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Bradford White EFR160T120 Series Installation & Operating Manual

Ef series ultra high efficiency gas water heater
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Download this manual See also: Service Manual
ULTRA HIGH EFFICIENCY GAS WATER HEATER
Ambler, PA 19002
Tech. Service (800) 334-3393
Service Parts (800) 538-2020
Warranty Service (800) 531-2111
INSTALLATION/OPERATING MANUAL
PLACE THESE INSTRUCTIONS ADJACENT TO WATER HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE
(EFR160T120 Series Models)
WITH TROUBLESHOOTING GUIDE
WARNING: If the information in
these instructions is not followed
exactly, a fire or explosion may
result causing property damage,
personal injury or death
-
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this 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's phone. Follow
the gas supplier's instructions.
 If you cannot reach your gas
supplier, call the fire department.
For your family's comfort, safety and
-
convenience, it is recommended this
water heater be installed and
serviced by a plumbing professional.
238-48144-00E
7/12

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  • Page 1 ULTRA HIGH EFFICIENCY GAS WATER HEATER (EFR160T120 Series Models) WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

  • Page 2: Table Of Contents

    SECTION I: IMPORTANT INFORMATION READ CAREFULLY This gas-fired water heater is design certified by CSA International under the American National Standard, Z21.10.3 (as indicated on the rating plate) and CAN/CGA 4.3-M (as indicated on the rating plate). These standards are available from CSA Standards Association, 5060 Spectrum Way Mississauga, Ontario L4W 5N6 CANADA.
  • Page 3 DANGER DO NOT store or use gasoline or other flammable, combustible, or corrosive vapors and/or liquids in the vicinity of this or any other appliance. DO NOT install any damaged venting system components. If damage is evident then please contact the supplier where the water heater was purchased or the manufacturer listed on the rating plate for replacement parts.
  • Page 4 WARNING This water heater needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air. Insufficient air supply will cause a recirculation of combustion products resulting in contamination that may be hazardous to life. This will result in carboning or sooting of the combustion chamber, burners, and flue tubes and creates a risk of asphyxiation.

  • Page 5: Specifications

    SECTION II: SPECIFICATIONS Figure 1. Dimensional Layout Recovery GPH DIMENSIONS ( INCHES ) At Degree Rise Del. Gal. Stg. Flr to Flr to Fl. to Front Space Input Cap. Therm. Flr to Inlet T&P Outlet Fl. to Wtr. Heating Relief Shpg.

  • Page 6: General Information

    SECTION III: GENERAL INFORMATION FEATURES This water heater contains the following features: MAIN POWER ON/OFF SWITCH – The front panel of this water heater has a lighted ON/OFF switch, which is illuminated when the main power is turned on to indicate power to the water heater. COMBUSTION SYSTEM –...
  • Page 7 LATCHES – The latches allow easy access for servicing the water heater from the top. Simply remove the two latches for servicing and re-latch upon completion. No tools are required to obtain access to the top of the water heater. MIXING VALVE –...
  • Page 8 CONDENSATE DRAIN – The water heater should either be raised several inches above the floor on a concrete slab or use a low profile condensate pump to allow free drainage of condensate from the elbow drain fitting. This water heater is a condensing type unit and requires a drain to be located in close proximity to allow the condensate to drain safely.

