Bradford-White MI303T'F(BN User Manual

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Flammable Vapor Ignition Resistant Water Heater

SERVICE

MANUAL

Troubleshooting Guide and Instruction for Service

(To be performed ONLY by qualified service providers)

For the Bradford White

Defender Safety System

Models:

MI30T*F(BN,CX)2

M430T*F(BN,CX)2

MI30S*F(BN,CX)2

M4403S*F(BN,CX)2

MI303T*F(BN,CX)2

M4403T*F(BN,CX)2

MI40T*F(BN,CX)2

M450S*F(BN,CX)

MI403S*F(BN,CX)2

M1XR403S*F(BN,CX)2

MI404T*F(BN,CX)2

M1XR504T*F(BN,CX)2

MI503*F(BN,CX)2

M2XR504T*F(BN,CX)2

MI50L*F(BN,CX)2

M2C504T*F(BN,CX)

MI504S*F(BN,CX)2

50T65F(BN,CX)

 

(*) Denotes Warranty Years.

Manual 44943A

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Flammable Vapor Ignition Resistant Water Heater

Table of Contents

 

Page

Service Procedure

Introduction

3

- - -

Trouble shooting Chart

4

- - -

Inner Door Gasket Removal, Inspection, Replacement and Installation

5

RG-I

Thermocouple Testing and Replacement

8

RG-II

Pilot Assembly Inspection Cleaning and Replacement

10

RG-III

Piezo Igniter and Electrode Testing

11

RG-IV

Combination Thermostat/Gas Valve Testing and Replacement

12

RG-V

Burner Operation Inspection, Adjustment, Cleaning and Replacement

17

RG-VI

Resettable Thermal Switch Testing and Replacement

20

RG-VII

ScreenLok Flame Arrestor Cleaning

22

RG-VIII

Dip Tube and Anode Inspection and Replacement

23

RG-IX

Generic Parts List

25

- - -

2

Introduction

The Bradford White DEFENDER Safety System

The Bradford White DEFENDER Safety SystemTM was designed to resist the ignition of flammable vapors that can occur outside of the water heater. Use and installation are nearly identical to previous versions of atmospherically fired and vented water heaters. A number of exclusive design features are incorporated in the system that will require additional knowledge on the part of the qualified service provider. The following information will instruct service professionals on the function, proper diagnosis and repair of water heaters employing the Bradford White DEFENDER Safety System .

How the Safety System Works

During normal operation, air for combustion is drawn into the water heater through the openings in the jacket. This air travels down and around the combustion chamber and enters through holes in the very bottom of the corrosion-resistantcombustion chamber. The air then travels up through the oriented flame arrestor plate louvers, where the velocity of the air is increased and its direction altered. The air then mixes in a normal manner with supplied gas and is efficiently combusted, producing very low NOx emissions. In the unlikely event trace amounts of flammable vapors are present in the air flowing into the combustion chamber, the vapors are harmlessly ignited by the burner / pilot flame. If flammable vapors are in sufficient quantity to prevent normal combustion, the burner / pilot flame is shut down. Should the flammable vapors continue to burn, the flame arrestor plate prevents the flames from traveling backwards and igniting vapors outside of the combustion chamber. The calibrated, multipurpose thermal switch recognizes this and shuts down the pilot and main burner. This switch also deactivates the burner and pilot in the unlikely event of restricted airflow caused by severe lint, dust or oil accumulation on the arrestor plate. If accumulation occurs, the ScreenLok flame arrestor can be easily cleaned and when the inner door is properly secured the unit can then be placed in operation. A cleaning procedure is included in this service manual.

3

Troubleshooting Chart

Flammable Vapor Ignition Resistant Water Heaters

SYMPTOM

 

PROBABLE CAUSE

CORRECTIVE ACTION

SERVICE

 

PROCEDURE

 

 

 

 

 

 

 

 

 

1. No incoming gas or too

1. Turn on gas supply and/or check line pressure.

1. See Service Procedure

 

 

low gas pressure.

RG-V,Page 12.

 

 

2. Review lighting instruction.

 

2.

Gas control knob set

 

 

Set combination/thermostat gas valve to correct

4. See Service Procedure

 

 

to wrong position.

 

 

position.

Pilot Will

3.

Pilot light button not being fully

RG-III,Page 10.

3. Review lighting instruction. Fully depress pilot

Not Light

 

depressed when attempting to

lighting button.

5. See Service Procedure

 

light pilot.

 

4. Clean, repair or replace.

 

4.

Pilot orifice or pilot tube is

RG-III,Page 10.

 

5. Verify correct electrode position.

 

 

obstructed or kinked.

 

 

 

Replace pilot assembly.

6. See Service Procedure

 

5.

Pilot electrode not sparking to pilot.

 

6. Replace Piezo igniter.

 

6.

Piezo igniter not functioning.

RG-IV,Page 11.

