Bradford White Corp Water Heater 238 48248 00 User Manual

PE MODEL WATER HEATERS  
SUPPLEMENT TO INSTRUCTION MANUAL  
P/N 238-44219-00  
(Replaces pg. 2 in instruction manual.)  
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 Programmable Flammable Vapor Ignition Resistant Gas  
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 when 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 maintenance section in the back of this  
manual.  
Special Flammable Vapor Ignition Resistant System:  
This water heater is equipped with a Flammable Vapor Ignition Resistant System. In  
the event of improper usage or storage of gasoline or other flammable materials in the  
location where the water heater is installed, the technology will resist ignition of the  
flammable vapors outside the confines of the water heater.  
The Flammable Vapor Ignition Resistant System Features:  
Advanced Flame Arrestor Design  
Re-settable Thermal Switch to prevent burner/pilot operation with restricted  
airflow  
Flammable Vapor Sensor  
Automatic Ignition Device  
Sight Window to observe operation of pilot and burner  
FOR YOUR SAFETY: Activation of the Flammable Vapor Ignition Resistant System  
occurs when flammable vapors are drawn into the water heater and are combusted. If  
flammable vapors are detected:  
Do not try to light any appliance.  
Do not touch any electrical switch; do not use any phone in your building.  
Leave the premises and immediately call the fire department from a  
neighbor’s phone. Follow the fire department’s instructions.  
Once the flammable vapor has been evacuated, contact your plumbing professional or  
the manufacturer for further instructions. Replacement of a Flammable Vapor Ignition  
Resistant System equipped water heater due to a flammable vapor shutdown is not  
covered under the terms of the limited warranty.  
238-48248-00A 10/09  
 
Lighting and Shutdown Instructions  
(Replaces pg. 18 in instruction manual.)  
FOR YOUR SAFETY READ BEFORE  
WARNING: If you do not follow these instructions exactly, a fire or explosion  
may result causing property damage, personal injury or loss of life.  
A. This appliance is equipped with an ignition device  
which automatically lights the pilot. Do not try  
to light the pilot by hand.  
If you cannot reach your gas supplier, call the  
fire department.  
C. Use only your hand to slide the gas control switch.  
Never use tools. If the switch cannot be moved by  
hand, do not try to repair it, call a service  
technician. Force or attempted repair may result in  
a fire or  
B. BEFORE OPERATING smell all around the  
ance area for gas. Be sure to smell next to the  
floor because some gas is heavier than air and  
will settle to the  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified  
technician to inspect the appliance and to replace  
any part of the control system and any gas  
control which has been under water.  
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's phone. Follow the gas supplier's  
instructions  
OPERATING INSTRUCTIONS  
1. STOP! Read the safety information above.  
6. Wait five (5) minutes to clear out any gas.  
Smell for gas, including near the floor.  
If you the smell gas, STOP! Follow  
"B" in the safety information at left on  
this label. If you don't smell gas, go to  
the next step.  
2. Turn off all electric power to the  
appliance  
3. Set the thermostat to lowest setting.  
4. This appliance is equipped with an  
ignition device which  
lights the pilot. Do not try to light  
the pilot by hand.  
7. Slide the switch on the right side of the  
gas valve up to the "ON" position.  
SWITCH SHOWN  
IN "ON" POSITION  
8. Set thermostat to desired setting.  
STATUS  
ON  
Honeywell  
9. Turn on all electric power to the appliance.  
VERY  
OFF  
HOT  
C
B
A
HOT  
10. If the appliance will not operate, follow  
the instructions "To Turn Off Gas To  
Appliance" and call your  
LOW  
THERMOSTAT  
DIAL  
technician or gas  
5. Slide the switch on the right side of the  
gas valve down to the "OFF" position  
TO TURN OFF GAS TO APPLIANCE  
1. Turn off all electric power to the  
appliance if service is to be  
3. Slide the switch on the right side of the  
gas valve down to the "OFF" position.  
2. Set the thermostat to the lowest setting.  
3
 