  • Page 9: Installation Instructions

    SECTION IV: INSTALLATION INSTRUCTIONS WARNING INSTALLATION OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE FIELD. PLUMBING, AIR SUPPLY, VENTING, GAS SUPPLY AND ELECTRICAL WORK ARE REQUIRED. DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE FOLLOWING: ...
  • Page 10 Sacrificial anode rods have been installed in the tank head of the water heater to extend tank life. The removal of these anodes for any reason will nullify the warranty. In areas where water is unusually active, an odor may occur at the hot water faucet due to a reaction between the sacrificial anode and the impurities in the water.
  • Page 11 Figure 3a. Minimum Clearance To Combustible Material Figure 3b. Recommended Minimum Clearances For Service Access...
  • Page 12 REMOVE CRATE Remove all banding and pry off crate sides carefully so as not to damage the water heater. Carefully roll/lift the water heater from the crate base. CAUTION Do not drop water heater. Do not bump water heater jacket against floor. Do not bump exhaust vent pipe against crate or other objects.
  • Page 13 MECHANICAL EXHAUSTING OF ROOM AIR 1. Where an exhaust fan is installed in the same room with this water heater and combustion air is drawn from inside the room, sufficient openings for air must be provided in the walls. UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE WATER HEATER’S VENTING SYSTEM, CAUSING POOR COMBUSTION THAT MAY BE HAZARDOUS TO LIFE.
  • Page 14 Figure 4. Typical Front Inlet Connection Figure 5. Typical Front Inlet Connect with Storage Heater...
  • Page 15 Figure 6. Typical Two Water Heater Connection Figure 7. Typical Three Water Heater Connection Figure 8. Typical Four Water Heater Connection...

  • Page 16: Water Connections

    SECTION V: WATER CONNECTIONS WARNING Failure to install and maintain a new, listed temperature and pressure relief valve will release the manufacturer from any claim, which might result from excessive temperature and pressures. Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time (generally two weeks or more).
  • Page 17 By setting the thermostat on this water heater to obtain the increased temperature water required by these appliances, you might create the potential for scald injury. To protect against injury, you must install the ASSE approved mixing valve supplied with the water heater in the water system. This valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines.

  • Page 18: Venting

    Figure 11. Typical Plumbing Schematic for Zoned Heating SECTION VI: VENTING WARNING The vent system must be properly installed. Failure to properly install the vent system could result in property damage, personal injury, or death. DO NOT install damaged venting system components. If damage is evident then please contact the supplier where the water heater was purchased or the manufacturer listed on the rating plate for replacement parts.

  • Page 19: For Installations In Canada

    NOTICE Single Wall Polypropylene venting systems that are listed on the Bradford White website are approved for use in the water heaters covered in this instruction manual. The venting system components are ULC S636 approved and listed by a recognized agency and may be installed in the U.S. and Canada. Complete instructions for the approved venting systems can be found on the Bradford White website, bradfordwhite.com or by calling the Technical Service Department at:800-334-3393.
  • Page 20 CAUTION Check to make sure flue gases do not recirculate into the air intake terminal when using direct venting. If the water heater is having service issues, flue recirculation may be a contributing factor. Even when the minimum vent terminal separation distances are followed, recirculation may still occur depending upon the location outside the building, the distance from other buildings, proximity to corners, weather conditions, wind patterns, and snow depth.
  • Page 21 VENTING The venting instructions must be followed to avoid restricted combustion or recirculation of flue gases. Such conditions cause sooting or risks of fire and asphyxiation. This water heater can be installed as either a direct vent system or power vent (air from inside) system. If it is installed as a direct vent system, then the air intake and the exhaust vent are piped to the outside.
  • Page 22 Figure 12a. Vent Terminal Clearances (Other than Direct Vent or “Power Vented” Installations) Canadian Canadian US Installations Installations Installations Installations Clearance above 12 inches 12 inches Clearance to each side 3 feet (.9 m) within a grade, veranda, porch, (30.5 cm) (30.5 cm) of center line extended height 15 feet (4.6 m)
  • Page 23 Figure 12b. Direct Vent Terminal Clearances Canadian Canadian US Installations Installations Installations Installations Clearance above grade, 12 inches 12 inches Clearance to each side 3 feet (.9 m) within a veranda, porch, deck or (30.5 cm) (30.5 cm) of center line extended height 15 feet (4.6 m) balcony above meter/regulator...
  • Page 24 The vent system must terminate so that proper clearances are maintained as cited in local codes or the latest edition of the National Fuel Gas Code, ANSI Z223.1.73.4e and 7.8a, b as follows: Do not terminate near soffit vents or crawl space or other area where condensate or vapor could create a nuisance or hazard or cause property damage.
  • Page 25 2. Use the proper cement to secure the exhaust vent and air intake terminals provided with the water heater to the pipes. The distance between the back edge of the exhaust vent terminal and the exterior wall (see Figure 13) must be 6 inches (15.3 cm) more for the exhaust vent terminal than the air intake terminal. Use the proper cement or sealant and assembly procedures to secure the vent connector joints between the terminal and the blower outlet.
  • Page 26 Figure 14. Typical Vertical Direct Vent System Installation (Note: Intake and exhaust terminals may be on different outside walls.) Through The Wall Venting With Low Ground Clearance: When venting cannot exit through the wall at a height greater than or equal to 12 inches (30.5 cm) (and above expected snow level) from the ground, then the installation must be modified as shown below (see Figure 15).
  • Page 27 Maximum Vent Length: Direct Vent Maximum Vent Length (Combined Maximum Length for Intake and Exhaust) Max Vent Length in Max Vent Length in Max Vent Length in Model feet (meters) for 2 feet (meters) for 3 feet (meters) for 4 Number inch (5.1 cm) inch (7.6 cm)
  • Page 28 CAUTION Failure to properly support the vent piping with hangers and clamps may result in damage to the water heater or venting system. Stress levels in the pipe and fittings can be significantly increased by improper installation. If rigid pipe clamps are used to hold the pipe in place, or if the pipe cannot move freely through a wall penetration, the pipe may be directly stressed, or high thermal stresses may be formed when the pipe heats up and expands.
  • Page 29 CAUTION Failure to properly support the vent piping with hangers and clamps may result in damage to the water heater or venting system. Follow the following procedure to vent through the roof: 1. Cut the necessary holes through the roof and ceiling. 2.
  • Page 30 Through The Wall Venting With Low Ground Clearance: When venting cannot exit through the wall at a height greater than or equal to 12 inches (30.5 cm) (and above expected snow level) from the ground, then the installation must be modified as shown below (see Figure 18). Refer to Tables 3 or 4 for maximum venting lengths using 2 inch (5.1 cm), 3 inch (7.6 cm) or 4 inch (10.2 cm) diameter plastic pipe.
  • Page 31 MULTIPLE INTAKE/EXHAUST TERMINAL SEPARATION DISTANCES Note: When installing multiple intake/exhaust terminals on the same wall of a building, the nearest intake terminal must be at leas from the nearest exhaust terminal. t 5 feet (1.5 m)
  • Page 32 CONCENTRIC VENT TERMINAL INSTALLATION PROCEDURE WARNING Improper installation, adjustment, service, or maintenance can cause property damage, personal injury, or death. Consult a qualified installer, service agency, or the gas supplier for information or assistance. This kit must be used only for terminating this water heater. Do not use this termination kit for any other appliance.
  • Page 33 Figure 21. Rain Cap to Small Vent Pipe Assembly 5. Install concentric Y fitting and pipe assembly through the structure’s hole and field-supplied roof boot/flashing. Do not allow insulation or other materials to accumulate inside pipe assembly when installing through the hole. 6.
  • Page 34 Horizontal Installation: 1. Become familiar with coaxial vent kit part no. 239-44069-02 as shown in Figures 19 through 21. 2. Determine the best location for the termination kit. NOTICE Position termination where vent vapors will not be adversely affected by wind condition. Position termination where it will not be damaged or be subjected to foreign objects.

  • Page 35: Vent Pipe Preparation

    It is acceptable to install a 90 degree elbow on IPEX concentric vent terminations use with this power direct vent water heater (see Figure 23b). A short length of appropriate diameter vent pipe should be used to transition from the vent terminal to the 90 degree elbow.

  • Page 36: Gas Connections

    INITIAL PREPARATION Make sure the solvent cement you are planning to use is designed for the specific application you are attempting. Know the physical and chemical characteristics and limitations of the PVC, PVC cellular core, ABS or CPVC piping materials that you are about to use. Know the reputation of your pipe and cement manufacturer and their products.
  • Page 37 Figure 24. Drip Leg The gas supply lines must meet all requirements of the National Fuel Gas Code ANSI Z223.1 (Latest Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.2 Propane Installation Code (Latest Edition). GAS METER SIZE –...

  • Page 38: Electrical Connections

    SECTION VIII: ELECTRICAL CONNECTIONS WARNING 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. 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 C22.2 Electrical Code.

  • Page 39: Operating Instructions

    SECTION IX: OPERATING INSTRUCTIONS WARNING Water heaters are heat-producing appliances. To avoid damage or injury there must be no materials stored against the water heater or direct vent system, and proper care must be taken to avoid unnecessary contact (especially by children) with the water heater and direct vent system.

  • Page 40: Lighting Instructions

    LIGHTING AND SHUT-DOWN INSTRUCTIONS FOR YOUR SAFETY READ BEFORE LIGHTING 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 does not have a pilot. Immediately call your gas supplier It is equipped with an ignition device from a neighbor's phone.
  • Page 41 TEMPERATURE ADJUSTMENT APPROXIMATE TIME/TEMPERATURE RELATIONSHIPS IN SCALDS 120°F (49°C) More than 5 minutes 125°F (52°C) 1½ to 2 minutes 130°F (54°C) About 30 seconds 135°F (57°C) About 10 seconds 140°F (60°C) Less than 5 seconds 145°F (63°C) Less than 3 seconds 150°F (66°C) About 1½...
  • Page 42 Condensation does not mean your tank is leaking. Most of reported tank leaks on installation are proven to be condensation. To avoid unnecessary inconvenience and expense, make sure the tank is leaking before calling an independent servicing contractor or qualified service professional. If the water heater is to remain idle for 30 days or more or is subjected to freezing temperatures while shut off, the water heater and piping should be fully drained and the drain valve should be left fully open.
  • Page 43 To Increase Setpoint Temperature Step 1: Depress and hold “Temperature Up” button until desired setpoint temperature appears in the display.  °F idle Operational Status SELECT Step 1 Step 2: “Setpoint” indicator begins flashing in the display after pressing “Temperature Up” button. "Setpoint"...
  • Page 44 To Decrease Setpoint Temperature Step 1: Depress and hold “Temperature Down” button until desired setpoint temperature appears in the display °F  idle Operational Status SELECT Step 1 Step 2: “Setpoint” indicator begins flashing in the display after pressing “Temperature Down” button. "Setpoint"...
  • Page 45 To Change Temperature Format in Display from F to C or ˚C to ˚F: Step 1: Press “SELECT” button until F/C is displayed. °F °F/°C idle Operational Status  SELECT Step 1 P ress select Step 2: Press “SET” button to change temperature format. Symbol F/C will flash. °F °F/°C idle...
  • Page 46 Step 3b: Press “Temperature Down” button to change temperature format to F. Changes to "°F" °F/°C Flashes °F °F/°C idle Operational Status SELECT Step 4: Press “SET” button to confirm ˚F or ˚C format. F/C will stop flashing. Setpoint display will appear in the format selected (˚F or ˚C) in 10 seconds.

