Bradford-White Corp 9kW, 900kW User Manual

Commercial Electric

Water Heaters

9kW – 900kW Input Models

CHP-I&S-01

INSTALLATION AND SERVICE MANUAL

1

If the information in this
manual is not followed exactly, a fire or
explosion may result causing property
damage, personal injury or loss of life

.

Do not store or use gasoline or other
flammable vapors and liquids in the vicinity of
this or any other appliance.

USE THIS APPLIANCE IF ANY
PART HAS BEEN UNDER WATER. THE
POSSIBLE DAMAGE TO A FLOODED
APPLIANCE CAN BE EXTENSIVE AND
PRESENT NUMEROUS SAFETY HAZARDS.
ANY APPLIANCE THAT HAS BEEN UNDER
WATER MUST BE REPLACED.

Installation and service must be performed by
Qualified Service Personnel Only

.

Factory warranty (shipped with unit) does not
apply to units improperly installed or improperly
operated.

Experience has shown that improper installation
or system design, rather than faulty equipment, is
the cause of most operating problems.

Excessive water hardness causing a lime/scale
build-up in the heater and/or on the immersion
heating elements is not the fault of the equipment
and is not covered under the manufacturer’s
warranty. (See Water Treatment and Water
Chemistry)

Do not energize electrical system before heater
is completely filled with water.

Damage caused
to the immersion heating elements by dry fire is
not covered under the manufacturer’s warranty.
Follow start up procedure in the manual.
Water heater corrosion and component failure
caused by air-borne chemical vapors is not
covered under the manufacturer’s warranty.
Corrosion damage caused by current leakage due
to improper grounding of electrical systems or
electronic components to the storage tank and
related piping is not covered by the
manufacturer’s warranty. Under no circumstance
will the manufacturer be liable for consequential
damages resulting from the installation or use of
this equipment. Correct installation procedure
and local codes must be adhered to.

This manual supplies information for the
installation, operation and servicing of the
appliance. It is strongly recommended that this
manual be reviewed completely before
proceeding with an installation. Upon receiving
equipment, check for signs of shipping damage.
Pay particular attention to parts accompanying
the water heater, which may show signs of being
hit or otherwise being mishandled. Verify total
number of pieces shown on packing slip with
those actually received. In case there is damage
or a shortage, immediately notify carrier.

CHECKING EQUIPMENT

WARNING:

NOTE: Retain this manual for future reference.

WARNING:

Improper Installation, Adjustment,
Alteration, Service or Maintenance

can cause injury or property damage. Refer

to this manual. For assistance or additional

information consult a qualified installer,

service agency or the electric utility.