THERMOSTAT ADJUSTMENT  
(Replaces pg. 19 in instruction manual.)  
The thermostat dial is adjusted to its lowest setting when shipped from the factory.  
When adjusting the thermostat, it should be remembered that lower temperature  
settings are more energy efficient. To adjust the thermostat, turn the dial clockwise until  
the minimum acceptable temperature is set. It is suggested that the starting point  
setting not exceed the 120°F (49°C) or “HOT” setting on the thermostat.  
SWITCH SHOWN  
IN "ON" POSITION  
STATUS  
ON  
Honeywell  
OFF  
C
HOT  
THERMOSTAT  
DIAL  
Figure 2. Gas Valve.  
The thermostat dial is set to its lowest temperature setting when shipped from the  
factory. Remember that lower temperature settings are more energy efficient. Adjust  
the temperature by turning the thermostat dial. It is suggested that the starting point  
setting not be greater than the “Hot” mark on the thermostat dial (approximately 120°F  
[48.9°C]). Rotate the thermostat dial counter-clockwise  
temperature setting. Rotate the thermostat dial clockwise  
to decrease the  
to increase the  
temperature setting. Adjust the dial until the minimum acceptable temperature is  
achieved.  
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.  
Note: This 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.  
Note: 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.  
4
 
BURNER FLAME CHECK  
(Replaces pg. 22 in instruction manual.)  
Steel Burner: These models are equipped with self adjusting air mixture and do not  
have an adjustable air shutter (See Figure 3). At periodic intervals, a visual check of  
the main burner and pilot flames should be made to determine  
if they are burning properly. The main burner flame should light smoothly from the  
pilot.  
Figure 3. Burner and Pilot Assembly Used.  
5
 
INSTALLATION FOR POTABLE WATER  
(Replaces pg. 28 in instruction manual.)  
Figure 4  
6
 
PARTS LIST DRAWING  
(Replaces pg. 29 in instruction manual.)  
1
2
5
6
3
7
8
9
4
10  
11  
17  
18  
19  
20  
14  
15  
12  
13  
21  
16  
22  
23  
27  
25  
24  
28  
26  
15A  
Figure 5  
7
 
PARTS LIST  
(Replaces pg. 30 in instruction manual.)  
PART NAME AND DESCRIPTION  
1. Draft hood  
15A. Resettable Thermal Switch  
16. Left side inner door  
17. Accessory Module  
18. Junction box wire harness  
19. Thermal well  
2. Setback Control Junction Box Assembly  
3. Jacket head  
4. Jacket  
5. Heat trap (outlet)  
6. Anode Outlet Device  
7. Heat trap (inlet)  
8. Baffle  
20. Gas control  
21. FV sensor / RTS wire harness  
22. FV sensor clip  
9. Diptube  
23. FV sensor  
10. T&P valve  
24. Outer door  
11. Tank  
25. Burner  
12. Combustion chamber  
13. Pedestal base  
14. Drain valve  
26. Orifice  
27. Pilot assembly  
28. Main burner feedline  
15. Right side inner door  
8
 
THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION  
OF:  
GAS WATER HEATERS SUITABLE FOR WATER (POTABLE)  
HEATING AND SPACE HEATING  
(Replaces pg. 31 in instruction manual.)  
All piping components connected to this water heater for space heating applications  
must be suitable for use with potable water. In Massachusetts, space heating piping  
length must not exceed 50 feet.  
1. Toxic chemicals, such as those used for boiler treatment, must not be introduced  
into potable water used for space heating.  
2. This water heater must not be connected to an existing heating system or  
component(s) previously used with a non-potable water heating appliance.  
3. When the system requires water for space heating at temperatures higher than  
required for other means, such as an ASSE approved mixing valve must be  
installed to temper the water for those uses in order to reduce the scald hazard  
potential.  
Please refer to Figure 6 for suggested piping arrangements.  
Figure 6  
9
 
