Troubleshooting guide | Boston Acoustics MCS 160 Home Theater System User Manual

ACCESSORY MODULE
Including Protection, Performance, and Inlet Shut-off Valve Packages
This manual must be used in
conjunction with the Installation and
Operation Manual for the water heater.
Ambler, PA 19002
www.bradfordwhite.com
Tech. Service ..........................(800) 334-3393
Service Parts ..........................(800) 538-2020
Warranty Department .............(800) 531-2111
-
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of the water heater 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 phone. Follow
the gas supplier instructions.
• If you cannot reach your gas
supplier, call the fire department.
-
For your family comfort, safety and
convenience, it is recommended these
packages be installed and serviced by
a plumbing professional.
-
Read and understand the water heater
manual before installing or operating
the Accessory Module and its
associated packages.
INSTALLATION & OPERATION MANUAL
With Troubleshooting Guide
PLACE THESE INSTRUCTIONS ADJACENT TO WATER HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE
238-47878-00B 04/10
Important Information
CONGRATULATIONS!
You have just purchased one of the finest water heater accessories on the market today!
This Installation and Operation Manual will explain in detail how to install and operate your
new Accessory Module, as well as the packages that can be connected to the Accessory
Module. We strongly recommend you contact a plumbing professional for the installation of
this new control.
We require that you carefully read this manual and your water heater manual and refer to
them when questions arise. If you have any specific questions concerning your warranty,
please consult the plumbing professional from whom your Accessory Module was
purchased. For your records, we recommend that you write the installation date for these
accessories in the back of this manual.
This manual should be kept with the Accessory Module.
NOTICE
The Accessory Module and its associated packages are for use only with Bradford White water
heaters equipped with compatible Honeywell gas controls.
The Accessory Module is always required in order to use the Protection, Performance, and/or
the Inlet Shut-off Valve Packages.
The Protection Package is required in order to use the Inlet Shut-off Valve Package.
For easier installation, the Integrated Mixing Device and Inlet Shut-off Valve should be installed
first.
Accessory Module:
The Accessory Module is an electronic component that allows the water heater gas control to be
connected to the Protection, Performance, and Inlet Shut-off Valve Packages.
Accessory Module:
Contains:
o Wire holders
o Accessory Module
o Wire ties
o Plug-in transformer
o Installation & Operation Manual
o Transformer wire harness
o Screws
o (2) gas control harnesses (only
(1) used per water heater)
Features:
o Multi-color LED used to display status and diagnostics
o Audible alarm to sound in the event a fault occurs
o Easily mounts to the water heater or can be remote mounted
o One Accessory Module fits all diameter water heaters
o Durable construction
-2-
Important Information
Protection Package (sold separately):
Contains:
o Leak sensor (2 piece)
o Wire holders
o Dam
o Wire ties
o Leak sensor wire harness
o Screws
Features:
o Senses a collection of water near the water heater
o Sounds the alarm to alert homeowners when a water heater leak is detected and
verified
o Alarm is re-settable and can be temporarily silenced
o Durable construction
o Easy installation – all wiring is provided
o Can be used without the need for a water heater drain pan
o Includes dam, which corrals the water in order for the leak to be detected
Performance Package (sold separately):
Contains:
o Integrated Mixing Device (IMD)
o Setback Control
ƒ Mixing valve
o Setback Control Junction Box
ƒ Cold water tee
Assembly
ƒ (2) flexible connectors (only
o Setback Control wire harness
(1) used per water heater)
o Wire ties
ƒ Thermo-strip
o Screws
Setback Control Features:
o 7 day / 4 period programming
o Conserves energy
o Hot water capacity indicator (provides an estimate of available hot water)
o Battery back-up stores programming during a power outage
o Can be programmed to comply with Sabbath requirements
o Similar interface to furnace / air conditioning thermostats
o Precision control of water temperature
Integrated Mixing Device Features:
o Push to turn handle
o Thermo-strip to indicate approximate outlet water temperature
o Port to draw off tank temperature water
o Port to return recirculation water into the mixing valve
o Port on cold water tee to draw off water for use without installing a saddle valve
o Allows water in the tank to be stored at higher temperatures while controlling the hot
water outlet temperature at a safe and comfortable level
o Precision control of water temperature
Inlet Shut-off Valve (sold separately):
Contains:
o Inlet shut-off valve with
o (2) 3/4” to 1” NPT bushing
integrated wire harness
o Wire ties
Features:
o Shuts off water supply to the water heater in the event a water heater tank leak is
detected
o Solid brass construction
o Robust design
o Easy wiring with integral wire harness
o Mounts directly to the water heater inlet
o Can be used on both 3/4” and 1” NPT inlet fittings
-3-
Important Information
READ CAREFULLY
The following terms are used throughout this manual to bring attention to the
presence of hazards at various risk levels, or to important information concerning
product life.
DANGER
CAUTION
Indicates an imminently hazardous
situation, which, if not avoided, will result
in death, serious injury or substantial
property damage.
Indicates potentially hazardous situation,
which, if not avoided, may result in
moderate or minor injury or property
damage.
WARNING
NOTICE
Indicates special instructions on
installation, operation or maintenance,
which are important but not related to
personal injury hazards.
Indicates a potentially hazardous
situation, which, if not avoided, could
result in death, serious injury or
substantial property damage.
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.
NOTICE
The 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.
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.
CAUTION
The water heater, when set at a lower temperature setting, is not capable of producing hot water
of sufficient temperature for sanitizing purposes.
-4-
Important Information
NOTICE
The lower the temperature setting, the greater the energy efficiency, both to heat the water and
to maintain the storage temperature during standby periods. Lower water temperatures also
extend tank life. Remember, no water heating system will provide exact temperatures at all
times. Allow a few days of operation at this setting to determine the correct temperature setting
consistent with the requirements for the installation.
WARNING
Do not operate the water heater or Accessory Module without the Accessory Module cover in
place. Do not operate the water heater or Setback Control without the Setback Control Junction
Box Assembly cover in place.
Do not operate water heater, Accessory Module, and Setback Control with jumpered or absent
controls or safety devices.
Turn off or disconnect the electrical power supply to the water heater and its accessories 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 Electrical
Code.
Do not use wire holders to the right of the water heater gas valve. The screws used for the wire
holders can damage the water heater internal components.
For energy efficient operation of your water heater, the suggested initial water temperature setting is
120˚F (49˚C). During the winter season, or any cold period, you may desire a higher water temperature
setting to adjust for the colder incoming water. This adjustment, however, may cause additional
condensation to form on the cooler tank surface. This does not mean the tank is leaking. During summer
months, the warmer incoming water temperatures will benefit the performance of your water heater and
reduce the amount of condensation developed.
Condensation does not mean your tank is leaking. Over 40% of reported tank leaks on installation are
proven to be condensation. To avoid unnecessary expense and inconvenience, make sure the tank is
leaking before calling a service technician.
Water temperature over 125°F
can cause severe burns
instantly or death from scalds.
Children, disabled and elderly
are at highest risk of being
scalded.
Review this instruction manual
before setting temperature
at water heater.
Feel water before bathing or
showering.
Temperature limiting valves
are available.