SPECIAL INSTRUCTIONS

TO OWNER

WARRANTY

DO NOT

2

CONTENTS

Star

t-Up Procedure

Filling the Water Heater . . . . . . . . .22

Start-Up Checks . . . . . . . . . . . . . . .23

Shutdown Procedure . . . . . . . . . . . .24

Maintenance

T&P Relief Valve . . . . . . . . . . . . . .24

Water Chemistry . . . . . . . . . . . . . . .25

Flushing the Tank . . . . . . . . . . . . . .25

Sediment Removal . . . . . . . . . . . . .25

Scale Removal - Elements . . . . . . .25

T

rouble Shooting

Not Enough Hot Water . . . . . . . . . .27

Water Is Too Hot . . . . . . . . . . . . . .27

Water Heater Sounds . . . . . . . . . . .27

Leakage . . . . . . . . . . . . . . . . . . . . .27

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . .1

Safety Warnings . . . . . . . . . . . . . . . .1

Checking the Equipment . . . . . . . . . .1

Codes . . . . . . . . . . . . . . . . . . . . . . . .4

Installation Requirements

Location . . . . . . . . . . . . . . . . . . . . . .4

Drain Pan Requirements . . . . . . . . . .5

Clearances . . . . . . . . . . . . . . . . . . . .6

Mounting . . . . . . . . . . . . . . . . . . . . .7

Water Connections . . . . . . . . . . . . . .7

Tank Construction . . . . . . . . . . . . . .8

Relief Valve . . . . . . . . . . . . . . . . . . .8

Thermal Expansion . . . . . . . . . . . . .8

Cathodic Protection . . . . . . . . . . . . .9

Electrical Ser

vice

Electrical Connection . . . . . . . . . . .9

Wire Sizing . . . . . . . . . . . . . . . . . . .9

Fusing . . . . . . . . . . . . . . . . . . . . . .9

Electrical Connection . . . . . . . . . . . .9

Jacket Assembly . . . . . . . . . . . . . . .10

Standard and Optional Controls . . .10

Components and Contr

ols

Terminal Block . . . . . . . . . . . . . . . .11

Fuses and Fuse Blocks . . . . . . . . . .12

Contactors . . . . . . . . . . . . . . . . . . .12

Transformer . . . . . . . . . . . . . . . . . .12

Immersion Thermostat . . . . . . . . . .13

Temperature Regulation . . . . . . . . .13

Risk of Scald Warnings . . . . . . . . .14

Temperature Control Sequencer . . .14

Display . . . . . . . . . . . . . . . . . . . . . .16

Temperature Adjustment . . . . . . . . .17

Error Messages . . . . . . . . . . . . . . . .18

Temperature Limit Control . . . . . . .18

Immersion Heating Elements . . . . .19

Safety Door Lock . . . . . . . . . . . . . .19

Low Water Cut-Off . . . . . . . . . . . . .20

Low Water Pressure Switch . . . . . .20

High Water Pressure Switch . . . . . .20

Manual Limiting Switches . . . . . . .20

Time Clock . . . . . . . . . . . . . . . . . . .21

Pilot Lights . . . . . . . . . . . . . . . . . . .21

Alarm Bell . . . . . . . . . . . . . . . . . . .21

3

FIG. 2 Front View Vertical Square Models

FIG. 1 Front View Vertical Round Models

FIG. 3 Front View Horizontal Models

To minimize the possibility
of serious personal injury, fire or damage to
your appliance, never violate the following
safety rules.

1. Always keep the area around your

appliance free of combustible
materials, gasoline, and other
flammable liquids and vapors.

2. Never cover your appliance, lean

anything against it, store trash or
debris near it, stand on it or in any
way block the access to your
appliance.

Be sure to turn off power
when working on or near the electrical
system of the water heater. Never touch
electrical components with wet hands or
when standing in water. When replacing
fuses, always use the correct size for the
circuit. Do not test electrical system before
the water heater is completely filled with
water. Follow the start-up procedure.

Consult and follow
local Electrical Codes, Building and Fire
Regulations and other Safety Codes that
apply to this installation. Consult local
codes officials and electric utility company
to authorize and inspect all field installed
electrical connections.

The equipment shall be installed in accordance
with those installation regulations in force in the
local area where the installation is to be made.

These shall be carefully followed in all cases.
Authorities having jurisdiction shall be consulted
before installations are made. In the absence of
such requirements, the installation shall conform
to the latest edition of the National Electrical
Code, NFPA 70. When the appliance is installed
in Canada, it must conform to the CAE C22.1,
Canadian Electrical Code, Part 1 and/or local
Electrical Codes.

This complete appliance is design certified and
Listed by Underwriters Laboratories as a
commercial storage electric water heater. This
water heater bears the UL certification for the
United States as tested under the Standard for
Electric Booster and Commercial Storage Tank
Water Heaters, UL1453 and C-UL in Canada as
tested under the Standard for Construction and Test
of Electric Storage Tank Water Heaters,
CAN/CSA-C22.2 No. 110-M90. All water heater
storage tanks conform to the latest edition of the
ASME Boiler and Pressure Vessel Code, Section IV.

1. Locate the appliance so that if water
connections should leak, water damage
will not occur. When such locations
cannot be avoided, it is recommended that
a suitable drain pan, adequately drained,
be installed under the unit. Under no
circumstances is the manufacturer to be
held responsible for water damage in
connection with this unit, or any of its
components.

2. Insure that the appliance is located near
an acceptable drain so that the vessel can
be properly drained when performing
service or maintenance. The drain must
also provide adequate drainage in the
event of leakage the tank or related
piping. The drain must prevent water
damage to the adjacent area and lower
floors of the structure.

4

INSTALLATION PROCEDURE

LOCATION OF UNIT

OWNER WARNING

IMPORTANT:



CAUTION:

WARNING:

CODES

APPROVALS

The information contained in this manual
is intended for use by qualified professional
installers, service technicians or the electric
utility. Consult your local expert for
proper installation or service procedures.

3. The appliance must be installed so that
the electrical components are protected
from water (dripping, spraying, etc.)
during appliance operation and service
(replacing of fuses, elements, etc.)

4. Appliances located in a garage or parking
structure shall be installed so that the
jacket and all piping shall be located or
protected so that it is not subject to
physical damage by a moving vehicle.

5. The appliance must be installed on a level
floor. Shim the base as necessary if
leveling is required.

6. The floor on which the appliance is
installed must be capable of supporting
the total weight of the water heater when
completely filled with water.
Combustible floor locations may be used.
Maintain required clearances from
combustible surfaces.

7. The appliance must not be installed on
carpet.

8. The appliance must be installed indoors
where it is protected from exposure to
wind, rain and weather.

9. Locate the appliance as close as possible
to the point of major hot water usage, the
water piping and branch electrical circuit
wiring.