 

 

 

 

 

 

 

 

1. Poor thermocouple connection at

1. Check connection at combination thermostat/gas

 

 

valve. Proper tightness should be finger tight

 

 

 

combination thermostat/gas valve.

plus 1/4 turn.

 

 

2.

Thermocouple not fully engaged in

2. Inspect thermocouple to ensure that it is fully

4. See Service Procedure

Pilot will not

 

pilot assembly bracket.

engaged into pilot bracket.

 

RG-II,Page 8.

3.

Pilot flame is not fully enveloping the

3. Adjust tip of thermocouple to be fully engulfed

stay lit when

 

thermocouple “hot” junction.

by pilot flame.

5. See ServiceProcedure

4.

Weak or defective thermocouple.

4. Check thermocouple and replace if necessary.

button is

5.

Open ECO on combination

5. Check ECO continuity and replace combination

RG-V,Page 13.

released

 

thermostat/gas valve.

thermostat/gas valve if necessary.

6. See Service Procedure

6.

Defective magnet in combination

6. Check magnet operation and replace

 

RG-V,Page 13.

 

 

thermostat/gas valve.

combination thermostat/gas valve if necessary.

 

 

 

 

7. Resettable thermal switch has

7. Determine cause of switch activation. To reset,

 

 

 

opened.

depress button on resettable thermal switch

 

 

 

 

located on inner door.

 

 

 

 

 

 

1. Combination thermostat/gas valve

 

2. See Installation

 

 

set too low for desired water temp.

1. Adjust temperature dial on combination

Pilot will light

 

& operation manual.

2.

Combination thermostat/gas valve

thermostat/gas valve.

but the main

 

temperature is satisfied.

2. Check temperature dial setting on combination

3. See Service Procedure

3.

Insufficient gas supply or low gas

thermostat/gas valve.

burner will

 

pressure.

3. Check gas supply and line pressure.

RG-V,Page 12.

4.

 

not come on

Combination thermostat/gas valve

4. Check combination thermostat/gas valve for

4. See Service Procedure

 

has wide differential or is out of

proper operation, replace if necessary.

 

 

calibration.

 

RG-V,Page 12.

 

 

 

 

 

 

 

 

 

Pilot goes out

 

 

1. Verify adequate combustion air is available to the

 

periodically

 

 

unit. Check and clear Jacket slot openings of any

 

1. Insufficient combustion air supply.

dirt, dust, restrictions or other obstructions.

1. See Service Procedure

(after heating

2.

Incorrect, clogged vent system/ vent

Inspect flame arrestor plate and clean with stiff

RG-VIII,Page 22.

cycles, once a

 

terminal or location.

bristled brush and/or vacuum to remove any

 

3.

Inconsistent gas supply or gas

debris accumulation.

3. See Service Procedure

day, once a

 

pressure.

2. Check venting for proper sizing and proper

RG-V,Page 12.

 

 

operation

 

week etc.)

 

 

3. Check gas supply and line pressure.

 

 

1. Combination thermostat/gas valve

1. Check dial on combination thermostat/gas valve.

 

 

 

set too low for desired water temp.

2. Extremely cold water going into the heater will

 

 

2.

Cold inlet water temp. is very cold.

decrease the amount of hot water produced.

5. See Service Procedure

Not enough

3.

High demand periods.

It may be necessary to temper incoming water

RG-V,Page 12

4.

Incorrectly sized water heater for

supply.

 

hot water

5.

application.

3. Adjust high demand usage.

6. See Service Procedure

 

Combination thermostat/gas valve is

4. Contact Plumbing professional.

RG-IX,Page 23

 

 

out of calibration/not functioning.

5. Check combination thermostat/gas valve for

 

 

6.

Out of spec dip tube is diluting hot

proper operation, replace if necessary.

 

 

 

water with cold water.

6. Inspect dip tube and replace if necessary.

 

 

 

 

 

 

4

SERVICE PROCEDURE RG-I

Inner Door/Gasket Removal, Inspection

Replacement and Reinstallation

Inner Door Removal Procedure

Step 1. Rotate knob of the combination thermostat/gas valve to the “OFF” position. Step 2. Remove outer jacket burner access door

Step 3. Inner Door Removal.

a)Disconnect resettable thermal switch wire leads (leading from combination thermostat/gas valve).

b)Remove (2) 1/4" hex drive screws from right side inner door.

c)Remove (2) 1/4" drive screws from flange section of inner door.

d)Remove (2) 1/4" drive screws from left side inner door.

e)Remove inner door and inspect per step 4.

Resettable Thermal Switch

Wire Connection

1/4" Hex Drive Screws at

Flange Area of Inner Door

1/4" Hex Drive Screws

Right and Left Side Inner Door

Step 4.

Fully inspect inner door gaskets for the following:

 

>Tears

>Other imperfections that will inhibit proper seal

 

>Missing Material

>Gasket adhesion to inner door

 

>Cracks

>Material left on combustion chamber (around opening)

 

>Dirt or debris

 

If the gasket is not effected by any of the above, gasket replacement is not required.