  • Page 47: Maintenance

    An automatic gas shut-off device (ECO) is incorporated in the sensor and control board which will shut off all gas supply to the burner if the water heater temperature exceeds 200°F (93°C). Should the ECO function (open), the water temperature should be reduced to approximately 120°F (49°C) and call a qualified service agent to place the water heater in operation.
  • Page 48 Figure 27. Sight Glass Location MAINTENANCE SCHEDULE WARNING Water heaters are heat producing appliances. To avoid damage or injury there must be no materials stored against the water heater or vent-air intake system, and proper care must be taken to avoid unnecessary contact (especially by children) with the water heater and vent-air intake system.
  • Page 49 Suggested Maintenance Schedule COMPONENT OPERATION INTERVAL REQUIRED Tank Sediment Removal Monthly Flushing At least every 2 Replace as Anode Rods Inspect years Required At least Relief Valve Check Operation Proper Operation annually Ignition Check for proper Inspect Annually System operation Table 5.
  • Page 50 The depth of the buildup should be measured periodically. Water heaters will have about 3 inches (7.6 cm) of lime buildup when the level of lime has reached the bottom of the cleanout opening or about 1 inch (2.5 cm) of lime buildup if it has reached the drain valve opening.
  • Page 51 CAUTION Before manually operating the valve, make sure that a drain line has been attached to the valve to direct the discharge to an open drain. Failure to take this precaution could mean contact with extremely hot water passing out the valve during this checking operation. If the combination temperature and pressure relief valve on the water heater discharges periodically, this may be due to thermal expansion in a closed water supply system.

  • Page 52: Diagnostic And Troubleshooting Guide

    SECTION XI: DIAGNOSTIC AND TROUBLESHOOTING GUIDE DIRECT SPARK HONEYWELL INTEGRATED CONTROL SYSTEM SEQUENCE OF OPERATION 1. When the tank temperature drops below the temperature setpoint on the display, the control sends power to the combustion blower for a 30 second pre-purge period. 2.
  • Page 53 ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY (FOR SERVICE PERSONNEL ONLY) The display has a “Service Mode” for changing the maximum setpoint and accessing information in aiding servicing of the water heater. This procedure is for service and installation personnel only. To enter the Service Mode, follow the steps illustrated below: WARNING The following procedure is for service and installation personnel only.
  • Page 54 The following is the sequence of modes available in “Service Mode” by pressing the “Select” button: Error Code Number (Display/Reset). This is only shown if there is an operating error in the “User Mode”. Error Code Shown in Water Heater Display Status Service Needed SELECT Lockout RESET...
  • Page 55 3. Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle) µA Heating Flame Current Operational Status  SELECT 4. Setpoint (Display/Change) setpoint °F idle Operational Status  SELECT 5. ˚F/˚C (Display/Change) °F °F/C° idle Operational Status  SELECT...
  • Page 56 6. Differential (Display only – shows the differential of the thermostat) Differential °F idle Status Operational  SELECT 7. Software Version (Display only) Soft idle Operational Status SELECT 8. Error Code History (Displays if there are present error codes or up to 10 previous error codes). Water Heater Display will show -- if there are no error codes.
  • Page 57 To change the Maximum Setpoint Limit (Max Setpoint) for the temperature setpoint: WARNING Setting the water temperature to the maximum set point can result in scalding hot water delivered to the faucets. It is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the installation.
  • Page 58 Step 3: Press the “UP” or “DOWN” buttons to change the maximum setpoint value. This will limit the maximum setpoint the user can select. Note: The maximum setpoint is approximately 180˚F (82˚C). flash "Max Setpoint" continues to while making adjustments °F Setpoint ...
  • Page 59 Display of Water Temperature: Step 1: In Service Mode, Press the “Select” button until “Water Temp” is displayed in the upper right section of the water heater display. This is the reading for the tank sensor. Water °F Temp idle Operational Status ...
  • Page 60 To Display and Change Temperature Setpoint: Step 1: In “Service Mode” press the “Select” button until “Setpoint” is shown in the water heater display. setpoint °F idle Status Operational  SELECT Step 2: Press the “Set” button to enter the setting mode. “Setpoint” will flash in the water heater display. "Setpoint"...