10. Insulate water piping to control heat loss
and possible condensation.

11. The appliance must be located in an area
that is not subject to freezing. The
ambient temperature of the space where
the appliance is installed must not go
below 32° F (0° C) or above 104° F (40° C).

The lower pan of the horizontal water heater
jacket or vertical square water heater jacket is
specially constructed to function as a drain pan.
A water discharge opening is located in either end
of the pan. The discharge opening(s) used must
be piped to a suitable floor drain. If only one
discharge opening in the jacket pan is piped to a
floor drain, the unused opening must be plugged.
This jacket pan provides an extra margin of
protection against water damage on vertical
square or horizontally constructed models.

5

Drain Pan on Horizontal Models

and Vertical Square Models

1250 Gallons and Larger

CAUTION:

This water heater, as well as all water
heaters will eventually leak. Installation of
the water heater should be accomplished in
such a manner that if the tank, piping or
any connections should leak, the flow of
water will not cause damage to the
structure. For this reason, it is not
advisable to install the water heater in an
attic or upper floor. When such locations
can not be avoided, a suitable drain pan
must be installed under the water heater.
Drain pans may be fabricated or
purchased from your plumbing wholesaler.
The drain pan must be piped to an
adequate drain. Under no circumstances is
the manufacturer to be held liable for any
water damage in connection with this
water heater.

Right Side - 6" (15cm) (24" (0.61m) for high kW vertical square models with an

additional control panel on right side)

Rear - 0"
Left Side - 0"
Front - 36" (0.91m) for service access to controls and heating elements
Top - 12" (30cm) for service access to electrical service, water connections and piping
Water Pipes - 1" (25.4mm)

6

FIG. 5 Clearances from Combustible Construction

12"

36"

6"

FIG. 4 Clearances from Combustible Construction

CLEARANCES FROM COMBUSTIBLE CONSTRUCTION

6"

12"

FIG. 6 Clearances from Combustible Construction

TABLE A

CLEARANCES FROM COMBUSTIBLE CONSTRUCTION

12"

6"

36"

7

Maintain minimum specified clearances for
adequate operation. All installations must allow
sufficient space for servicing the electrical
components, water pipe connections, piping and
other auxiliary equipment, as well as the appliance.

Multiple appliances may be installed in a modular
water heater installation. Multiple appliances
may be installed side by side with minimum
clearance between the sides of adjacent
appliances because no service access is required
from the sides on most models. Note that high
kW input vertical square water heaters may have
an additional control access panel located on the
right side of the jacket requiring an additional
service access from the right side.

The water heater should be mounted to the floor
following applicable architectural and local code
requirements or accepted standards for the specific
site and model purchased. In areas prone to seismic
activity, it is recommended that the water heater be
mounted to the floor according to recommended
procedures for the site. In some geographic areas,
additional strapping or braces may be required,
consult local codes for specific requirements.
Proper mounting will help to make the water heater
less susceptible to seismic damage.

WATER CONNECTIONS

HANDHOLE
CLEANOUT

DRAIN

HOT WATER
OUTLET

TEMPERATURE & PRESSURE
RELIEF VALVE

COLD WATER
INLET

FIG. 7 Water Connections- Vertical Round Models

TEMPERATURE & PRESSURE
RELIEF VALVE

HOT WATER
OUTLET

DRAIN PAN
CONNECTION

COLD WATER
INLET

FIG. 8 Water Connections- Vertical Square Models

MOUNTING

WATER CONNECTIONS

TEMPERATURE & PRESSURE
RELIEF VALVE

HOT WATER
OUTLET

COLD WATER
INLET

MANWAY (OPTIONAL)

DRAIN

FIG. 9 Water Connections- Horizontal Models

Before making any
connections to the cold water inlet or hot
water outlet, insure that all piping is clean and
free of material or scale. This can usually be
accomplished by “blowing out the pipe.” Any
foreign material or scale entering the water
heater can adversely affect operation and
performance.

Inlet and Outlet Connections

For ease of service, install unions on the cold
water inlet and hot water outlet of the water
heater. The cold water inlet connection is located
on the lower right side of the water heater. A
manual shutoff valve should be installed
upstream on the cold water source as an isolation
device. The hot water outlet connection is located
on the top center of the water heater. A manual
shutoff valve should be installed downstream on
the hot water outlet source as an isolation device
in case the water heater must be disconnected
from the system.