If replacement is required, proceed to Inner Door Gasket Replacement Procedure.

Inner Door Gasket Replacement Procedure

! WARNING

If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

Step 5. After inspection of inner door as noted in step 4, completely remove gasket and adhesive residue from right and left side inner doors as needed.

Step 6. Use RTV sealant (recommended bead size 1/8") to secure the inner door gasket to the inner door sections (right & left). Refer to illustration on next page for proper application. Note the overlap configuration in the flange area of the inner door. Set the flange section first, this will help to achieve the proper over lap position.

5

SERVICE PROCEDURE RG-I

Inner Door/Gasket Removal, Inspection

Replacement and Reinstallation

Installation of Inner Door with Gasket

Step 7.

Clean any residual gasket residue or other debris

 

 

from combustion chamber surface before

 

 

installing the inner door/gasket assembly.

Step 8.

into position first.

 

 

channel of the inner

 

 

 

 

the 1/4” hex

 

 

 

 

left side inner

 

 

SCREWS.

Step 9.

tube and Piezo wire

 

 

 

 

gasket.

 

 

 

 

RADIUSED

 

 

.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

! WARNING

Stripped fastener connections may allow for seal breach of inner door. A seal breach may result in a fire or explosion causing property damage, personal injury or death. Do not over tighten screws in steps 8, 10 and 11.

If a fastener connection is stripped, contact the manufacturer listed on the water heater rating plate.

Radiused Channel for Feedline

Position thermocouple,

pilot tube and Piezo wire

 

6

SERVICE PROCEDURE RG-I

Inner Door/Gasket Removal, Inspection

Replacement and Reinstallation

Step 10. Firmly place right side inner door flange against the left side inner door flange and secure with two 1/4” drive screws from step 3c. DO NOT OVER TIGHTEN SCREWS.

Step 11. Align right side inner door to combustion chamber and verify the fastener holes of the combustion chamber are aligned with the right side inner door slotted opening. Verify seal integrity around combustion chamber opening. Secure right side inner door using 1/4” hex drive screws from step 3b.

DO NOT OVER TIGHTEN SCREWS. Verify both left and right sides of the inner door are properly positioned and sealed against the combustion chamber.

Verify threaded hole alignment with slotted openings in inner door

Secure flange with 1/4" drive screws

Step 12. Reconnect lead wires from combination thermostat/gas valve to in step 3). Note, wire terminations are interchangeable with either connections.

Step 13. Replace outer jacket burner access door.

Step 14. To resume operation follow the instructions located on the lighting instructions located in the installation and operation manual.

7

SERVICE PROCEDURE RG-II

Thermocouple Testing and Replacement

Closed Circuit Thermocouple Testing

Step 1. Disconnect thermocouple from combination thermostat/gas valve.

Step 2. Connect a thermocouple adapter (BWC P/N 239-44642-00,Robertshaw P/N 75036) at the thermocouple location in the combination thermostat/gas valve.

Step 3. Reconnect thermocouple to adapter. make certain all connections are tight (finger tight plus 1/4 turn)

Step 4. Using a multimeter capable of measuring millivolts, connect one alligator clip to the set screw of the adapter, and the other alligator clip to copper portion of the thermocouple.

Step 5. Following the lighting instruction label on the heater, proceed to light the pilot and allow to operate for three minutes. If the pilot will not stay lit, hold the red reset button (located on the combination thermostat/gas valve) down during this test.

Step 6. If meter reads 13 millivolts or higher, the thermocouple is OK. If reading is below13 millivolts replace the thermocouple.

Open Circuit Thermocouple Testing

Step 1. Disconnect thermocouple from combination thermostat/gas valve.

Step 2. Using a multimeter capable of measuring millivolts, connect one alligator clip to the end ball or contact portion of the thermocouple, and the other alligator clip to copper portion of the thermocouple.

Step 3. Following the lighting instruction label on the heater, proceed to light the pilot and allow to operate for three minutes. It will be necessary to hold the red reset button continuously

throughout this test. If meter reads 20 millivolts or higher, the thermocouple is OK. If reading is below20 millivolts, replace the thermocouple.

8

SERVICE PROCEDURE RG-II

Thermocouple Testing and Replacement

Thermocouple Replacement

Step 1. Turn off gas supply to water heater. Rotate knob of combination thermostat/gas valve to “OFF” position.

Step 2. Remove outer jacket door.

Step 3. Remove right side of inner door per SERVICE PROCEDURE RG-I,steps 3a through 3c.

Step 4. Disconnect thermocouple from combination thermostat/gas valve (3/8" wrench). Locate other end of thermocouple inside of combustion chamber and remove from pilot bracket. Pull firmly pulling away from the pilot assembly.

Step 5. Install new thermocouple into pilot bracket making certain thermocouple is fully engaged into the pilot bracket. Position thermocouple against left side inner door flange at its original position. Connect other end of thermocouple to combination thermostat/gas valve (finger tight + 1/4 turn).

Position thermocouple, in its original position

Make certain thermocouple is fully engaged into bracket

Step 6. Inspect inner door gasket per SERVICE PROCEDURE RG-I,Step 4.

Step 7. Install right side inner door per SERVICE PROCEDURE RG-I,Step 10 through Step 13.

Step 8. To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual.

9

SERVICE PROCEDURE RG-III

Pilot Assembly Inspection,

Cleaning and Replacement

Pilot/Electrode Assembly Inspection,

Cleaning and Replacement

Step 1. Turn off gas supply to water heater. Rotate knob of combination thermostat/gas valve to “OFF” position.

Step 2. Remove outer jacket door.

Step 3. Remove right side of inner door per SERVICE PROCEDURE RG-I,steps 3a through 3c.

Step 4. Disconnect thermocouple from combination thermostat/gas valve (3/8" wrench). Disconnect pilot tube from combination thermostat/gas valve (7/16" wrench). Disconnect feedline from combination thermostat/gas valve (3/4" wench).

Primary Air Step 5. Disconnect Piezo ignition wire from Piezo igniter. Opening

Step 6. Remove burner assembly from combustion chamber.

Step 7. Remove pilot/electrode assembly from feedline (1/4" drive tool).

Step 8. Inspect pilot for the following: (not required if replacing with new pilot)

a)Primary air openings for blockage. Must be free from any debris (dirt, lint, etc).

b)Kinks or cracks in the pilot tube. If found, the tubing must be replaced.

Step 9. Inspect pilot orifice: (not required if replacing with new pilot)

a)Remove 1/2" nut from bottom of pilot assembly.

b)Remove pilot tube and pilot orifice.

c)inspect pilot orifice for blockage, must be cleaned or replaced.

Step 10. Install pilot/electrode assembly to feedline, secure with screw from step 7.

Step 11. Re-Installburner assembly into combustion chamber, connect feedline, pilot tube and thermocouple to combination thermostat/gas valve.

Step 12. Install inner door per SERVICE PROCEDURE RG-I,step 4 through 13.

Step 13. To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual.

10

SERVICE PROCEDURE RG-IV

Piezo Igniter, Electrode

Testing and Replacement

Piezo Igniter, Electrode Testing and Replacement

With the pilot not in operation (no pilot flame) you can check the Piezo and electrode circuit by viewing pilot thru the sight glass located on the inner door and observing the spark action.

Step 1. Remove outer jacket door.

Step 2. Repeatedly depress the Piezo igniter while viewing the pilot thru the sight glass. If a spark is present, the circuit is OK. If there is no spark, proceed to step 3.

Repeatedly

Depress Piezo

Igniter View spark Action through

Sight glass

Remove orange wire from Piezo igniter and install a jumper wire in its place. Hold per by the wire insulation or using an insulated tool, next to an unpainted

or gas valve and depress the Piezo igniter. If there is a spark, the igniter is OK, functioning and must be replaced, see SERVICE PROCEDURE RG-IIIfor pilot re present the igniter is not functioning and must be replaced.

orange wire disconnected from Piezo igniter. Using a common screw driver, under Piezo bracket and gently pry bracket from front of combination

unhook bracket from rear of combination thermostat/gas valve.

Common

Screw Driver

11

SERVICE PROCEDURE RG-V

Combination Thermostat/Gas Valve

Testing and Replacement

Combination Thermostat/Gas Valve Testing and Replacement

The combination thermostat/gas valve is a non repairable device. If trouble shooting has determined a problem with the combination thermostat/gas valve, it must be replaced. If the burner and/or pilot do not function, service checks for gas pressure, thermocouple output, magnet assembly and ECO are to be performed. If these check OK, the combination thermostat/gas valve may be faulty.

LINE PRESSURE

The combination thermostat/gas valve is designed for a maximum line pressure of 14.0" w.c. and a minimum line pressure of 1.0"w.c. over the water heater rated manifold pressure.

MANIFOLD PRESSURE TESTING (this procedure assumes a maximum line pressure of 14.0" w.c.)

Step 1. Set combination thermostat/gas valve to “OFF” position.

Step 2. Remove pressure tap plug (3/16" Allen wrench) and install pressure tap (7/16 wrench)

Pressure Tap

Shown Installed

Step 3. Connect manometer to pressure tap.

Step 4. Follow lighting instructions and proceed to light main burner.

Step 5. Manometer gauge should read 4.0" w.c. for Natural gas and 10.0" w.c. for L.P. gas

Step 6. If adjustment is necessary proceed to step 7. If pressure is OK, set combination to “OFF” remove manometer and pressure tap and replace pressure tap plug. before placing water heater back in operation.

Step 7. While burner is in operation, remove regulator access cap to expose the regulator

With small screw driver, rotate adjusting screw clockwise to increase pressure and to decrease pressure.

Step 8. Set combination thermostat/gas valve to “OFF”. Remove manometer and pressure tap plug. Check for gas leaks before placing water heater back in o

12

SERVICE PROCEDURE RG-V

Combination Thermostat/Gas Valve

Testing and Replacement

THERMOCOUPLE TESTING

See SERVICE PROCEDURE II

MAGNET ASSEMBLY TESTING

Step 1. Disconnect thermocouple from combination thermostat/gas valve.

Step 2. Connect a thermocouple adapter (BWC P/N 239-44642-00,Robertshaw P/N 75036) at the thermocouple location in the combination thermostat/gas valve.

Step 3. Reconnect thermocouple to adapter. Make certain all connections are tight (finger tight plus 1/4 turn).

Step 4. Using a multimeter capable of measuring millivolts, connect one alligator clip to the set screw of the adapter and the other alligator clip to copper portion of the thermocouple.

Step 5. Following the lighting instruction label on the heater, proceed to light the pilot and allow to operate for three minutes.

Step 6. With a meter reading of 13 millivolts or greater, rotate knob of combination thermostat/gas valve to the “OFF” position.

Step 7. The magnet should remain closed for a drop of at least 5 millivolts. You will here a “snap” or “click” sound when the magnet opens, if you hear this sound prior to a drop of 5 millivolts, the magnet is out of specification and the combination thermostat/gas valve should be replaced.

ECO (Energy Cut Off) TESTING

Step 1. Disconnect thermocouple from combination thermostat/gas valve.

Step 2. Using a multimeter capable of measuring Ohms (or continuity), attach one lead (alligator clip) to the pilot tube. Insert the other lead (probe) fully into the magnet opening, Be sure the probe makes contact only at the top center of the magnet opening. Do not allow the probe to make contact with the threaded sides of the opening.

Step 3. If continuity is indicated, the ECO is OK. If continuity is not indicated, the ECO has opened and the combination thermostat/gas valve must be replaced.

13

SERVICE PROCEDURE RG-V

Combination Thermostat/Gas Valve

Testing and Replacement

COMBINATION THERMOSTAT/GAS VALVE REPLACEMENT

Step 1. Rotate knob of the combination thermostat/gas valve to the “OFF” position.

Step 2. Turn off gas supply to water heater.

Step 3. Disconnect gas supply line from combination thermostat/gas valve.

Step 4. Turn off water supply and drain water heater completely.

Step 5. Remove outer jacket burner access door.

Step 6. Right side inner door removal.

a)Disconnect resettable thermal switch wire leads (leading from combination Thermostat/Gas Valve) and remove wire tie from feedline.

b)Remove (2) 1/4" hex drive screws from right side inner door.

c)Remove (2) 1/4" drive screws from flange section of inner door.

d)Remove right side inner door and set aside. Be careful not to damage gasket material on inner door.

Switch

Remove Wire Tie

1/4" Hex Drive Screws shown on Right Side Inner Door

1/4" Hex Drive Screws at Flange section of Inner Door

14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SERVICE PROCEDURE RG-V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Combination Thermostat/Gas Valve

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Testing and Replacement

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Step 7.

 

 

 

 

 

 

Removal of combination thermostat/gas valve.

Refer to

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SERVICE PROCEDURE RG-IV

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

a) Disconnect main burner feedline

 

 

 

 

 

 

 

to remove Piezo igniter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(3/4” wrench), pilot tube (7/16"

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

wrench) and thermocouple (3/8"

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

wrench) from combination

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

thermostat/gas valve & remove

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

from the combustion chamber.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

b) Remove Piezo bracket with Piezo

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

igniter (refer to SERVICE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PROCEDURE RG-IV)from

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

combination thermostat/gas valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

c) Remove combination thermostat/gas valve from heater, rotating counter clockwise using an

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

appropriately sized wrench. Use caution not to damage cast aluminum body of combination

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

thermostat/gas valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Step 8.

 

 

 

 

 

 

Installation of combination thermostat/gas valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

a) Install new combination thermostat/gas valve. Be certain not to damage the bundled wire leads.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Note: combination thermostat/gas valve must be installed in proper upright position to

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

assure the feedline will align properly at the inner door flange.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

b) Reattach Piezo bracket with Piezo igniter to combination thermostat/gas valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

c) Reattach main burner feedline, pilot tube and thermocouple to combination thermostat/gas valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

d) Gather wire leads of combination thermostat/gas valve and Piezo igniter and secure along side of

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

feedline using new wire tie provided.

 

 

 

 

 

 

 

Step 9.

 

 

 

 

 

 

Reinstallation of inner door assembly.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

a) Prior to reinstallation of inner door, fully inspect inner door gasket for the following:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

> Tears

 

> Gasket Adhesion to inner door

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

> Missing material

 

> Other imperfections that will inhibit proper seal

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

> Cracks

 

> Material left on combustion chamber

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

> Dirt or debris

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

If the gasket is not affected by any of the above, gasket replacement will not be required.

If replacement is required, replace using new gasket kit following the instructions provided with kit.

15

SERVICE PROCEDURE RG-V

Combination Thermostat/Gas Valve

Testing and Replacement

Step 9. Reinstallation of inner door assembly. (cont.)

b)Clean any gasket residue or other debris from combustion chamber surface before installing the inner door/gasket assembly.

c)Position thermocouple, pilot tube and Piezo wire against left side inner door flange gasket.

DO NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE. Be sure that thermocouple and pilot tube are not in position to interfere with outer jacket burner access door when reinstalled.

 

 

 

! WARNING

 

 

 

A seal breach may result in a fire or

Position thermocouple,

 

 

explosion causing property damage,

 

 

personal injury or death.

pilot tube and Piezo wire

 

 

 

 

 

 

 

 

 

 

side inner door flange against the left side inner door flange and secure with two screws from step 6c. DO NOT OVER TIGHTEN SCREWS.

inner door to combustion chamber and verify the fastener holes of the combustion aligned with the right side inner door slotted openings. Verify seal integrity around pening. Secure right side inner door using 1/4” hex drive screws from step 6b.

TIGHTEN SCREWS. Verify both left and right sides of the inner door are properly sealed against the combustion chamber.

Secure flange with

 

Verify threaded hole

1/4" drive screws

 

 

 

alignment with slotted

 

 

openings in inner door

 

 

 

Step 10. Reconnect wire leads from combination thermostat/gas valve to resettable thermal switch (See photo in step 6). Note: wire terminations are interchangeable with either resettable thermal switch connection.

Step 11. Replace outer jacket burner access door.

Step 12. Reconnect gas supply to combination thermostat/gas valve.

Step 13. Resume water supply to water heater. Be sure tank is full of water.

Step 14. To resume operation follow the instructions located on the lighting instruction label or the lighting

instructions located in the installation and operation manual.

16

SERVICE PROCEDURE RG-VI

Burner Operation Inspection,

Adjustment, Cleaning and Replacement

MAIN BURNER: Inspection, Adjustment, Cleaning and Replacement

At periodic intervals (not more then 6 months) a visual inspection should be made of the main burner for proper operation and to insure no debris accumulating.

Main burner should light smoothly from pilot and burn with a blue flame with a minimum of yellow tips.

Steel burner models have a self adjusting air mixture and do not have an adjustable air shutter. Cast iron burner can have the gas and air mixture properly proportioned by adjusting the air shutter on the mixer face of the main burner (see step 2 below).

Main burner must be free from any debris accumulation that may effect burner operation (See next page for cleaning procedure).

CAST IRON BURNER ADJUSTMENT

! DANGER

Under no circumstances shall flammable materials be used or stored in the vicinity of the water heater. With the inner door removed the Bradford White Defender Safety System will be inactivated.

If flammable vapors are present, a fire or explosion may result causing property damage, personal injury or death.

Upon completion of the cast iron burner adjustment procedure, the inner door must be replaced per SERVICE PROCEDURE RG-1,steps 4 through 14 to reactivate Bradford White Defender Safety System.

! WARNING

Inner door and burner components may be HOT when performing this operation. Take necessary precaution to prevent personal injury.

Step 1. With main burner in operation, remove right side inner door per service procedure I, steps 3b & 3c. Be sure to maintain wire connection to resettable thermal switch for this adjustment procedure.

Step 2. To adjust for proper burning, loosen the air shutter nut, rotate the shutter to close the opening in the burner, then slowly rotate the shutter until the yellow tips disappear and the flame becomes blue. Tighten the air shutter nut. Too much air will cause the flame to lift off the burner ports and create noisy burner operation. Too little air (yellow tips) will result in soot formation. Place right side inner door into proper position to confirm proper burner flame pattern and correct air shutter adjustment. It may be necessary to allow the burner to operate for several minutes for burner flame to stabilize.

Air Shutter Nut

17

SERVICE PROCEDURE RG-VI

Burner Operation Inspection,

Adjustment, Cleaning and Replacement

MAIN BURNER: Inspection, Adjustment, Cleaning and Replacement (cont.)

Step 3. Fully inspect inner gasket per SERVICE PROCEDURE RG-I,step 4. Replace gasket if required following SERVICE PROCEDURE I, steps 5 & 6.

Step 4. Be certain that thermocouple, pilot tube and Piezo wire are routed by inner door flange as shown and Reinstall inner door per SERVICE PROCEDURE RG-I,step 10 and 11.

Position thermocouple, pilot tube and Piezo wire

Step 5. Observe burner operation

2, if not, repeat procedure com door in place.

should operate as adjusted in step proper burner operation with inner

Step 6.

It may be necessary to clean main

 

achieve proper burner operation.

 

If cleaning is required proceed to

procedure.

BURNER CLEANING (Steel & Cast Iron)

 

 

 

Step 1.

Remove inner door assembly per

ps 1 through 3c.

Step 2.

Disconnect main burner feed line

wrench) and thermocouple (3/8)

 

wrench from combination

 

assembly from combustion

 

chamber.

 

 

 

Step 3.

Thoroughly inspect burner surface

 

any loose debris accumulation.

 

 

 

 

Burner

 

 

 

 

 

 

 

 

 

 

 

 

Surface

 

 

 

 

 

 

Area

 

 

 

 

 

 

 

 

 

Burner

Port

Area

Step 4.

On cast iron burners, inspect for

 

Burner Venturi

 

any debris build up inside burner

 

 

 

 

venturi. If found, disconnect

 

Opening

 

feedline from burner and remove

 

 

 

debris build up.

 

Feedline

 

 

 

 

18

SERVICE PROCEDURE RG-VI

Burner Operation Inspection,

Adjustment, Cleaning and Replacement

BURNER CLEANING (cont.)

Step 5. Disconnect (unscrew) main burner (stamped steel “B” burner) from main burner orifice or on cast iron burners (“C” burner), loosen air shutter & disconnect (unscrew) feedline from burner.

Step 6. Remove main burner orifice from feed line (1/2” wrench on steel burner, 3/8" wrench on cast iron). Inspect and clean if necessary.

Step 7. Remove pilot assembly, refer to SERVICE PROCEDURE RG-IIIfor cleaning and inspection.

Step 8. Reassemble burner.

Step 9. Inspect combustion chamber area of heater prior to reinstallation of burner assembly. If cleaning is required, refer to SERVICE PROCEDURE RG-VIII.

Step 10. Reinstall burner assembly into combustion chamber, reconnect feedline, thermocouple and pilot tube to the combination thermostat/gas valve.

Step 11. Reinstall inner door per SERVICE PROCEDURE RG-I,steps 4 through 13.

Step 12. To resume operation, follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual.

19

SERVICE PROCEDURE RG-VII

Resettable Thermal Switch

Testing and Replacement

RESETTABLE THERMAL SWITCH CONTINUITY TESTING

Step 1. Remove outer jacket door.

Step 2. Disconnect wire leads from resettable thermal switch.

Step 3. Using a multimeter capable of measuring continuity (Ohms), place one probe of meter on one of the brass connection tabs of the resettable thermal switch, and the remaining probe on the other connection tab.

Step 4. If continuity is indicated, the switch is closed, allowing millivolt current to pass.

Step 5. If continuity is not indicated, the switch is open, possibly due to an overheating condition. The switch is designed to open at predetermined temperatures depending on model. An open switch can be reset by depressing the red colored button located at the center of the switch.

The overheating condition must be determined prior to putting the heater back in service.

PROBABLE CAUSE FOR RESETTABLE THERMAL SWITCH ACTIVATION

PROBABLE CAUSE

CORRECTIVE ACTION

 

 

 

 

1. Verify adequate combustion air supply is available.

Insufficient

2. Clear jacket slot openings of any dirt, dust, restrictions

combustion Air

or other obstructions.

 

 

3. Inspect flame arrestor plate and clean with stiff brush

 

and/or vacuum to remove scale deposits and debris.

 

 

 

1. Weak switch or

1. Replace resettable thermal switch

switch out of

 

 

calibration.

 

 

2. Incorrect switch.

2. Verify switch color code and approximate temperature.

 

 

 

 

 

Flammable vapor

1. Replace water heater.

incident

 

 

 

 

 

Resettable thermal switch color code reference.

Approximate switch

Color Code activation temperature

(open)

Blue 240˚

Yellow 270˚

Red 290˚

20

SERVICE PROCEDURE RG-VII

Resettable Thermal Switch

Testing and Replacement

RESETTABLE THERMAL SWITCH REPLACEMENT

Step 1. Rotate knob of combination thermostat gas valve to the off position.

Step 2. Remove outer jacket door.

Step 3. Disconnect wire leads from resettable thermal switch.

Step 4. Remove resettable thermal switch from inner door (Phillips screw driver).

Step 5. Place new resettable thermal switch in place. Be sure contact surface of resettable thermal switch and inner door are free of any debris. Secure resettable thermal switch into place using screws from step 4.

DO NOT OVER TIGHTEN SCREWS.

Step 6. Reconnect wire leads from combination thermostat/gas valve to resettable thermal switch.

Note: wire termination are interchangeable with either resettable thermal switch connection.

Step 7. Replace outer jacket door.

Step 8. To resume operation follow the instructions located on the lighting instruction label or the lighting instruction located in the installation and operation manual.

