips head

screwdriver

Accessory

Module

Figure 15

Insert the Transformer Wire Harness into the Accessory Module

Step 16: Insert each wire stripped end of the Transformer wire harness under the screws labeled “R1”
and “C1.” This is shown in Figure 16.

Transformer

Wire Harness

Accessory

Module

Figure 16

-20-

Accessory Module Installation

Connect the Transformer Wire Harness and the Accessory Module

Step 17: Tighten both screws, “R1” and “C1,” while holding the Transformer wire harness in place, as
shown in Figure 17.

Accessory

Module

Philips head

screwdriver

Transformer

Wire Harness

Figure 17

Connect Accessory Module to WV4460 Wire Harness

Step 18: If the water heater gas control has an intermittent pilot (WV4460 gas control), loosen the (3)
screws on the Accessory Module labeled “D/1,” “R/2,” and “C/3.” This is shown in Figure 18. If the water
heater has a standing pilot, proceed to Step 25.

Philips head

screwdriver

Accessory

Module

Figure 18

-21-

Accessory Module Installation

Assemble the WV4460 Wire Harness and Accessory Module

Step 19: Insert the red wire, from the WV4460 wire harness, under the screw labeled “D/1.” This is shown
in Figure 19.

Accessory

Module

WV4460 Wire

Harness Red Wire

Figure 19

Connect the WV4460 Wire Harness and Accessory Module

Step 20: Tighten the screw labeled “D/1,” as shown in Figure 20.

Philips head

screwdriver

Accessory

Module

WV4460 Wire

Harness Red Wire

Figure 20

-22-

Accessory Module Installation

Assemble the WV4460 Wire Harness and Accessory Module – cont’d

Step 21: Insert the black wire, from the WV4460 wire harness, under the screw labeled “R/2.” This is
shown in Figure 21.

Accessory

Module

WV4460 Wire

Harness Red Wire

Harness Black Wire

Connect the WV4460 Wire Harness and Accessory Module – cont’d

Step 22: Tighten the screw labeled “R/2,” as shown in Figure 22.

WV4460 Wire

Harness Red Wire

Philips head

screwdriver

Figure 21

WV4460 Wire

Accessory

Module

WV4460 Wire

Harness Black Wire

Figure 22

-23-