This appliance uses a glass lined steel tank to
store the heated water for use. The storage tank
is constructed in accordance with the ASME
Boiler and Pressure Vessel Code requirements,
stamped and registered with the National Board
of Boiler and Pressure Vessel Inspectors. The
tank is furnished with threaded connections for
cold water inlet, hot water outlet, a relief valve
and a drain connection. The storage tank has a
hand hole for ease of inspection, cleanout and
service. An optional manhole may be specified
for greater ease of inspection. The interior of the
storage tank is glass lined and fired to 1600˚F

(871˚C) to insure a molecular fusing of glass and
steel to protect the steel base metal against
corrosion . A magnesium anode(s) is standard to
help prevent dissipation of the tank material by
electrolytic action.

This water heater is supplied with a temperature
and pressure relief valve(s) sized in accordance
with ASME Boiler and Pressure Vessel Code,
Section IV. Some water heaters may be supplied
with an optional pressure only relief valve. The
relief valve(s) is installed in the vertical position
and mounted in the tapping provided in the
storage tank. No valve is to be placed between
the relief valve and the water heater. To prevent
water damage, the discharge from the relief valve
must be piped to a suitable floor drain for
disposal when relief occurs. No reducing
couplings or other restrictions shall be installed in
the discharge line. The discharge line shall allow
complete drainage of the valve and line. Relief
valves should be manually operated at least once
a year. A relief valve that fails to completely
reseat and continues to discharge water must be
immediately replaced with a new, properly sized,
temperature and pressure relief valve.

A relief valve that discharges periodically may be
due to thermal expansion in a closed system. A
water heater installed in a closed system, such as
one with a backflow preventer or check valve
installed in the cold water supply, shall be
provided with means to control expansion.
Contact the water supplier or local plumbing
inspector on how to correct this situation.

DO NOT plug or cap the relief valve.

8

STORAGE TANK

NOTE: 

When using copper tubing,
solder tubing to an adapter before attaching
to the threaded nipple connection provided
on the water heater. Soldering directly to the
threaded connection may harm a lining in the
nipple or damage the tank lining.

NOTE: 

RELIEF VALVE

Avoid contact with hot
discharge water. Insure that no one is in
front of or around the relief valve discharge
line. Make sure that the extremely hot
water manually discharged from the relief
valve will not cause bodily injury or
property damage.

CAUTION:

THERMAL EXPANSION OF WATER

discharge!

Hydrogen gas can be produced in a hot water
system that has not been used for a long period of
time (generally two weeks or more). Hydrogen
gas is extremely flammable. To prevent the
possibility of injury under these conditions, we
recommend the hot water faucet be open for
several minutes at a sink close to the water heater
before you use any electrical appliance which is
connected to the hot water system. If hydrogen is
present, there will be an unusual sound such as air
escaping through the pipe as the hot water begins
to flow. There should be no smoking or open
flames near the faucet at the time it is open.

All installation procedures involving electric
power connection should only be performed by a
trained, certified electrician.

9

HINGED DOOR TO
ELECTRIC CONTROL
COMPARTMENT

ELECTRIC ACCESS

FIG. 11 Electric Power Connections –

Electrical Control Panel – Square Models

HINGED DOOR
TO ELECTRICAL
COMPARTMENT

ELECTRIC
ACCESS

FIG. 10 Electric Power Connections –

Electrical Control Panel – Round Models

The appliance, when installed, must be
electrically grounded in accordance with the
requirements of the authority having
jurisdiction or in the absence of such
requirements, with the latest edition of the
National Electrical Code, NFPA No. 70.
When the appliance is installed in Canada, it
must conform to the CAE C22.1, Canadian
Electrical Code, Part 1 and/or local Electrical Codes.

1. Use copper conductors only. All wiring
between the appliance and field installed devices
shall be made with copper wire suitable for at
least 75° C (167° F) temperature rating. If the
wiring from an old water heater installation was
aluminum, replace the old wire with copper wire.

2. The factory internal wiring is attached to a
terminal block inside the unit. The branch
circuit is connected to the terminal block
through an opening provided on the top of the
water heater electrical access panel.

3. Line voltage wire exterior to the appliance
must be enclosed in approved conduit or
approved metal clad cable.

4. To avoid serious damage,

DO NOT energize
the appliance until the system is full of
water

. Ensure that all air is removed from the

storage tank and piping before beginning

CATHODIC PROTECTION

ELECTRICAL CONNECTIONS

WATER HEATER IS
EQUIPPED FOR OPERATION ON ONE
VOLTAGE ONLY.

Check the rating plate on
the front of the control panel access for the
correct voltage and phase.

DO NOT use this

water heater with any other voltage other than
the voltage specified on the rating plate.
Failure to use the correct voltage can cause
problems that can result in death, serious
bodily injury or property damage.

DO NOT CONNECT THE
WATER HEATER TO AN IMPROPER
SOURCE OF ELECTRICITY!

CAUTION:

WARNING: