Bradley Keltech S193 Series User manual

P.O. Box 309, Menomonee Falls, WI USA 53052-0309
PHONE 800.BRADLEY (800.272.3539) FAX [phone]
bradleycorp.com
Installation
215-1712EW Rev. B; ECM 12-05-038
© 2012 Bradley
Page 1 of 14 12/5/2012
Keltech S193 Series
Tankless Water Heating Solutions
Table of Contents
Pre-Installation Information ..........................3
Supplies Required for Installation .....................3
Pre-Installation Storage Instructions ...................3
System Mounting................................4–5
Plumbing Connections..............................6
Electrical Connections ..............................7
Controller Operation .............................8–9
Operation Installation Test .......................10–11
Optional Features ................................12
Preventive Maintenance and Troubleshooting........ 12-13
Field Wiring Schematic (Appendix A) .................14

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S193 Series Installation
12/5/2012 Bradley • 215-1712EW Rev. B; ECN 12-05-38
IMPORTANT
Read this installation manual completely to ensure proper installation, then file it with the
owner or maintenance department. Compliance and conformity to drain requirements and
other local codes and ordinances is the responsibility of the installer.
Separate parts from packaging and make sure all parts are accounted for before discarding
any packaging material. If any parts are missing, do not begin installation until you obtain the
missing parts.
Flush the water supply lines before beginning installation and after installation is complete.
Test the unit for leaks and adequate water flow. Main water supply to the emergency fixture
should be “ON” at all times. Provisions shall be made to prevent unauthorized shutoff. Please
refer to the enclosed instructions for flushing the unit prior to use.
The ANSI Z358.1 standard requires an uninterrupted supply of flushing fluid. Bradley plumbed
emergency fixtures require a minimum of 30 PSI (0.21 MPa) flowing pressure. Flushing fluid
should be tepid per ANSI Z358.1.
The inspection and testing results of this equipment should be recorded weekly to verify
proper operation. This equipment should be inspected annually to ensure compliance with
ANSI Z358.1.
For questions regarding the operation, installation or maintenance of this product, visit
bradleycorp.com or call 800.BRADLEY (800.272.3539).
Product warranties and parts information may also be found under ”Products” on our web site
at bradleycorp.com.
Installation and maintenance of this system must be completed by a qualified plumber
and electrician according to the information contained in this installation manual and in
compliance with all national and local codes. When making electrical connections be sure to
follow all lockout–tagout safety procedures.
It is recommended that all water supply and electrical connections be made at temperatures
above freezing (32° F (0° C). Failure to do so may result in major product and/or property
damage.
Installation
THIS
SIDE
UP
Packing List
•
•
•
•
P.O.Box309, Menomonee Falls, WI 53051
R
TESTTHISUNIT EACHWEEK
Test-operatevalve(s) each week and sign below.
Reportany malfunctions immediately.
Ventil(e)wöchentlich im Testbetrieb prüfen, bestätigt
durchUnterschrift. Jegliche Störung sofort melden.
Date
Datum
Date
Signed
Unterschrift
Signe
Date
Date
Date Signed
Signed
Signed
DIESESGERÄT1ST WÖCHENTLICH ZU PRÜFEN.
ESSAIHEBDOMADAIRE
Testle fonctionnement des valves chaque semaine et
signeen bas. S'il y à quelque chose qui ne va pas fait
unrapport immédiatement.

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Installation S193 Series
Bradley • 215-1712EW Rev. B; ECN 12-05-38 12/5/2012
Supplies Required for Installation:
• (2) Unions ¾" NPT
• Pressure and Temperature Relief Valve ¾" NPT
• Y-Strainer (100 mesh) or Inline Filter (150 microns) ¾" NPT
• (2) Gate or Ball Type Valves ¾" NPT
• Drain Pipe ¾" NPT
• Conduit Inlet Fitting
Pre-Installation Storage Information
• Keep units stored in original packaging until installation.
• Care should be taken to minimize excessive on-site transport reducing risk of shock and impact damage.
• Temperature for storage must exceed 35ºF at all times (indoor storage is recommended).
• Units kept in their original crates will withstand outdoor elements for a brief period (about one month in most climates).
For units stored outdoors, take precautions to protect the units from rain or falling precipitation using tarps or other
waterproof material. Avoid runoff and/or accumulation of groundwater (from any source) that may exceed one inch.
CAUTION! Uninstalled units ordered without ENHT freeze protection option may not be stored in environments where
temperature will fall below 35°F. For ENHT supplied heaters, if unit was stored where the temperature could
fall below 45°F, the unit must be powered immediately after hydraulic testing in order to ensure internal
freeze protection components are activated. Once the unit is installed and the on-site plumbing has been
hydraulically tested, the power supply must remain constant until the risk of freeze is eliminated.
Packaging
• Crates are made of ¾ AC plywood and the dimensions are approximately 44" x 28" x 12".
• Crated units must be stacked evenly and placed no more than two crates high.
• All crates and packaging should be considered "Fragile" and transported accordingly. Standard safety procedures for
forklift transport and large items less than 1000 lbs should be followed at all times.
• Support for crates stored on an elevated industrial capacity rack or shelf must be provided for the entire length and
width of the crates.

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S193 Series Installation
12/5/2012 Bradley • 215-1712EW Rev. B; ECN 12-05-38
System Mounting
WARNING! To prevent high voltage shock, disconnect the power supply before performing any work inside the system
enclosure.
CAUTION! If the system use is infrequent and mounted in an area where freezing can occur between uses, drain water
from the heat exchanger.
CAUTION! Connecting pipe to the male threads on the outside of the bulkhead will cause leaking or other damage to
the system.
The best location for mounting the tankless system is central or close to the points of use. Long pipe runs are not recommended
due to heat loss of up to 1°F for every 10 feet of uninsulated pipe. Position the units as close as possible to the fixture to reduce
delivery times of tepid water. When determining location, consider the possibility that start-up verification and testing may be
performed with the service door open. Placement outside the splash zone or partitioned from any fixture and its direct runoff is
recommended.
1. Set the system in a vertical, upright position with the outlet located at the top.
2. Mount the system to the wall using the (4) mounting brackets on the back of the enclosure.
3. Bolt the heater to a vertical surface.
IMPORTANT! The vertical surface must support 150 pounds or more.

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Installation S193 Series
Bradley • 215-1712EW Rev. B; ECN 12-05-38 12/5/2012
System Mounting
Dim. "A" Dim. "B"
18kW 31½" 30"
25kW 37½" 36"
¾" NPT Outlet ¾" NPT Inlet
2"
A
6"
B
14½"
16"
3¹⁄₈"
8"
Suggested Region For Power Entrance.
Entrance Holes To Be Provided By Installer.

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S193 Series Installation
12/5/2012 Bradley • 215-1712EW Rev. B; ECN 12-05-38
Plumbing Connections
CAUTION! Use gate or ball type valves to reduce restrictions caused by other valve types. Plumbing connections are
¾" female National Pipe Thread (NPT).
1. Install the pressure and temperature relief valve onto the union on the HOT water outlet.
• The valve must empty into a well-located drain. The dump should also empty into this drain.
2. Install the shutoff valve above the union on the inlet connection.
3. Connect the pressure and temperature relief valve (150 psi and 210°F) to the plumbing on the water outlet side of system,
and drain.
• Make sure there is no valve or restriction between the relief valve and the system.
4. Install the shutoff valve onto the pressure and temperature relief valve on the hot water outlet.
CAUTION! To avoid water damage, install a drain pipe from the pressure relief valve and the dump outlet to a well-
located drain.
5. Install a 100 Mesh Y-strainer or inline filter of 150 microns between the inlet shutoff valves and the system.
CAUTION! Do not perform hydraulic system test until electrical service installation has been completed.

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Installation S193 Series
Bradley • 215-1712EW Rev. B; ECN 12-05-38 12/5/2012
Electrical Connections
IMPORTANT! Install system according to national and local electrical codes. Follow all lockout/tagout procedures when
performing and wiring to the system.
CAUTION! To prevent damage to the electronics or internal wiring, do not perform any brazing or sweat soldering inside
the enclosure box.
1. Open the enclosure door.
2. Make an appropriate hole in the enclosure at the appropriate location for the conduit inlet fitting (supplied by installer) as
shown on page 5.
3. Install an appropriate conduit connector.
4. Route the grounded electrical supply through the fitting in the enclosure.
5. Route the wires through the conduit.
6. Connect the wires to the system terminal block inside the enclosure.
Set-Up
1. Make sure the 3-pole circuit breaker is OFF and that all connections have been properly made.
2. Turn ON the water supply.
3. Turn ON the emergency fixture to bleed off trapped air in the heat exchanger.
CAUTION! Failure to bleed air properly will damage elements and cause system malfunction.
4. Turn OFF the hot water faucet and check for plumbing leaks.
CAUTION! Before turning on the power, close the electrical box.
IMPORTANT! On all S193 series model systems, the preprogrammed digital temperature controller is mounted in the
chassis cover. The controller LED will read OFF until water is flowing through the heater. Refer to the
Controller Operation section for more information.
Electrical Specifications
Model Voltage Amps Kilowatts
Min. Wire Size
(based on Amperage
rating of THHN wires)
18kW 480/600 22/18 18 10/10 AWG
25kW 480/600 30/24 25 8/10 AWG

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S193 Series Installation
12/5/2012 Bradley • 215-1712EW Rev. B; ECN 12-05-38
Controller Operation
CAUTION! To prevent damage to the system, do not attempt to program your controller.
9 of 20
Operate Controller
CAUTION: Do not attempt to program your controller.
The following information assists the customer with understanding and use of the digital controller:
Upper Lower
Description Display Display Function
EZ Key Toggles output on/off
Setpoint Up button Increases output temperature
Setpoint Down button Decreases output temperature
Infinity Key H2O Temp-Out Setpoint Back to Home page
Advance Key Advances through parameter prompts
Auto, Man, Off C.r71 - Turns Control Loop On/Manual/Off
XX.X% h.Pr1 - Heater Power %
no AUt1 - Autotune (Contact Factory)
C or F C_F1 - Change Temperature Units from F to C
Outputs Active (L1-L5) indicators Indicate when output 1,2,3,4 or 5 are active
Setpoint Temperature Display Displays:
(Lower Display) - Setpoint
- Percent Power
- Temperature units F or C
- Menu prompt name
- Alarm code
Output Temperature Display Displays:
(Upper Display) - Actual process temp. of outgoing water
- Prompt parameter value
- Error code
Feature Disabled

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Installation S193 Series
Bradley • 215-1712EW Rev. B; ECN 12-05-38 12/5/2012
Controller Operation
ON - HEATING
OFF – NO FLOW

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S193 Series Installation
12/5/2012 Bradley • 215-1712EW Rev. B; ECN 12-05-38
Performing Operation Installation Test #1
Test the System
1. Set the 3-pole switch or circuit breaker to the ON position.
2. Turn ON the applicable hot emergency fixture.
3. When the flow rate reaches approximately 0.75 gpm, the flow switch activates.
IMPORTANT! If water flow exceeds the system's maximum heating capacity, the water temperature at the outlet will be
lower than the temperature on the LED controller. Refer to the Temperature Rise Capabilities table shown
below to determine maximum temperature rise capabilities.
IMPORTANT! Systems installed into pump-and-well supplied water systems may require an operating pressure
adjustment to a differential pressure of approximately 10 psi. For example, if the high limit pressure is 40
psi, adjust the low limit pressure to 30 psi with the pressure switch located on the supply pump.
When the Flow Switch Activates
• Heating elements energize via the solid-state relays.
• Phase indicator lights illuminate on the front bezel. This verifies power supply connection to the heating elements.
• Lower display on the LED controller changes from OFF to indicate the set-point temperature.
When Modulation Begins
• Phase indicator lights flash in unison.
IMPORTANT! Located on the panel is a (18kW or 25kW) green ready light. When illuminated, the safety circuit is
engaged and ready for use. Green ready lights may not be present on older system models.
1. Test the water temperature and stability at the outlet by viewing the display. Controller displays the temperature of water
exiting the system.
2. Turn OFF the hot water faucet. The flow switch will deactivate and shut off the heater. The lower display of the controller will
read OFF.
IMPORTANT! The system will not energize heating elements if the inlet water temperature is equal to or greater than
the temperature set on the LED controller.
temperature rise Capabilities (Temperature Rise vs. Flow)
Gallons per Minute / Temperature Rise by kW
Model kW 1 2 3 4 5 6 7 8 9 10 11 12
18kW 18 122 61 41 30 25 200 17 15 13 12
25kW 25 170* 85 57 43 34 28 24 21 19 17
*may exceed the maximum temperature setting of the heater.

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Installation S193 Series
Bradley • 215-1712EW Rev. B; ECN 12-05-38 12/5/2012
Safety Shower Operation
When a Low Flow Condition Occurs
• When a low flow condition (less than 15 gpm) occurs, such as operation of the eyewash system, only two (2) or four
(4) elements energize depending on the geographical location of the installation.
• One set of PID values is selected on the controller for accurate temperature control at low flow conditions.
When the System Detects High Flow Conditions
• When the system detects high flow conditions (greater than 15 gpm), all elements energize.
• A second set of PID values is selected on the controller for accurate temperature calibrations at high flow conditions.
When the System Shuts Down
• When the system shuts down or switches from a high to low flow condition, the dump valve opens and purges the
system of latent heat. This ensures safe water temperatures at both the eyewash and shower stations.
• This system also provides anti-scald for applications where environmental temperatures are above 95°F.

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S193 Series Installation
12/5/2012 Bradley • 215-1712EW Rev. B; ECN 12-05-38
Optional Features
Ground Fault
Provides equipment electrical protection to ground.
After installation of water and power, test the ground fault.
1. Press the GF Test button.
• Watch for the ground fault light to illuminate and Bank Ready light(s) to shut off. The Ground Fault system is active
and working properly.
2. Press the GF Reset button to reset the ground fault.
IMPORTANT! If a trip occurs under normal operation, DO NOT RESET the Ground Fault without first evaluating and
servicing the unit.
IMPORTANT! Normal state is Ground Fault light OFF, Bank Ready lights ON.
Freeze Protection (ENHT)
Protects system and internal components in sub-freezing conditions. Allows unit to function at -23°F with an 11 mph wind. With
this option, three phase power must be continuously applied to the SN heater for the internal freeze protection heater to operate.
If three phase power cannot be continuously applied, the heat exchanger must be completely drained of water and electrically
locked out and tagged or freezing may occur. Use start up procedure previously outlined to restart this equipment. This option
does not require a separate electrical circuit.
IMPORTANT! All freeze protected SN heaters are equipped with a temperature sensor that can provide a signal to a
remote device when temperature inside the cabinet falls below 40°F (refer to the schematics for more
information).
NEMA 4X
Corrosion-proof enclosure made of stainless steel which is ideal for harsh environments.
Computer Interface Temperature Controls
Controls temperature from a remote location.
• To create an if/then scenario and set 2 input points to determine safe range of temperatures.
• Absolute temperature control to maintain specific set temperature.
Explosion Proof Purge System
Electrical components installed in a NEMA 4 enclosure allow the system to be pressurized by clean instrument air or inert gas.
The purge process removes flammable gases and/or prevents the accumulation of ignitable dusts within the protected enclosure.
Heat, moisture, dust and corrosion are eliminated by a slow, continuous flow of inert gas or dry compressed air. This type of
system conforms to Class 1, Division 2 hazardous area standards. Other Class and Division ratings may be available.
Preventive Maintenance
For your system to work properly and have protection from freezing, keep the system dry inside the enclosure. Moisture inside an
enclosure increases the humidity inside, which condenses on cooler surfaces of the enclosure. This causes electrical problems
and reduces the efficiency of enclosure insulation.
Preventive Maintenance
1. Dry out the enclosures.
2. Seal any weeping leaks in seals or walls.
3. Replace missing plugs on the back of the enclosure.
4. Check seals monthly when temperatures rise above 32°F and weekly when temperatures fall below 32°F.
5. Check the performance of the internal freeze protection system for proper performance prior to the first seasonal freeze.
Check weekly during temperatures below 32°F. Refer to the "Optional Features" section for additional information on freeze
protection.
6. The manual reset safety overheats on the heat exchangers may trip when temperatures fall below 32°F. The overheats are
set to trip at 100°F. Heat trace installed on piping can heat water to temperatures above 100°F. This causes the overheats to
trip. Reset the overheats and lower the heat trace temperature to below 100°F.
If systems are sealed and checked at the frequency outlined above during weekly OSHA Shower Checks, the system will provide
years of reliable service. Preventive measures to correct small problems that may arise over the years will prevent more costly
failures or catastrophic freeze failures in the future.

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Installation S193 Series
Bradley • 215-1712EW Rev. B; ECN 12-05-38 12/5/2012
Troubleshooting
If the System Is Not Working or Works Intermittently
1. Check the following:
• Flow switch works properly.
• At the wires from the flow switch read Open without flow and Closed with flow.
• Water flow through the system is adequate to activate the flow switch at 0.75 gpm.
• System is wired with the proper breaker and wire size. Refer to the Electrical Connections section for proper
requirements.
• Unit is receiving voltage from all three phases of the power source. A load voltage reading is also helpful.
IMPORTANT! Before recording any Ohm readings, turn OFF the power.
2. Record Ohm reading:
• Insert test leads of the volt-ohm meter at flow switch test leads in terminal blocks 1 and 2.
The switch should read an OPEN circuit without flow and CLOSED circuit with flow. If the flow switch is always in the CLOSED position:
• Disassemble flow switch and check to make sure there is no debris lodged in the switch.
• Clean and adjust the flow switch as necessary.
If the System Has No Power
1. Verify the power is on.
2. Check the following:
• Fuses: make sure none are blown.
• Breaker: make sure it has not tripped.
• Safety interlock door: make sure it has not activated.
• System limit control: make sure it has not latched.
• Wiring: make sure it is not open.
• Input Power: make sure it is correct.
• Part Number: for input power required, then measure power upstream for required level.
If Alarms Do Not Occur
1. 1Make sure alarm:
• Set points are correct.
• Is not latched.
• Side settings are correct.
• Type settings are correct.
• Controller is not diagnostics mode.
If Alarms Do Not Clear
1. Check the following:
• Power limit setting.
• Operation mode.
• Alarm output function.
• Temperature setting.

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S193 Series Installation
12/5/2012 Bradley • 215-1712EW Rev. B; ECN 12-05-38
Appendix A - Unit Schematic