(In addition to the instruction manual.)  
Do not block or in any way restrict jacket air inlet slots  
located at the bottom front of the water heater.  
Do not operate water heater with jumpered, altered,  
loosely tightened or absent controls and/or components.  
Do not operate water heater with replacement controls  
and/or components which are not exact duplicates of  
original equipment.  
Thoroughly inspect and replace, (as needed) burner inner  
door gasket and/or sight window gasket any time burner  
inner door is removed or disturbed.  
Replace water heater if involved in flammable vapor  
incident.  
This water heater is equipped with a flammable vapor  
sensor. If the sensor is exposed to flammable vapor, the  
water heater control will shut down the water heater and  
display a code of 7 flashes and then a 3 second pause.  
If a 7 flash error code is present, check to see if flammable  
vapor is present in the area. If flammable vapor is  
present or suspected in the area, immediately leave the  
area and contact a service professional.  
Do not try to light any appliance.  
Do not touch any electric switch; do not use any  
phone in your building.  
If you are certain there is no flammable vapor present,  
check the flammable vapor sensor to make certain  
it has not become disconnected from the control.  
See the instruction manual for troubleshooting.  
CAUTION  
Protect the Setback Control and Accessory Module from solder and falling  
water during installation.  
10  
 
Electrical Connections  
(In addition to the instruction manual.)  
All electrical wiring and connections must be in accordance with the National Electric  
Code ANSI/NFPA No. 70-Latest Edition, or the Canadian Electrical Code C22.1-Latest  
Edition, and any local codes which may apply. The water heater must be electrically  
grounded.  
If a flexible line cord and plug is permitted by local code, then provide a (3) three wire  
grounding type receptacle within 6 ft (1.9 m) of the water heater and use the flexible  
cord provided. Do not plug the line cord into a receptacle that can have its power  
supply interrupted by a switch that is used to turn on and off lights.  
Turn off the water heater gas control and disconnect power to the water heater and  
Accessory Module. If wiring in conduit is required, cut the flexible line cord at least 6 in.  
(15.2 cm) from the bushing. Unscrew and remove the Setback Control Junction Box  
Assembly lid. Pull the cord into the junction box assembly housing. Cut the three  
wires from the line cord at the bushing inside of the housing. Enlarge the hole in the  
back of the junction box assembly to receive a 1” electrical conduit connector. Wire the  
power supply into the circuit at the appropriate locations.  
Replace the Setback Control Junction Box Assembly cover and re-install the screws  
previously removed. Connect power to the water heater and Accessory. Turn the  
water heater gas control back on.  
CAUTION  
Turn off or disconnect the electrical power supply to the water heater before servicing.  
Label all wires prior to disconnection when servicing controls. Wiring errors can cause  
improper and dangerous operation. Verify proper operation after servicing.  
11  
 
Wiring Diagram  
(In addition to the instruction manual.)  
GAS  
PILO  
Honeywell  
VERY  
HOT  
C
B
A
HOT  
LOW  
W
W
BK  
R
FLAMMABL  
VAPOR SENSOR  
B
B
B
R
B
B
B
G
B
G
W
Y
W
B
WATER  
TEMPERATURE  
SENSO  
POWER  
W
B
B
W
RE-  
THERMAL  
W
B
G
ACCESSOR  
MODUL  
G
W
B
R
Y
SETBACK  
JUNCTION  
R
W
PLUG-IN  
TRANSFORME  
B
B
W
A
A
BK  
W
SETBACK  
ELECTRICAL RATING  
115 VOLTS 60HZ LESS THAN 12 AMPS  
IF ANY OF THE ORIGINAL WIRES SUPPLIED WITH THE APPLIANCE MUST BE  
REPLACED, IT MUST BE REPLACED WITH APPLIANCE WIRE MATERIAL WITH A  
MINIMUM TEMPERATURE RATING OF 105°C AND A MINIMUM SIZE OF NO. 18 AWG.  
12  
 