21

SERVICE PROCEDURE RG-VIII

ScreenLok Flame Arrestor Cleaning

ScreenLok Flame Arrestor Cleaning

Step 1. Rotate knob of combination thermostat gas valve to the off position.

Step 2. Remove outer jacket door.

Step 3. Remove inner door per SERVICE PROCEDURE RG-I,step 3a through 3e.

Step 4. Disconnect main burner feed line (3/4 wrench), pilot tube (7/16 wrench) and thermocouple (3/8) wrench from combination thermostat gas valve and remove burner assembly from combustion chamber.

Step 5. Clean ScreenLok Flame Arrestor using stiff brush, compressed air and/or shop vacuum to remove any scale or other debris accumulation. Using a

soft brush, clear jacket openings from any dirt, dust, restrictions or other obstructions.

Step 6. Remove any debris from burner assembly per SERVICE PROCEDURE RG-Vand reinstall burner assembly into combustion chamber.

Step 7. Reconnect feedline, thermocouple and pilot tube to the combination thermostat/gas valve.

Step 8 Reinstall inner door per SERVICE PROCEDURE RG-I,steps 4 through 13.

Step 9. To resume operation follow the instructions located on the lighting instruction label or the lighting instruction located in the installation and operation manual.

22

SERVICE PROCEDURE RG-IX

Dip Tube and Anode

Inspection and Replacement

Dip Tube Inspection and Replacement

! WARNING

Heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

Step 1. Rotate knob of combination thermostat/gas valve to “OFF” position.

Step 2. Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain. Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow heater to drain to a point below the inlet connection nipple.

Step 3. Disconnect inlet nipple from plumbing system.

Step 4. With an appropriate wrench, remove inlet nipple/dip tube from the water heater. Use caution not to damage pipe threads.

Step 5. Visually Inspect inlet nipple/dip tube. Inlet nipple/dip tube should be free of cracks and any blockage. Hydro-jetslocated near the bottom of the dip tube should be open and free of any blockage.Anti-siphonholes located approximately 6" from the bottom of nipple, should be free of any blockage. Any damage such as cracks, restriction due to deformation or unintentional holes are not field repairable and the inlet nipple/dip tube must be replaced.

Step 6. Upon completion of inspection or subsequent replacement, reinstall inlet nipple/dip tube into heater. Connect nipple to plumbing system, resume water supply and refill heater with water.

Step 7. To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual.

23

SERVICE PROCEDURE RG-IX

Dip Tube and Anode

Inspection and Replacement

Anode Inspection and Replacement

! WARNING

Heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

Step 1. Turn off water supply to water heater. Rotate knob of combination thermostat/gas valve to “OFF” position.

Step 2. Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain. Open a nearby hot water faucet to vent heater for draining. Open drain spigot of water heater and allow heater to drain to a point below the outlet connection nipple.

Step 3. Disconnect outlet nipple from plumbing system.

Step 4. With an appropriate wrench, remove outlet nipple/anode from the water heater. Use caution not to damage pipe threads.

Step 5. Visually Inspect outlet nipple/anode. Outlet nipple/anode should show signs of depletion, this is normal. If depletion is 1/2 of the original anode diameter (approximately 3/4” diameter), replacement is recommended. If any of the steel core of the anode is exposed, replacement is recommended.

Step 6. Upon completion of inspection or subsequent replacement, reinstall outlet nipple/anode into heater. Connect nipple to plumbing system, resume water supply and refill heater with water.

Step 7. To resume operation, follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual.

24

PARTS LIST

1

Draft Hood

19 Main Burner Orifice

2

Hot Water Outlet/Anode

20

Pilot Assembly

3

Cold Water Inlet Tube

21 Pilot Orifice

4

Flue Baffle

22

Thermocouple

5

T&P Relief Valve

23

Feed Line

6

Thermostat

24

Complete Cast Iron Burner Assembly

7

Piezo Igniter

25

Cast Iron Burner Only

8

Brass Drain Valve

26

Main Burner Orifice

9

Screw-#8-18x 3/4 Hex Washer Head

27

Pilot Assembly

10

Screw-#10-12x 3/4 Hex Washer Head

28

Pilot Orifice

11 Left Side Inner Door with Gasket

29

Air Shutter

12

Complete Right Side Inner Door

30

Air Shutter Nut

12A Right Side Inner Door with Gasket

31 Thermocouple

13

Sight Glass Assembly

32

Feed Line

14

Resettable Thermal Switch

33

ASSE Approved Mixing Valve (Optional)

15 Screw#6-20x 3/8 PHCR

34

3/4 NPT Tank Plug (XR models)

16

Outer Door

35

Inner Door Gasket Kit

17

Complete BN Burner Assembly

36

Wire Tie

18

BN Burner Only

 

 

25

Notes

26

Notes

27

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

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

Fax on Demand:

888-538-7833

www.bradfordwhite.com

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

www.bradfordwhitecanada.com