-5-
Table of Contents
Page
Tools Required............................................................................................ 7
Package Components................................................................................. 8
Accessory Module ........................................................................... 8
Protection Package ......................................................................... 9
Performance Package..................................................................... 10
Inlet Valve Shut-off Package ........................................................... 11
Wiring Diagram ........................................................................................... 12
Accessory Module Installation..................................................................... 13
Setback Control Installation ........................................................................ 27
Integrated Mixing Device - IMD ................................................................... 39
Leak Sensor Installation.............................................................................. 40
Inlet Shut-off Valve Installation.................................................................... 49
Remote Mounting the Setback Control ....................................................... 56
Start-up Procedure...................................................................................... 67
Diagnostic Codes ........................................................................................ 73
Notes........................................................................................................... 74
Warranty...................................................................................................... 75
-6-
Tools Required
Slotted Screwdriver
Philips Screwdriver
1/8” Drill bit
Drill
Needle nose pliers
Pipe dope
Adjustable wrench
Caulk gun
RTV sealant (silicone)
Pipe cutter
Propane torch
Solder
Flux
Wire Cutters
Wire Strippers
Fine Point Marker
-7-
Package Components
Accessory Module
ACCESSORY MODULE DIAGNOSTIC CODES
FOR USE WITH THE FOLLOWING GAS VALVES:
222-47463-01
222-47463-02
222-47464-01
222-47464-02
222-47465-01
222-47465-02
222-47466-01
222-47466-02
222-46402-01
222-46402-02
222-46990-01
222-46990-02
222-46991-01
222-46991-02
LED STATUS
COLOR
GREEN
ACCESSORY MODULE
R1
C1
BK
LK
C2
NO
NC
D/1
R/2
C/3
A1
A2
BK
BL
BR
BK
R
BK
W
BK
Y
W
R
BK
W
R
ACCESSORY MODULE STATUS
PATTERN
LED on continuously.
Power on (no fault).
One flash and three second pause.
Leak alarm fault. Water shut-off valve open.
Two flashes and three second pause.
Leak alarm fault. Water shut-off valve closed.
AMBER
Three flashes and three second pause.
Anode depletion alarm or not connected.
AMBER
Four flashes and three second pause.
Leak sensor malfunction.
AMBER
Five flashes and three second pause.
Gas valve missing/not connected.
LED strobe (quick flashes).
Hardware error.
RED
RED
RED
See Installation and Operation Instruction Manual for probable causes
associated with each control status code.
238-47879-00A
*WHEN CONNECTING LEAK SENSOR, REMOVE RESISTOR
BETWEEN C1 & LK.
**WHEN CONNECTING ANODE DEPLETION SENSOR, REMOVE RESISTOR
BETWEEN A1 & A2.
SEE INSTALLATION AND OPERATION MANUAL FOR MORE INFORMATION.
FOR USE WITH THE FOLLOWING GAS VALVES:
222-45613-01
222-45613-02
222-45614-01
222-45614-02
ACCESSORY MODULE
R
BK
W
R1
C1
BK
LK
C2
NO
NC
D/1
R/2
C/3
A1
A2
BK
BL
BR
BK
R
BK
W
BK
Y
D
R
C
W
R
*WHEN CONNECTING LEAK SENSOR, REMOVE RESISTOR
BETWEEN C1 & LK.
**WHEN CONNECTING ANODE DEPLETION SENSOR, REMOVE RESISTOR
BETWEEN A1 & A2.
SEE INSTALLATION AND OPERATION MANUAL FOR MORE INFORMATION.
238-47880-00A
Table 1
1A
2A
3A
4A
5A
6A
7A
8A
9A
10A
11A
Accessory Module
Description
Plug-in Transformer
WV4460 Wire Harness
Transformer Wire Harness
WV8840 Wire Harness
Wire Holders
Installation & Operation Manual
Wiring Diagram Label
Diagnostic Label
Wire Ties
Screws
Accessory Module
Quantity
1
1
1
1
4
1
1
1
4
9
1
NOTICE
The WV4460 wire harness must be used with gas controls with intermittent pilots. The WV8840
wire harness must be used with gas controls with standing pilots.
-8-
Package Components
Protection Package
Table 2
1B
2B
3B
4B
5B
6B
7B
Protection Package
Description
Leak Sensor Bracket
Leak Sensor Housing
Dam
Screws
Leak Sensor Wire Harness
Wire Holders
Wire Ties
-9-
Quantity
1
1
1
6
1
4
4
Package Components
Performance Package
Table 3
1C
2C
3C
4C
5C
6C
7C
8C
Performance Package
Description
Setback Control Wire Harness
Integrated Mixing Device, IMD
- Cold Water Tee
- Mixing Valve
- 8” Flexible Connector
- 11” Flexible Connector
- Instruction & Operation Manual
- Thermo-strip
Setback Control (batteries included)
Wire Ties
Setback Control Junction Box Assembly
Screws
Setback Cover Plate
Setback Control Instruction & Operation
Manual
-10-
Quantity
1
1
1
2
1
6
1
1
Package Components
Inlet Shut-off Valve Package
Table 4
1D
2D
3D
Inlet Shut-off Valve
Description
Inlet Shut-off Valve with Integrated Wire
Harness
¾” x 1” NPT Brass Bushings
Wire Ties
-11-
Quantity
1
2
4
Wiring Diagram
-12-
Accessory Module Installation
In the following section, the instructions detail how to install the Accessory Module. Properly
locating and mounting the Accessory Module is required.
Unpack the Accessory Module
Step 1: Remove the Accessory Module and its components from their packaging, as shown in Figure 1.
Figure 1
Determine the Gas Control Wire Harness
Step 2: If the gas control uses an intermittent pilot, the WV4460 wire harness must be used. The
WV4460 gas control and wire harness are shown in Figure 2. Discard the WV8840 wire harness.
Otherwise, proceed to Step 3.
Determine gas control
number using label on side
of control
WV4460
Gas Control
WV4460 Wire
Harness
Figure 2
-13-
Accessory Module Installation
Determine the Gas Control Wire Harness – cont’d
Step 3: If the gas control uses a standing pilot, the WV8840 wire harness must be used. The WV8840
gas control and wire harness are shown in Figure 3. Discard the WV4460 wire harness.
WV8840 Wire
Harness
WV8840
Gas Control
Figure 3
Determine gas control
number using label on side
of control
Locate the Accessory Module
Step 4: The Accessory Module must be mounted to the left of the water heater gas control. Hold the
Accessory Module to the water heater jacket as high as possible and practical. Do not cover any safety
or warning labels on the water heater. This is shown in Figure 4.
Accessory Module must
be mounted to the left of
this line
Figure 4
WARNING
Failure to properly locate the Accessory Module may cause damage to the water heater wiring
harness.
-14-
Accessory Module Installation
Mark the Location of the Accessory Module
Step 5: Using a marker, mark the location of the Accessory Module screw holes. This is shown in
Figure 5.
Water
Heater
Accessory
Module
Marker
Figure 5
Set the Accessory Module Aside
Step 6: Remove the Accessory Module from the water heater jacket, as shown in Figure 6.
Accessory
Module
Water
Heater
Figure 6
-15-
Accessory Module Installation
Drill the Accessory Module Screw Holes
Step 7: Using a 1/8” drill bit and drill, drill the (2) screw holes that were marked in Step 5. This is shown
in Figure 7.
Water
Heater
Marked drill
locations
Drill
Figure 7
Position the Accessory Module
Step 8: Put the Accessory Module up against the water heater jacket and position it to the pre-drilled
holes. This is shown in Figure 8.
Pre-drilled
holes
Accessory
Module
Water
Heater
Figure 8
-16-
Accessory Module Installation
Mounting the Accessory Module
Step 9: Using (2) of the included Philips head screws, screw the Accessory Module to the water heater
jacket, as shown in Figure 9.
Water Heater
jacket
Accessory
Module
Philips head
screwdriver
Figure 9
Apply the Necessary Labels
Step 10: Apply both the wiring diagram and diagnostic labels. These labels should be applied to the
water heater jacket near the Accessory Module. This is shown in Figure 10.
Accessory Module
Apply the Wiring
Diagram and
Diagnostic labels
Water Heater
Figure 10
-17-
Accessory Module Installation
Remove the Accessory Module Cover
Step 11: Using a Philips head screwdriver, loosen both screws on the Accessory Module cover, as
shown in Figure 11. The cover screws are permanently retained and cannot be completely removed.
Retain the cover for later use.
Accessory
Module base
Accessory
Module base
Philips head
screwdriver
Wiring Diagram
label
Accessory Module
cover screws
Figure 11
Prepare the Plug-in Transformer for Assembly
Step 12: Loosen the (2) slotted screws on the transformer. These screws are permanently retained and
cannot be completely removed. This is shown in Figure 12.
Plug-in
Transformer
Slotted head
screwdriver
Figure 12
Slotted screws
-18-
Accessory Module Installation
Assemble the Transformer and its Wire Harness
Step 13: Take one end of the transformer wire harness and slide each fork terminal under one of the
screws. This is shown in Figure 13.
Plug-in
Transformer
Transformer
slotted screws
Transformer
wire harness
Figure 13
NOTICE
If the Transformer wire harness is not of sufficient length, move the nearest electrical box to
within reaching distance.
Connect the Transformer and its Wire Harness
Step 14: Tighten both screws on the transformer down, as shown in Figure 14.
Plug-in
Transformer
Slotted head
screwdriver
Transformer
slotted screws
Figure 14
-19-
Transformer
wire harness
Accessory Module Installation
Prepare to Connect the Transformer Wire Harness to the Accessory Module
Step 15: Loosen the (2) Philips head screws on the Accessory Module, labeled “R1” and “C1.” This is
shown in Figure 15.
Accessory
Module
Philips head
screwdriver
Figure 15
Insert the Transformer Wire Harness into the Accessory Module
Step 16: Insert each wire stripped end of the Transformer wire harness under the screws labeled “R1”
and “C1.” This is shown in Figure 16.
Accessory
Module
Transformer
Wire Harness
Figure 16
-20-
Accessory Module Installation
Connect the Transformer Wire Harness and the Accessory Module
Step 17: Tighten both screws, “R1” and “C1,” while holding the Transformer wire harness in place, as
shown in Figure 17.
Accessory
Module
Philips head
screwdriver
Transformer
Wire Harness
Figure 17
Connect Accessory Module to WV4460 Wire Harness
Step 18: If the water heater gas control has an intermittent pilot (WV4460 gas control), loosen the (3)
screws on the Accessory Module labeled “D/1,” “R/2,” and “C/3.” This is shown in Figure 18. If the water
heater has a standing pilot, proceed to Step 25.
Accessory
Module
Philips head
screwdriver
Figure 18
-21-
Accessory Module Installation
Assemble the WV4460 Wire Harness and Accessory Module
Step 19: Insert the red wire, from the WV4460 wire harness, under the screw labeled “D/1.” This is shown
in Figure 19.
Accessory
Module
WV4460 Wire
Harness Red Wire
Figure 19
Connect the WV4460 Wire Harness and Accessory Module
Step 20: Tighten the screw labeled “D/1,” as shown in Figure 20.
Accessory
Module
Philips head
screwdriver
WV4460 Wire
Harness Red Wire
Figure 20
-22-
Accessory Module Installation
Assemble the WV4460 Wire Harness and Accessory Module – cont’d
Step 21: Insert the black wire, from the WV4460 wire harness, under the screw labeled “R/2.” This is
shown in Figure 21.
Accessory
Module
WV4460 Wire
Harness Red Wire
WV4460 Wire
Harness Black Wire
Figure 21
Connect the WV4460 Wire Harness and Accessory Module – cont’d
Step 22: Tighten the screw labeled “R/2,” as shown in Figure 22.
Accessory
Module
WV4460 Wire
Harness Red Wire
Philips head
screwdriver
WV4460 Wire
Harness Black Wire
Figure 22
-23-
Accessory Module Installation
Assemble the WV4460 Wire Harness and Accessory Module – cont’d
Step 23: Insert the white wire, from the WV4460 wire harness, under the screw labeled “C/3.” This is
shown in Figure 23.
Accessory
Module
WV4460 Wire
Harness Red Wire
WV4460 Wire
Harness Black Wire
WV4460 Wire
Harness White Wire
Figure 23
Connect the WV4460 Wire Harness and Accessory Module – cont’d
Step 24: Tighten the screw labeled “C/3,” as shown in Figure 24. Proceed to Step 26 when finished.
Accessory
Module
WV4460 Wire
Harness Red Wire
Philips head
screwdriver
WV4460 Wire
Harness White Wire
Figure 24
-24-
WV4460 Wire
Harness Black Wire
Accessory Module Installation
Connect the Accessory Module to the WV8840 Wire Harness
Step 25: Insert one end of the WV8840 wire harness over the edge of the Accessory Module circuit board.
This connection point is on the bottom right hand side of the circuit board, and it is shown in Figure 25.
Proceed to Step 27 when finished.
Accessory
Module
WV8840 Wire
Harness
WV8840 Wire
Harness
Figure 25
Connect the WV4460 Wire Harness to the WV4460 Gas Control
Step 26: Push the plastic connector on the WV4460 wire harness into the recessed area on the right side
of the WV4460 gas control. This is shown in Figure 26.
WV4460 Gas
Control
WV4460 Wire
Harness
Figure 26
-25-
Accessory Module Installation
Connect the WV8840 Wire Harness to the WV8840 Gas Control
Step 27: Push the plastic connector on the WV8840 wire harness into the recessed area on the bottom
side of the WV8840 gas control. This is shown in Figure 27.
WV8840 Gas
Control
WV8840 Wire
Harness
Figure 27
The Accessory Module installation is complete. Proceed to the
installation sections for the other purchased packages.
-26-
Setback Control Installation
In the following section, the instructions detail how to install the Setback Control on the water
heater. The Accessory Module must be installed for the Setback Control to work with the water
heater gas control.
Unpack the Setback Control Junction Box Assembly
Step 1: Remove the Setback Control Junction Box Assembly and its components from their packaging.
This is shown in Figure 28.
Figure 28
Unpack the Setback Control
Step 2: Remove the Setback Control and its batteries from their packaging, as shown in Figure 29.
Supplied AAA
Batteries
Setback
Control
Figure 29
-27-
Setback Control Installation
Remove the Setback Control Battery Holder
Step 3: Depress the top side of the battery holder and remove it. This is shown in Figure 30.
Battery
Holder
Setback
Control
Figure 30
Install the Setback Control Batteries
Step 4: Install the (2) supplied AAA batteries into the battery holder of the Setback Control, as shown in
Figure 31.
Battery
Holder
(2) Supplied AAA
Batteries
Figure 31
-28-
Setback Control Installation
Install the Setback Control Battery Holder
Step 5: Install the Setback Control Battery Holder, just as it was installed prior to Step 3. This is shown in
Figure 32.
Battery
Holder
Setback
Control
Figure 32
Remove the Protective Plate
Step 6: Remove the Setback Control protective plate from the Setback Control by pulling these items
apart. This is shown in Figure 33. Some force may be required to separate these. Discard the protective
plate.
Protective
Plate
Setback
Control
Figure 33
NOTICE
Do not discard the Protective Plate if the Setback Control is going to be remote mounted.
-29-
Setback Control Installation
Locate the Setback Control Junction Box Assembly
Step 7: Place the Setback Control Junction Box Assembly on top of the water heater. This assembly must
face the front of the water heater, and it must be located close to the centerline of the water heater. This is
shown in Figure 34. The Setback Control Junction Box Assembly must be located as far from the draft
hood as possible, if installed on an atmospheric water heater.
Move the Setback Control
Junction Box Assembly as
far from the draft hood (or
blower) as possible
Water Heater
Centerline
Figure 34
WARNING
Do not mount the Setback Control Junction Box Assembly close to the draft hood.
Mark the Location of the Setback Control Junction Box Assembly
Step 8: Using a marker, mark the location of both holes in the Setback Control Junction Box Assembly.
This is shown in Figure 35.
Setback Control
Junction Box Assembly
Top of Water
Heater
Marker
Figure 35
-30-
Setback Control Installation
Remove the Setback Control Junction Box Assembly
Step 9: Remove the Setback Control Junction Box Assembly from the top of the water heater, as shown in
Figure 36.
Setback Control
Junction Box Assembly
Top of Water
Heater
Figure 36
Drill the Setback Control Junction Box Assembly Mounting Holes
Step 10: Using a 1/8” drill bit and drill, drill the (2) screw holes that were marked in Step 8. This is shown
in Figure 37.
Drill
Marked Drill
Locations
Figure 37
-31-
Top of Water
Heater
Setback Control Installation
Position the Setback Control Junction Box Assembly
Step 11: Put the Setback Control Junction Box Assembly back on top of the water heater and position it to
the pre-drilled holes. This is shown in Figure 38.
Setback Control
Junction Box Assembly
Top of Water
Heater
Figure 38
Mount the Setback Control Junction Box Assembly
Step 12: Using (2) of the included Philips head screws, screw the Setback Control Junction Box Assembly
to the top of the water heater, as shown in Figure 39.
Setback Control
Junction Box Assembly
Top of Water
Heater
Philips head
screwdriver
Figure 39
WARNING
Do not mount the Setback Control Junction Box Assembly close to the draft hood. Position this
assembly as close to the front of the water heater as possible.
-32-
Setback Control Installation
Install the Setback Control
Step 13: Snap the Setback Control into the backplate on the Setback Control Junction Box Assembly.
Align the Setback Control to the backplate, and press until it is fully seated. This is shown in Figure 40.
Setback Control
Junction Box Assembly
Backplate Already
Installed
Setback
Control
Top of Water
Heater
Figure 40
Connect the Setback Control Wire Harness to the Setback Control Junction Box Assembly
Step 14: Take the plastic connector end of the Setback Control wire harness, and connect it to its
connector mate in the back of the Setback Control Junction Box Assembly. This is shown in Figure 41.
Setback Control Junction
Box Assembly
Top of Water
Heater
Connector
Mate
Setback Control
Wire Harness
Figure 41
-33-
Setback Control Installation
Connect the Setback Control Wire Harness to the Accessory Module
Step 15: If the water heater gas control has an intermittent pilot (WV4460 gas control), the connection,
“D/1,” is already being used. This same connection point is used to connect the Setback Control. Loosen
the screw “D/1.” This is shown in Figure 42.
Accessory
Module
WV8840 Wire
Harness (if installed)
WV4460 Wire Harness
Red Wire (if installed)
WV4460 Wire Harness
White Wire (if installed)
Philips head
screwdriver
WV4460 Wire Harness
Black Wire (if installed)
Figure 42
Assemble the Setback Control Wire Harness and Accessory Module
Step 16: Insert the red wire, from the Setback Control wire harness, under the screw labeled “D/1.” If the
water heater has a WV4460 gas control, the gas control wire harness red wire must be retained
underneath this screw also. This is shown in Figure 43.
Accessory
Module
WV8840 Wire
Harness (if installed)
WV4460 Wire Harness
Red Wire (if installed)
Setback Control Wire
Harness Red Wire
WV4460 Wire Harness
White Wire (if installed)
Figure 43
-34-
WV4460 Wire Harness
Black Wire (if installed)
Setback Control Installation
Connect the Setback Control Wire Harness and Accessory Module
Step 17: Tighten the screw labeled “D/1,” as shown in Figure 44.
Accessory
Module
WV8840 Wire
Harness (if installed)
WV4460 Wire Harness
Red Wire (if installed)
Setback Control Wire
Harness Red Wire
WV4460 Wire Harness
White Wire (if installed)
Philips head
screwdriver
WV4460 Wire Harness
Black Wire (if installed)
Figure 44
Assemble the Setback Control Wire Harness and Accessory Module – cont’d
Step 18: If the water heater gas control has an intermittent pilot (WV4460 gas control), the connection,
“R/2,” is already being used. This same connection point is used to connect the Setback Control. Loosen
the screw “R/2.” This is shown in Figure 45.
Accessory
Module
WV8840 Wire
Harness (if installed)
Setback Control Wire
Harness Red Wire
WV4460 Wire Harness
White Wire (if installed)
Philips head
screwdriver
WV4460 Wire Harness
Black Wire (if installed)
WV4460 Wire Harness
Red Wire (if installed)
Figure 45
-35-
Setback Control Installation
Assemble the Setback Control Wire Harness and Accessory Module – cont’d
Step 19: Insert the black wire, from the Setback Control wire harness, under the screw labeled “R/2.” If
the water heater has a WV4460 gas control, the gas control wire harness black wire must be retained
underneath this screw also. This is shown in Figure 46.
Accessory
Module
WV4460 Wire Harness
Red Wire (if installed)
WV8840 Wire
Harness (if installed)
Setback Control Wire
Harness Red Wire
WV4460 Wire Harness
White Wire (if installed)
Setback Control Wire
Harness Black Wire
WV4460 Wire Harness
Black Wire (if installed)
Figure 46
Connect the Setback Control Wire Harness and Accessory Module – cont’d
Step 20: Tighten the screw labeled “R/2,” as shown in Figure 47.
Accessory
Module
WV4460 Wire Harness
Red Wire (if installed)
WV8840 Wire
Harness (if installed)
Setback Control Wire
Harness Red Wire
WV4460 Wire Harness
White Wire (if installed)
Philips head
screwdriver
WV4460 Wire Harness
Black Wire (if installed)
Setback Control Wire
Harness Black Wire
Figure 47
-36-
Setback Control Installation
Assemble the Setback Control Wire Harness and Accessory Module – cont’d
Step 21: If the water heater gas control has an intermittent pilot (WV4460 gas control), the connection,
“C/3,” is already being used. This same connection point is used to connect the Setback Control. Loosen
the screw “C/3.” This is shown in Figure 48.
Accessory
Module
WV4460 Wire Harness
Red Wire (if installed)
WV8840 Wire
Harness (if installed)
Setback Control Wire
Harness Red Wire
WV4460 Wire Harness
White Wire (if installed)
Philips head
screwdriver
WV4460 Wire Harness
Black Wire (if installed)
Setback Control Wire
Harness Black Wire
Figure 48
Assemble the Setback Control Wire Harness and Accessory Module – cont’d
Step 22: Insert the white wire, from the Setback Control wire harness, under the screw labeled “C/3.” If
the water heater has a WV4460 gas control, the gas control wire harness white wire must be retained
underneath this screw also. This is shown in Figure 49.
Accessory
Module
WV8840 Wire
Harness (if installed)
WV4460 Wire Harness
Red Wire (if installed)
WV4460 Wire Harness
White Wire (if installed)
Setback Control Wire
Harness Red Wire
Setback Control Wire
Harness White Wire
Setback Control Wire
Harness Black Wire
WV4460 Wire Harness
Black Wire (if installed)
Figure 49
-37-
Setback Control Installation
Connect the Setback Control Wire Harness and Accessory Module – cont’d
Step 23: Tighten the screw labeled “C/3,” as shown in Figure 50.
Accessory
Module
WV8840 Wire
Harness (if installed)
WV4460 Wire Harness
Red Wire (if installed)
WV4460 Wire Harness
White Wire (if installed)
Setback Control Wire
Harness Red Wire
Setback Control Wire
Harness White Wire
Philips head
screwdriver
WV4460 Wire Harness
Black Wire (if installed)
Setback Control Wire
Harness Black Wire
Figure 50
The Setback Control installation is complete. Proceed to the
installation sections for the other purchased packages. Or, if finished,
proceed to the Start-up Procedure on page 67.
-38-
Integrated Mixing Device - IMD
Refer to the instructions included with Integrated Mixing Device (IMD), on how to install and
operate the IMD. Figure 51 shows the contents included with the integrated mixing device.
Figure 51
CAUTION
The piping diagram supplied with the water heater must be followed.
-39-
Leak Sensor Installation
In the following section, the instructions detail how to install the Leak Sensor. The Accessory
Module must be installed for the Leak Sensor to work with the water heater gas control.
The leak sensor can take up to 15 minutes to sense and verify a water heater tank leak.
Unpack the Leak Sensor and its Components
Step 1: Remove the Leak Sensor and its components from their packaging, as shown in Figure 52.
Figure 52
Assemble the Leak Sensor
Step 2: Insert the Leak Sensor bracket into the Leak Sensor housing, as shown in Figure 53.
Leak Sensor
Housing
Leak Sensor
Bracket
Figure 53
-40-
Leak Sensor
(assembled)
Leak Sensor Installation
Connect the Leak Sensor and its Wire Harness
Step 3: Connect the Leak Sensor wire harness to the Leak Sensor (specifically the end with the plastic
connector), as shown in Figure 54.
Leak Sensor
Leak Sensor
Wire Harness
Plastic
Connector
Figure 54
Prepare the Accessory Module for the Leak Sensor
Step 4: Loosen the screw labeled “C1,” as shown in Figure 55. Ensure that the Transformer wire harness
wire going to this same location remains inserted under this screw.
Accessory
Module
Philips head
screwdriver
Leak Sensor
Resistor
Transformer
Wire Harness
Figure 55
-41-
Leak Sensor Installation
Prepare the Accessory Module for the Leak Sensor – cont’d
Step 5: Loosen the screw labeled “LK,” as shown in Figure 56.
Accessory
Module
Philips head
screwdriver
Leak Sensor
Resistor
Transformer
Wire Harness
Figure 56
Remove the Leak Sensor Resistor
Step 6: Using needle nose pliers, remove the Leak Sensor resistor from the Accessory Module and
discard. This is shown in Figure 57.
Accessory
Module
Leak Sensor
Resistor
Transformer
Wire Harness
Figure 57
-42-
Leak Sensor Installation
Assemble the Leak Sensor Wire Harness and the Accessory Module
Step 7: Insert the red wire, from the Leak Sensor wire harness, under the screw labeled “C1.” This is
shown in Figure 58. Ensure that the wire from the Transformer wire harness at this location is retained
under this screw.
Accessory
Module
Transformer
Wire Harness
Leak Sensor Wire
Harness Red Wire
Figure 58
Connect the Leak Sensor Wire Harness and Accessory Module
Step 8: Tighten the screw labeled “C1,” as shown in Figure 59.
Philips head
screwdriver
Accessory
Module
Leak Sensor Wire
Harness Red Wire
Transformer
Wire Harness
Figure 59
-43-
Leak Sensor Installation
Assemble the Leak Sensor Wire Harness and the Accessory Module – cont’d
Step 9: Insert the black wire, from the Leak Sensor wire harness, under the screw labeled “LK.” This is
shown in Figure 60.
Accessory
Module
Transformer
Wire Harness
Leak Sensor Wire
Harness Black Wire
Leak Sensor Wire
Harness Red Wire
Figure 60
Connect the Leak Sensor Wire Harness and Accessory Module – cont’d
Step 10: Tighten the screw labeled “LK,” as shown in Figure 61.
Accessory
Module
Transformer
Wire Harness
Philips head
screwdriver
Leak Sensor Wire
Harness Black Wire
Leak Sensor Wire
Harness Red Wire
Figure 61
-44-
Leak Sensor Installation
Position the Leak Sensor
Step 11: Position the Leak Sensor up against the water heater jacket, as shown in Figure 62. The Leak
Sensor must be positioned to the left of the water heater gas control. The Leak Sensor must sit flat on the
floor or in the drain pan.
Position the Leak Sensor 3” from the Air Slots or
if not Present, Position it 6” from the Doorway
Air Slots
Leak Sensor
Doorway
Figure 62
Mark the Location of the Leak Sensor
Step 12: Using a marker, mark the location of the hole in the Leak Sensor bracket, as shown in Figure 63.
Marker
Leak Sensor
Wire Harness
Leak Sensor
Bracket
Figure 63
CAUTION
The water heater must be installed on a level floor.
WARNING
The Leak Sensor can be mounted in a water heater drain pan. If the installation does not use a
drain pan, the dam should be used to corral the water heater tank leak to the Leak Sensor.
The bottom of the Leak Sensor must be touching the floor. Failure to do so will result in
inaccurate leak detection.
-45-
Leak Sensor Installation
Remove the Leak Sensor
Step 13: Remove the Leak Sensor from the water heater jacket, and set it aside. This is shown in Figure
64.
Leak Sensor
Wire Harness
Leak Sensor
Figure 64
Drill the Leak Sensor Mounting Hole
Step 14: Using a 1/8” drill bit and drill, drill the screw hole that was marked in Step 12. This is shown in
Figure 65.
Marked Drill
Location
Drill
Figure 65
-46-
Leak Sensor Installation
Position the Leak Sensor
Step 15: Put the Leak Sensor back in position against the water heater jacket and position to the predrilled hole, as shown in Figure 66.
Water Heater
Jacket
Leak Sensor
Wire Harness
Leak Sensor
Figure 66
Mount the Leak Sensor
Step 16: Using (1) of the included Philips head screws, screw the Leak Sensor to the water heater jacket.
This is shown in Figure 67.
Leak Sensor
Wire Harness
Philips Head
Screw
Philips head
screwdriver
Leak Sensor
Figure 67
-47-
Leak Sensor Installation
Position the Dam
Step 17: Position the dam around the water heater, so it surrounds the water heater and corrals a water
heater tank leak towards the Leak Sensor. This is shown in Figure 68.
Dam
Leak Sensor
Figure 68
WARNING
The dam must be mounted against the floor or it will not hold any water.
Fill in the Gaps
Step 18: Fill in any gaps between the dam and the floor. This is shown in Figure 69.
Caulk Gun with
RTV Silicone
Fill Gaps
between Floor
and Dam
Figure 69
The Leak Sensor installation is complete. Proceed to the installation
sections for the other purchased packages. Or, if finished, proceed to
the Start-up Procedure on page 67.
-48-
Inlet Shut-off Valve Installation
In the following section, the instructions detail how to install the Inlet Shut-off Valve. If installed,
this device will shut off the water supply to the water heater after the Leak Sensor has sensed
and verified a water heater tank leak has occurred. The Accessory Module and Leak Sensor
must be installed for the Inlet Shut-off Valve to work with the water heater gas control.
The inlet shut-off valve can take up to 16 minutes to close, if installed, after a water heater tank
leak is sensed and verified.
Unpack the Inlet Shut-off Valve
Step 1: Remove the Inlet Shut-off Valve and its components from their packaging, as shown in Figure 70.
Figure 70
Prepare the Water Heater for the Installation of the Inlet Shut-off Valve
Step 2: If the water heater is already installed and the water heater is full of water, pressure must be
removed from the water heater tank, and the tank must be at least partially drained.
WARNING
If installed properly, the Inlet Shut-off Valve will prevent continuous flow when a water heater
tank leak is detected and verified. If damage will occur, a drain pan must be installed and piped
to an adequate floor drain.
-49-
Inlet Shut-off Valve Installation
Determine if Bushings are Necessary
Step 3: If the water heater uses a 3/4” NPT thread water inlet, the (2) included 3/4” x 1” NPT bushings
must be used. Proceed to Step 4. Otherwise, proceed to Step 6.
Prepare Bushings for Installation
Step 4: Apply pipe dope (suitable for potable water use) to the threads of the bushings, as shown in
Figure 71.
Put Pipe Dope
onto Bushing
Threads
Figure 71
-50-
Inlet Shut-off Valve Installation
Install the Bushings
Step 5: Thread the bushings into each end of the Inlet Shut-off Valve, as shown in Figure 72.
Inlet Shut-off
Valve
Bushings
Figure 72
Install the Inlet Shut-off Valve
Step 6: Thread the Inlet Shut-off Valve onto the water heater inlet (cold). Or, if an integrated mixing
device is used, thread the Inlet Shut-off Valve onto the IMD inlet. This is shown in Figure 73.
Inlet Shut-off
Valve
Water Heater
Inlet (cold)
IMD Inlet (cold)
Figure 73
NOTICE
Remove the draft hood and venting to install the Inlet Shut-off Valve, if necessary.
-51-
Inlet Shut-off Valve Installation
Connect the Cold Water Supply
Step 7: Pipe the cold water supply piping to the Inlet Shut-off Valve inlet, as shown in Figure 74.
Cold Water
Supply Piping
Inlet Shut-off
Valve
Figure 74
CAUTION
The piping diagram supplied with the water heater must be followed.
Connect the Inlet Shut-off Valve Harness to the Accessory Module
Step 8: Loosen the (3) screws on the Accessory Module labeled “C2,” “NO,” and “NC.” This is shown in
Figure 75.
Philips head
screwdriver
Accessory
Module
Figure 75
-52-
Inlet Shut-off Valve Installation
Assemble the Inlet Shut-off Valve Wire Harness and the Accessory Module
Step 9: Insert the blue wire, from the Inlet Shut-off Valve wire harness, under the screw labeled “C2,” as
shown in Figure 76.
Accessory
Module
Inlet Shut-off
Valve Wire
Harness Blue
Wire
Figure 76
Connect the Inlet Shut-off Valve Wire Harness to the Accessory Module
Step 10: Tighten the screw labeled “C2.” This is shown in Figure 77.
Accessory
Module
Inlet Shut-off
Valve Wire
Harness Blue
Wire
Philips head
screwdriver
Figure 77
-53-
Inlet Shut-off Valve Installation
Assemble the Inlet Shut-off Valve Wire Harness and the Accessory Module – cont’d
Step 11: Insert the brown wire, from the Inlet Shut-off Valve wire harness, under the screw labeled “NO,”
as shown in Figure 78.
Accessory
Module
Inlet Shut-off Valve
Wire Harness Blue
Wire
Inlet Shut-off Valve
Wire Harness Brown
Wire
Figure 78
Connect the Inlet Shut-off Valve Wire Harness and the Accessory Module – cont’d
Step 12: Tighten the screw labeled “NO.” This is shown in Figure 79.
Accessory
Module
Inlet Shut-off Valve
Wire Harness Blue
Wire
Philips head
screwdriver
Inlet Shut-off Valve
Wire Harness Brown
Wire
Figure 79
-54-
Inlet Shut-off Valve Installation
Assemble the Inlet Shut-off Valve Wire Harness and the Accessory Module – cont’d
Step 13: Insert the black wire, from the Inlet Shut-off Valve wire harness, under the screw labeled “NC,” as
shown in Figure 80.
Accessory
Module
Inlet Shut-off Valve
Wire Harness Blue
Wire
Inlet Shut-off Valve
Wire Harness Brown
Wire
Inlet Shut-off Valve
Wire Harness Black
Wire
Figure 80
Connect the Inlet Shut-off Valve Wire Harness to the Accessory Module – cont’d
Step 14: Tighten the screw labeled “NC.” This is shown in Figure 81.
Accessory
Module
Inlet Shut-off Valve
Wire Harness Blue
Wire
Inlet Shut-off Valve
Wire Harness Brown
Wire
Philips head
screwdriver
Figure 81
Inlet Shut-off Valve
Wire Harness Black
Wire
The Inlet Shut-off Valve installation is complete. Proceed to the
installation sections for the other purchased packages. Or, if
finished, proceed to the Start-up Procedure on page 67.
-55-
Remote Mounting the Setback Control
In the following section, the instructions detail how to Remote Mount the Setback Control.
Remove the Setback Control from the Backplate
Step 1: Remove the Setback Control from the backplate attached to the Setback Control Junction Box
Assembly. Some force may be required. This is shown in Figure 82.
Setback Control
Junction Box
Assembly
Setback
Control
Backplate (already
installed)
Figure 82
Prepare the Backplate for Wiring
Step 2: Loosen the (3) slotted screws on the backplate attached to the Setback Control Junction Box
Assembly. This is shown in Figure 83.
Slotted head
screws
Slotted head
screwdriver
Setback Control
Junction Box
Assembly
Figure 83
-56-
Backplate (already
installed)
Remote Mounting the Setback Control
Mount the Protective Plate
Step 3: Mount the Setback Control Protective Plate in a desired location. Be sure that the Setback
Control will not be direct sunlight, as the display may be difficult to read. This is shown in Figure 84.
Drill
Wall
Protective
Plate
Figure 84
Measure Wire for Remote Mounting
Step 4: Measure and cut (3) pieces of 18 AWG wire to a sufficient length to reach from the backplate on
the Setback Control Junction Box Assembly to the Setback Control Protective Plate. This is shown in
Figure 85.
18 AWG
Wire
Figure 85
-57-
Remote Mounting the Setback Control
Label the Wires for Remote Mounting
Step 5: Label the (3) cut wires (A), (B), and (C) respectively. Label both ends of the wires. This is shown
in Figure 86. Masking tape can be used to label the wires.
Label Each
Wire
Figure 86
Prepare the Wires for Installation
Step 6: Strip approximately 1/4” of the wire’s insulation from each end of the three wires. This is shown in
Figure 87.
Strip
Approximately 1/4”
from Each End of
All (3) Wires
Figure 87
-58-
Remote Mounting the Setback Control
Install Wire (A) – Backplate
Step 7: Using wire (A), insert one end into the top terminal location on the backplate (located on the
Setback Control Junction Box Assembly). This is shown in Figure 88. Be sure that the wire already
located in this location is not dislodged.
Wire (A)
Wires Already
Installed
Backplate
Figure 88
Fasten Wire (A) into its Designated Location – Backplate
Step 8: Tighten the slotted screw in the top terminal location on the backplate (located on the Setback
Control Junction Box Assembly). This is shown in Figure 89.
Wire (A)
Setback Control
Junction Box Assembly
Slotted head
screwdriver
Figure 89
-59-
Backplate
Remote Mounting the Setback Control
Install Wire (B) – Backplate
Step 9: Using wire (B), insert one end into the middle terminal location on the backplate (located on the
Setback Control Junction Box Assembly). This is shown in Figure 90. Be sure that the wire already
located in this location is not dislodged.
Wire (B)
Wire (A)
Wires Already
Installed
Backplate
Figure 90
Fasten Wire (B) into its Designated Location – Backplate
Step 10: Tighten the slotted screw in the middle terminal location on the backplate (located on the
Setback Control Junction Box Assembly). This is shown in Figure 91.
Wire (A)
Wire (B)
Setback Control
Junction Box Assembly
Slotted head
screwdriver
Figure 91
-60-
Backplate
Remote Mounting the Setback Control
Install Wire (C) – Backplate
Step 11: Using wire (C), insert one end into the bottom terminal location on the backplate (located on
the Setback Control Junction Box Assembly). This is shown in Figure 92. Be sure that the wire already
located in this location is not dislodged.
Wire (B)
Wires Already
Installed
Wire (A)
Wire (C)
Backplate
Figure 92
Fasten Wire (C) into its Designated Location – Backplate
Step 12: Tighten the slotted screw in the bottom terminal location on the backplate (located on the
Setback Control Junction Box Assembly). This is shown in Figure 93.
Wire (A)
Wire (B)
Wire (C)
Slotted head
screwdriver
Figure 93
Setback Control
Junction Box Assembly
Backplate
-61-
Remote Mounting the Setback Control
Route Wires to Protective Plate
Step 13: Route all three wires to the Setback Control Protective Plate.
Install Wire (A) – Protective Plate
Step 14: Using wire (A), insert one end into the top terminal location on the Protective Plate. This is
shown in Figure 94.
Wire (A)
Figure 94
Protective
Plate
-62-
Remote Mounting the Setback Control
Fasten Wire (A) into its Designated Location – Protective Plate
Step 15: Tighten the slotted screw in the top terminal location on the Protective Plate. This is shown in
Figure 95.
Wire (A)
Figure 95
Slotted head
screwdriver
Protective
Plate
Install Wire (B) – Protective Plate
Step 16: Using wire (B), insert one end into the middle terminal location on the Protective Plate. This is
shown in Figure 96.
Wire (A)
Wire (B)
Figure 96
-63-
Protective
Plate
Remote Mounting the Setback Control
Fasten Wire (B) into its Designated Location – Protective Plate
Step 17: Tighten the slotted screw in the middle terminal location on the Protective Plate. This is shown in
Figure 97.
Wire (A)
Wire (B)
Figure 97
Slotted head
screwdriver
Protective
Plate
Install Wire (C) – Protective Plate
Step 18: Using wire (C), insert one end into the bottom terminal location on the Protective Plate. This is
shown in Figure 98.
Wire (A)
Wire (B)
Protective
Plate
Wire (C)
Figure 98
-64-
Remote Mounting the Setback Control
Fasten Wire (C) into its Designated Location – Protective Plate
Step 19: Tighten the slotted screw in the bottom terminal location on the Protective Plate. This is shown
in Figure 99.
Wire (A)
Wire (B)
Protective
Plate
Wire (C)
Figure 99
Slotted head
screwdriver
Install Setback Control
Step 20: Snap the Setback Control into the Protective Plate. Align the Setback Control to the Protective
Plate, and press until it is fully seated. This is shown in Figure 100.
Setback
Control
Protective
Plate
Figure 100
-65-
Remote Mounting the Setback Control
Install Cover Plate
Step 21: Snap the Setback Cover Plate onto the backplate (located on the Setback Control Junction Box
Assembly). This is shown in Figure 101.
Cover Plate
Setback Control
Junction Box
Assembly
Backplate
Figure 101
Remote Mounting the Setback Control is complete. Proceed to the
installation sections for the other purchased packages. Or, if
finished, proceed to the Start-up Procedure on page 67.
-66-
Start-up Procedure
In the following section, the instructions detail the Start-up Procedure for the Accessory Module,
once any or all of its packages are completely installed.
Route the Wire Harnesses in the Accessory Module
Step 1: Route all of the wire harnesses out of the openings in the bottom and left side of the Accessory
Module. And, hold them in place. This is shown in Figure 102.
Accessory
Module
Route the Wire
Harnesses
through These
Holes
Figure 102
Re-install Accessory Module Cover
Step 2: With all wire harnesses properly routed, place the Accessory Module cover back onto the
Accessory Module base. This is shown in Figure 103.
Accessory Module
Cover
Figure 103
-67-
Start-up Procedure
Fix the Accessory Module Cover in Place
Step 3: Tighten both Accessory Module cover screws, as shown in Figure 104.
Philips head
screwdriver
Accessory
Module
Figure 104
Route the Various Wire Harnesses
Step 4: Route the wire harnesses along the jacket and group them using the included wire ties. This is
shown in Figure 105.
Water Heater
Jacket
Group the Wire
Harnesses with the
Included Wire Ties
Wire Harnesses
Figure 105
-68-
Start-up Procedure
Fix the Wire Harnesses
Step 5: Using the included wire holders, fix the wire harnesses to the water heater jacket only to the left of
the water heater gas control, as shown in Figure 106. Wire holders can be used to fix the wire harnesses
to the water heater jacket only to the left of the water heater gas control.
Use Wire Holders
to the Left of this
Line Only
Wire Holders
Wire Harnesses
Figure 106
Route Transformer Wire Harness
Step 6: Route the Transformer wire harness, so it is not in trip contact or touching the floor between the
water heater and dam. This is shown in Figure 107.
Transformer
Transformer Wire
Harness
Figure 107
WARNING
Failure to properly located the Transformer Wire Harness will result in a trip hazard or potential
electrical hazard.
-69-
Start-up Procedure
Plug in Transformer
Step 7: Plug in the Transformer that powers the Accessory Module, as well as its components. This is
shown in Figure 108.
Transformer
Figure 108
Observe Accessory Module Start-up Sequence
Step 8: Watch the LED on the Accessory Module, and observe as it progresses through the Start-up
Sequence. This is shown in Figure 109. If the LED on the Accessory Module goes green at the end of the
Start-up Sequence, proceed to Step 11 on page 72.
Observe LED
Accessory
Module
Figure 109
-70-
Start-up Procedure
Action Required for Improper Start-up Sequence
Step 9: If the Start-up Sequence results in a red LED strobe, the internal electronics on the Accessory
Module failed. The Accessory Module must be replaced. This is shown in Figure 110.
Observe LED
Accessory
Module
Figure 110
Faulty Component / Improper Assembly of Components
Step 10: If another LED sequence is showing (other than a red LED strobe), diagnose the sequence using
the Diagnostic Codes table on page 73.