TROUBLESHOOTING  
(In addition to instruction manual.)  
LED Status  
None (LED not on  
or flashing)  
Control Status  
Probable Cause  
Electrical power not  
present  
1. Control power switch in "OFF" position  
2. Supply voltage interrupted  
One short flash  
every four  
Stand-by mode,  
Thermostat is satisfied (no  
faults)  
Temperature demand is satisfied (no call for  
heat)  
seconds  
Alternates bright  
and dim  
Thermostat calling for heat Tank temperature below setpoint of  
(no fault)  
thermostat  
(heartbeat)  
1. Unstable pilot  
2. Pilot tube block or restricted  
3. Oxidation build-up on pilot electrode  
4. Wire damage to pilot assembly or bad  
connection at gas valve  
Short flash once Weak pilot signal on last  
every second  
call for heat  
Two flashes,  
three second  
pause  
Relay not working  
Relay not working  
Faulty relay  
Faulty relay  
Three flashes,  
three second  
pause  
Four flashes,  
three second  
pause  
Excessive tank  
temperature, system must  
be reset  
1. Thermal well sensor out of calibration  
2. Faulty gas valve  
Five flashes,  
three second  
pause  
False pilot flame present Pilot valve stuck in open position  
1. Unstable pilot  
2. Pilot tube block or restricted  
system resets after (5) 3. Oxidation build-up on pilot electrode  
Six flashes, one  
flash, three  
second pause  
(Soft Lockout)  
Failed to light pilot,  
minutes  
4. Wire damage to pilot assembly or bad  
connection at gas valve  
13  
 
Troubleshooting continued-  
LED Status  
Control Status  
Probable Cause  
Six flashes, two Relay not working properly  
flashes, three  
second pause  
(Soft Lockout)  
during burner operation,  
system auto resets after  
(5) minutes  
Faulty relay  
1. Unstable pilot  
Six flashes, three  
flashes, three  
second pause  
(Soft Lockout)  
2. Pilot tube block or restricted  
3. Oxidation build-up on pilot electrode  
4. Wire damage to pilot assembly or bad  
connection at gas valve  
Pilot flame extinguished,  
system auto resets after  
(5) minutes  
5. Insufficient combustion air  
Six flashes, four Undesired false pilot flame  
flashes, three  
second pause  
sensed, system auto  
resets  
Pilot valve stuck in open position  
1. Flammable vapor present  
Flammable vapor sensor or 2. Flammable vapor sensor exposed to  
resettable thermal switch excessive moisture  
Seven flashes,  
three second  
pause  
fault detected, see  
warning label  
3. Flammable vapor sensor exposed to  
extreme ambient temperature  
4. Resettable thermal switch open  
1. Flammable vapor sensor out of  
specification  
Eight flashes, one Flammable vapor sensor  
flash, three  
out of specification,  
possible short  
2. Possible short in flammable vapor sensor  
or resettable thermal switch wiring  
second pause  
1. Damage to thermal well wires  
2. Thermal well sensor resistance out of  
range  
Eight flashes,  
three flashes,  
three second  
pause  
Thermal well sensor  
damaged or unplugged or  
gas valve electronics fault  
detected  
3. Replace thermal well  
4. Verify control is not wet or physically  
damaged  
5. Reset control on/off switch  
6. Replace electronic module if 8-3 error  
persists  
1. Verify control is not wet or physically  
damaged  
Eight flashes, four  
flashes, three  
Gas valve fault detected  
2. Reset control on/off switch  
3. Replace gas control if 8-4 error persists  
second pause  
Fault  
Probable Cause  
1. Insufficient combustion air  
2. Flammable vapors present  
Resettable Thermal Switch Tripped (Open)  
14  
 
Troubleshooting continued-  
Control Sequence of Operation  
Start up Sequence  
Upon powering up, the control checks for the presence of the flammable vapors, if the  
resistance is in the expected range the control will begin normal operation after 5 to 8  
seconds.  
Normal Heating Sequence  
1. The thermostat senses a call for heat.  
2. The control checks that the relay contacts are open.  
3. The control sends power to the relay, which then closes the relay contacts.  
4. The control starts the ignition process by providing a spark at the pilot electrode  
and allowing gas to flow to the pilot.  
5. When the pilot is lit, the gas control senses the pilot flame and opens the main gas  
valve.  
6. The main burner is lit.  
7. The main burner continues to operate until the thermostat is satisfied.  
8. When the thermostat is satisfied, the main and pilot gas valves close.  
9. The relay contacts remain closed for a short period before opening.  
The water heater remains in the stand-by mode until the next call for heat.  
15  
 
Notes  
16  
 

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