Bradford White VR-150-(kW) Manual

INSTALLATION AND SERVICE MANUAL
Electric Power Water Heater
12kW – 162kW
NOTE: retain this manual for future reference
Installation and service must be performed by Qualified Service Personnel Only.
WARRANTY:
Factory warranty (available on web site) 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 procedures
and local codes must be adhered to.
SPECIAL INSTRUCTIONS TO OWNER:
WARNING:
Improper Installation,Adjustment, Alteration, ServiceorMaintenance 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
CHECKING EQUIPMENT:
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. Incase there is damage or a shortage, immediately notify carrier.
DO NOT USETHIS APPLIANCE IF ANYPART HAS BEEN UNDER WATER. THE POSSIBLE
DAMAGE TO A FLOODED APPLIANCE CAN BE EXTENSIVE AND PRESENT NUMEROUS
SAFETY HAZARDS. ANY APPLIANCE THAT HASBEENUNDERWATERMUSTBE REPLACED.
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WARNING A
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.
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CONTENTS
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
ReliefValve 8
Thermal Expansion 8
Cathodic Protection 9
Electrical Service
Electrical Connection 9
Wire Sizing 9
Fusing 9
Electrical Connection 9
Jacket Assembly 10
Standard and Optional Controls 10
Components and Controls
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
Start-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
Trouble Shooting
Not Enough Hot Water.................27
Water Is Too Hot...........................27
Water Heater Sounds....................27
Leakage 27
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OWNER WARNING:
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.
IMPORTANT:
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.
CAUTION:
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.
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WARNING
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 material, 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 any
way block the access to your appliance.
CODES:
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.
APPROVALS:
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 testedundertheStandardforConstructionandTest of Electric Storage Tank Water Heaters,
CAN/CSA-C22.2 No. 110-M90. Allwaterheater storage tanks conform to the latest edition of the ASME
Boiler and Pressure Vessel Code, SectionIv.
INSTALLATION PROCEDURE LOCATION OF UNIT
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 sized, 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.
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.
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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).
CAUTION:
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 cannot 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.
TABLE A – CLEARANCES FROM COMBUSTIBLE
CONSTRUCTION:
Right Side - 6” (15cm)
Rear 0”
Left Side Inspection Opening & Anode Rods
Front 36” (0.91m) for service to controls
and heating elements
Top 12” (30cm) for service access to
electrical service, water connections
and piping
Water Pipes 1” (25.4mm)
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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.
MOUNTING:
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:
NOTE:
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.
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.
Inlet and out let connections
For ease of service, install dielectric 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.
STORAGE TANK:
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
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hand hole for ease of inspection, cleanout and service. An optional manhole may be specified for a
greater ease of inspection. The interior of the storage tank is glass lined and fired insure a molecular
fusing of glass and steel to protect the steel base metal against corrosion. A magnesium anode(s) is standard
to enhance the protection of the substrate metal of the tank.
RELIEF VALVE:
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.
CAUTION:
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.
THERMAL EXPANSION OF WATER:
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 an 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.
CATHODIC PROTECTION:
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.
ELECTRICAL CONNECTIONS:
All installation procedures involving electric power connection should only be performed by a trained,
certified electrician. 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.l, Canadian Electrical Code, Part 1 and/or local Electrical Codes .
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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 initial operation. Operation
of a water heater without a completely filled tank may result in serious damage to the appliance and
heating element burn out.
5. The water heater should be connected with a separate grounded branch circuit with over current
protection and disconnect switch. The water heater should be grounded in accordance with national
and local codes. A ground terminal is provided for ground connection only.
6. Provide the appliance with proper overload protection in the branch circuit. It is suggested that the
electrician size the branch circuit at 125 percent of the heater ampere rating and further increase wire
size as necessary to compensate for voltage drop in long runs. Branch circuit voltage drop should not
exceed 3% at the heater.
7. Voltage applied to the heater should not vary more than +5% to -10% of the model and rating plate
marking for satisfactory operation.
8. A wiring diagram is provided with the water heater for the electricians use.
WARNING:
WATER HEATER IS EQUIPPED FOR OPERATION ON ONE VOLTAGE ONLY. Check the rating
plate label 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 label. Failure to use the correct voltage can cause problems that can
result in death, serious bodily injury or property damage.
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CAUTION:
DO NOT CONNECT THE WATER HEATER TO AN IMPROPER SOURCE OF ELECTRICITY!
CAUTION:
Never turn on the electric power or attempt to use this electric water heater unless it is completely
full of water. Water must flow from the hot water faucet before turning electrical power "ON."
Operation of a water heater without a completely filled tank may result in serious damage to the
appliance and heating element burn out.
JACKET ASSEMBLY:
Outer Jacket - The outer jacket assembly is constructed from steel, painted with enamel on both sides. This
coating process insures a long life from the jacket assembly.
STANDARD EQUIPMENT:
Your commercial electric water heater is equipped with the following as standard equipment:
•Low watt density immersion heating elements with an incoloy sheath.
•Internal fusing of all elements in a maximum of 48 amp increments provides additional safety. Fuse
cartridges are related at 1,000,000 amps interrupting capacity.
•A painted enamel steel outer jacket and electrical control panel are provided.
•Channel iron skid base.
•Electrical control panel is provided with a hinged door and key lock.
•A glass lined steel tank constructed to ASME specifications and provided with magnesium anode(s).
•ASME rated temperature and pressure relief valve provided by factory to insure safe heater operation.
•Terminal block connections are installed by the factory for safe easy wiring connection.
•Manual reset high water temperature limit control.
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