  • Page 61 Step 4: To lower the temperature setpoint, press the “Temperature Down” button until the desired temperature is shown on the water heater display. "Setpoint" Flashes setpoint °F  idle Operational Status SELECT Step 5: When the desired setpoint is reached on the water heater display, press the “Set” button to confirm the new setpoint.
  • Page 62 Step 2: Press “Set” button to change temperature format. “˚F/˚C” symbol will flash in the water heater display. "°F/°C" Flashes °F °F/C° idle Operational Status  SELECT Step 3a: Press “Temperature Up” button to change temperature format to ˚C. Changes to "°C" "°F/°C"...
  • Page 63 Step 4: Press “Set” button to confirm ˚F or ˚C format. ˚F/˚C will stop flashing. "°F/°C" Symbol Stops Flashing °F °F °F/C° idle Status Operational  SELECT Step 5: Pressing “Select” button will return display to setpoint in format selected (˚F or ˚C) immediately. Setpoint shown in °F °F idle...
  • Page 64 How to reset the control from Lockout Conditions: WARNING The following procedure is for service and installation personnel only. Resetting lockout conditions without correcting the malfunction can result in a hazardous condition. If an error code is displayed (except for #4, low flame sense current), the water heater will be in a “lockout condition” with the water heater display showing the error code number and “Service Needed”...
  • Page 65 Error Codes and Error History Display: If there is an operating problem with the water heater, an error code number will appear on the water heater display with “Service Needed” to the right of the “Status” indicator. The error code label is located below the water heater display and the following section in this Installation and Operating Instruction Manual explains the error codes with corrective actions to repair the water heater.
  • Page 66 Step 2: Press the “Temperature Down” button to select the error code index, starting with the most recent error code “10”. Error Code Index  idle Operational Status SELECT Step 3: Press the “Select” button to view the error code for “code 10”. If there is a number displayed, note what the number is. The label next to the water heater display will identify the code number.
  • Page 67 Step 4: Press the “Temperature Down” button to change to the previous code index, code #9. Error Code Index  idle Operational Status SELECT Step 5: Press the “Select” button for code index #9 to view if there are any code numbers. Stored Error Code For Code Index #9 idle...
  • Page 68 Step 6: Continue pressing the “Temperature Down” button to change to the next error code index and press “Select” to view the error code number, if any, for that index number. Continue on to index #1, the oldest error code index. The water heater display will store up to 10 error codes with the oldest code starting in code index #1 with the most recent code in code index #10.
  • Page 69 Error Definition of Code Cause of Problem and Actions Taken to Correct Code The blocked vent pressure switch contacts have opened. Check to make sure the venting system is not blocked. Check to make sure the condensate drain is not clogged and is sloping toward the drain. Make sure the vent length does Pressure Switch not exceed the specified limits.
  • Page 70 Procedure for Checking Thermostat Sensors Set the thermostat above water temperature (See temperature adjustment section) and observe system through one (1) complete cycle. Make sure system operates as desired. To check the sensor assembly, compare the resistance of the sensor wires (either outside black to center wire with yellow marking) as measured by an ohmmeter to the water temperature as measured by an accurate thermometer.

  • Page 71: Parts List

    SECTION XII: PARTS LIST EF™ – Series Water Heater 1 Combustion Surround Assembly 2 Burner Assembly (Specify model) 3 2nd Pass Top Collector Cover 4 Screw 10-16 x ¾ 5 Vent Termination Elbow 6 Thermostat Sensor Probe 7 Baffle 4” Flue (Specify Model) 8 Mag.
  • Page 72 Combustion Surround Assembly AA Keeper Latch & Catch BB Screw 8-32 x ½ RHCR CC Control Panel Assembly DD Jacket Head 28 ¼" Grey EE Switch Main Power FF Control Display GG Combustion Surround Customer must specify complete model number and serial number when ordering service parts.
  • Page 73 2 Combustion Assembly (pictured previous page) 1A Combustion Assembly (Specify model) 14A Inlet (PVC) Blower/Gas Valve Assembly (Specify Gasket Blower Transition (Specify model) model) 3A Burner Assembly (Specify model) 16A Screw 8-32 x ¼ RHCR 4A Blower – EBM (Specify model) 17A Gasket Flame Sensor 5A Silicone Hose 18A Flame Sensor...
  • Page 74 NOTES...
  • Page 75 NOTES...
  • Page 76 NOTES...

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