-71-
Start-up Procedure
Verify Inlet Shut-off Valve Operation (if installed)
Step 11: If the Inlet Shut-off Valve is installed, the valve will open during the Start-up Sequence. Verify
that the valve is open by drawing water from a faucet (specifically hot water). This is shown in Figure 111.
Figure 111
Program the Setback Control (if installed)
Step 12: Refer to the instructions included with the Setback Control on how to program the control.
The Start-up Procedure is complete. The installation of the Accessory
Module and its components is complete.
-72-
Diagnostic Codes
LED Status
Accessory Module
Status
1. No power at outlet.
2. Transformer bad, replace
transformer.
3. Transformer wire harness not
properly connected. Check all wire
connections.
n/a
None
No LED.
Green
LED on continuously.
Red
One flash and three
second pause.
Red
Two flashes and three
second pause.
Amber
Four flashes and three
second pause.
Leak sensor
malfunction.
1. Leak Sensor resistor removed.
2. Leak Sensor improperly
connected to Accessory Module.
Amber
Five flashes and three
second pause.
Gas control missing /
not connected.
1. Wrong gas control wire harness
was used.
2. Accessory Module was not
connected to gas control.
Red
LED strobe (quick
flashes).
Hardware error.
Internal electronics failure, replace
Accessory Module.
Status
Setback Control not on.
Setback Control is showing
“Conn” error.
Power not on.
Probable Cause
Power on (no fault).
Leak alarm fault.
Inlet Shut-off valve
open.
Leak alarm fault.
Inlet Shut-off valve
closed.
Water heater tank leak.
Water heater tank leak.
Probable Cause
1. No power at Setback Control or outlet.
2. Transformer bad, replace transformer.
3. Transformer wire harness not properly connected.
Check all wire connections.
1. The Setback Control is not connected to the Accessory
Module and/or the water heater gas control (at all).
2. The Setback Control wire harness has some wrong
connections. Replace the wire harness.
NOTICE
The leak detection alarm can be muted. Press the button on the front of the Accessory Module
to mute this alarm for 1 day.
CAUTION
Perform a cycle of the Test Mode on the Accessory Module on a regular basis. Perform the
cycle by depressing the “Mute” button on the Accessory Module for at least (7) seconds. In the
Test Mode, the Accessory Module will go through the following sequence:
• Inlet Shut-off Valve opened for (10) seconds with continuously shown Amber LED and
the alarm on for the first second
• Inlet Shut-off Valve closed for (10) seconds with continuously shown Red LED with and
Inlet Shut-off Valve installed (or flashing Red LED without Inlet Shut-off Valve).
• Inlet Shut-off Valve opened for (10) seconds with flashing Green LED.
-73-
Notes
-74-
LIMITED PARTS WARRANTY
WHAT DOES THIS LIMITED WARRANTY COVER?
This limited warranty covers component parts for
malfunction caused by defects in materials and/or
workmanship. It extends to the first buyer and to any
subsequent owner(s) at the original place of installation.
WHAT DOES THIS LIMITED WARRANTY NOT COVER?
h
1.
This limited warranty does not cover malfunction
caused by:
a)
Excessive use
b)
Defective Installation, and specifically, any
installation which is made:
i. in violation of applicable state or local
plumbing, housing or building codes, or
ii. contrary to the written instructions
furnished with the unit.
c)
Adverse local conditions, misuse, and
specifically, operation, and maintenance contrary to the
written instructions furnished with the unit, or accidental or
other exterior damage.
2.
This warranty also does not cover:
a)
Incidental property damage, loss of use,
inconvenience or other incidental or consequential costs.
b)
Costs associated with the replacement
and/or repair of the unit, including:
i. any freight, shipping or delivery charges
ii. any removal, installation or re-installation
charges
iii. any material, and/or permits required for
installation, re-installation or repair
iv. charges to return the component part to
the manufacturer.
WHAT IS THE PERIOD OF COVERAGE?
This limited warranty runs for six (6) years from date
of installation when used in a single family housing unit or
three (3) years when used in other than a single family
housing unit. PROOF OF PURCHASE/INSTALLATION IS
REQUIRED FOR ANY WARRANTY CLAIM.
WHAT IS THE
WARRANTY?
DURATION
OF
THE
IMPLIED
ANY IMPLIED WARRANTIES, INCLUDING
WARRANTY OF MERCHANTABILITY IMPOSED ON
SALE OF THE PRODUCT UNDER THE LAWS OF
STATE OF SALE ARE LIMITED IN DURATION TO
YEAR FROM DATE OF ORIGINAL INSTALLATION.
THE
THE
THE
ONE
HOW DOES STATE LAW RELATE TO THE WARRANTY?
Some states do not allow:
1. Limitations on how long an implied warranty lasts.
2. Limitations on incidental or consequential damages.
So the above limitations or exclusions may not apply to you.
This warranty gives you specific legal rights, and you
may also have other rights which vary from state to state.
•Restrictions are not applicable to implied warranties in
California. See “Special State Provisions.”
-75-
WHAT WILL WE DO TO CORRECT PROBLEMS?
If a defect occurs within the warranty period, we will:
1. Provide a replacement part (or at our option repair)
any part which fails to function within the parts
warranty period. To obtain a replacement, you must
forward the defective part to us. If government
regulations require the replacement part to have
features not found in the defective part, you will be
required to pay the difference in price represented
by those government required features.
We do reserve the right to verify any claims of defect by
inspection.
WHAT WILL WE NOT DO?
We will not:
1. Repair or replace any part, subject to conditions
outlined in “What Does This Limited Warranty Not
Cover?”
2. Reimburse any costs associated with repair and/or
replacement.
HOW DO YOU GET WARRANTY ASSISTANCE?
Upon discovering a defect or problem, you should:
1. Contact either the installer or dealer, or
2. Contact us:
BRADFORD WHITE CORPORATION
WARRANTY SUPPORT GROUP
200 LAFAYETTE
MIDDLEVILLE, MI 49333
(800) 531-2111
CALIFORNIA RESIDENTS CALL 1-800-538-2020
WHAT SHOULD YOU DO TO KEEP THE WARRANTY
IN EFFECT?
To facilitate warranty assistance, you should:
1. Follow all instructions enclosed with the product.
2. Retain all bills of sale or receipts for proof of
installation,
etc.
PROOF
OF
PURCHASE/INSTALLATION IS REQUIRED FOR
ANY WARRANTY CLAIM.
3. Contact your installer, dealer or our Warranty
Department as soon as any problem or defect is
noticed.
4. When necessary, allow us, or our chosen
representative, to inspect the unit.
SPECIAL STATE PROVISIONS
For water heaters installed in California or Oregon,
paragraphs 2 (b), (i) and (iv) of the paragraph
“WHAT DOES THIS WARRANTY NOT COVER?” do not
apply.
All other terms and conditions of this warranty apply as
stated.
PLEASE RETAIN THIS WARRANTY IN A SAFE
LOCATION FOR FUTURE REFERENCE.
Ambler, PA
For U.S. and Canada field service,
contact your professional installer or
local Bradford White sales representative.
Sales/800-523-2931
Fax/215-641-1670
Parts Fax/215-641-2108
Technical Support/800-334-3393
Fax/269-795-1089
Warranty/800-531-2111
Fax/269-795-1089
International:
Telephone/215-641-9400
Telefax/215-641-9750
Mississauga, ON
Sales/866-690-0961
905-238-0100
Fax/905-238-0105
Technical Support/800-334-3393
Email:
parts@bradfordwhite.com
techserv@bradfordwhite.com
www.bradfordwhite.com
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