Bradford-White TTW M4TW50T'F User Manual

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TTW ® Series

Through-The-WallGas Water Heaters

SERVICE

MANUAL

Troubleshooting Guide and Instructions for Service

(To be performed ONLY by qualified service providers)

Models Covered

by This Manual:

M1TW40S*F (BN,CX,SX)

M1TW50S*F (BN,CX,SX)

M1TW60T*F (BN,CX,SX)

M4TW40T*F (BN,SX)

M4TW50T*F (BN,SX)

M4TW60T*F (BN,SX)

M2TW50T*F (BN,CX,SX)

M2TW65T*F (BN,CX,SX)

TW450S65F (B,C,S)*(N,X) TW465S65F (B,C,S)*(N,X)

(*) Denotes Warranty Years

Manual 238-46238A-00A

Save this manual for future reference

The Bradford White

Through-The-WallGas Water Heaters

 

Page

TTW Service Procedure

Introduction

4

- - -

How to use this manual

5

- - -

Tool required for service

5

- - -

Specifications

6

- - -

Control Timings

9

- - -

Sequence of Operation

10

- - -

Troubleshooting

13

- - -

Burner Inspection, Cleaning and Replacement

15

I

Pilot Testing, Cleaning and Replacement

17

II

Pressure Switch Testing and Replacement

18

III

Blower Testing and Replacement

20

IV

Blower Temperature Switch Testing and Replacement

22

V

Gas Control & Thermal well Testing & Replacement

24

VI

Flammable Vapor Sensor Testing and Replacement

28

VII

Safety Circuit Voltage Trace

29

VIII

115VAC Circuit Trace

30

IX

Dip Tube inspection and Replacement

31

X

Anode Inspection and Replacement

32

XI

Flue Baffle Inspection and Replacement

33

XII

Inner Door Removal, Inspection & Replacement

34

XIII

ScreenLok® Flame Arrestor Cleaning

37

XIV

Glossary of Terms

38

- - -

Parts List

39

- - -

Page 2

Page 2

2

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

FOR YOUR SAFETY

Do not store or use gasoline or other flammable, combustible, or corrosive vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance.

Do not touch any electrical switch; do not use any phone in your building.

Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

CAUTION

Incorrect operation of this appliance may create a hazard to life and property and will nullify the warranty.

DANGER

Do not store or use gasoline or other

flammable, combustible, or corrosive

vapors and liquids in the vicinity of this

or any other appliance.

IMPORTANT

Before proceeding, please inspect the water heater and its components for possible damage. DO NOT install any water heater with damaged components. If damage is evident then please contact the supplier where the water heater was purchased or the manufacturer listed on the rating plate for replacement parts.

WARNING

Water heaters are heat producing appliances. To avoid damage or injury, do not store materials against the water heater or vent-airintake system. Use proper care to avoid unnecessary contact (especially by children) with the water heater andvent-airintake components. UNDER NO CIRCUMSTANCES MUST FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER,VENT-AIRINTAKE SYSTEM OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER ORVENT-AIRINTAKE SYSTEM.

CAUTION

If sweat fittings are to be used DO NOT apply heat to the nipples on top of the water heater. Sweat the tubing to the adapter before fitting the adapter to the water connections. It is imperative that heat is not applied to the nipples containing a plastic liner.

WARNING

Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the possibility of injury under these conditions, we recommend the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system. If hydrogen is present, there will be an unusual sound such as air escaping through the pipes as hot water begins to flow. Do not smoke or have open flame near the faucet at the time it is open.

WARNING

DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE FOLLOWING:

Liquefied petroleum gases/propane gas and natural gas have an odorant added by the gas supplier that aids in the detection of the gas.

Most people recognize this odor as a “sulfur” or “rotten egg” smell.

Other conditions, such as “odorant fade” can cause the odorant to diminish in intensity, or ”fade”, and not

be as readily detectable.

If you have a diminished sense of smell, or are in any way unsure of the presence of gas, immediately contact your gas supplier from a neighbor's

telephone.

Gas detectors are available. Contact your gas supplier, or plumbing professional, for more information.

WARNING

FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED 3/4” X 3/4” TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE MANUFACTURER FROM ANY CLAIM THAT MIGHT RESULT FROM EXCESSIVE TEMPERATURE AND PRESSURES.

CAUTION

Turn off or disconnect the electrical power supply to the water heater before servicing. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

Page 3

Page 3

3

Introduction

The new Bradford White TTW1, TTW2 & TW4 water heaters are designed to provide reliable performance with enhanced standard features. New design features include reliable spark to pilot ignition system, enhanced diagnostics, simplified servicing, significantly quiet operation and additional vent lengths.

Spark to Pilot Ignition System - employing the spark to pilot ignition system promotes reliable and consistent pilot and main burner ignitions to provide hot water on demand.

Integrated Immersion Thermostat/Gas Control Valve with LED - was developed for ease of troubleshooting by providing simple diagnostic codes to pinpoint an installation or component performance issue.

New Powerful Blower - will eliminate problems with difficult venting situations.

Quieter and Cooler Blower Operation - blower noise is significantly reduced for both interior and exterior environments. Cooler operation increases blower life by reducing bearing wear and noise.

Rugged Wiring Connections - receptacle type connections promote error free wiring.

Increased Vent Lengths - increased venting performance is achieved while maintaining Energy Factor & FHSR performance.

The TTW1 (M1TW), TTW2 (M2TW) & TW4 water heaters use a combustion system were flue gases are combined with dilution air to reduce the flue gas temperature in the blower. The diluted flue gases are evacuated to the exterior through low temperature vent materials. The gas control maintains water temperature, ignition sequence and regulates gas flow. A safety circuit consisting of a pressure switch and blower temperature switch verifies proper conditions exist for safe and reliable operation. If a situation outside of normal operating parameters exists, the gas control diagnostic LED will flash a code to positively identify an operational issue.

This service manual is designed to facilitate problem diagnosis and enhance service efficiency. To further promote quicker service times the new gas valve can be removed and replaced without draining the water heater. A special tool is required and will be provided with each gas valve kit shipped from our Service Parts department.

Please read the service manual completely before attempting service on this new series of power vent models.

Page

4

How to Use This Manual

It is intended for this manual to be used by qualified service personal for the primary purpose of troubleshooting and repair of the Bradford White TTW Series water heaters. Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting the water heater.

The Honeywell WV4460E Electronic Gas Control will display error codes in the event of abnormal operation. Error codes are listed in the troubleshooting chart beginning on page 13 of this service manual. The troubleshooting chart will also indicate the probable cause for the error code and direct the service professional to a service procedure to properly diagnose the abnormal operation.

In some difficult to diagnose conditions, it may be necessary to isolate the heater from the vent system to determine the problem.

Contact the Bradford White technical support group immediately if diagnosis can not be made using the methods described in this service manual.

Manometer:

A liquid “U” tube type or a digital (magna-helic)type can be used. This

 

device is used to measure gas and/or air pressure and vacuum.

Multi-Meter:

A digital type is strongly recommended. This device is used to measure

 

electrical values. The meter you select must have the capability to

 

measure volts AC, volts DC, Amps, micro-ampsand ohms.

Electronic Probes:

In some cases, standard multi-meterprobes will damage or simply

 

not be effective to obtain certain voltage and ohm reading. It will be

 

necessary to have special electronic “pin” type multi-meterprobes.

 

These probes are available at most electronic wholesale outlets.

Thermometer:

Used to measure water temperature. An accurate thermometer is

 

recommended.

Water Pressure Gage:

Used to measure water supply pressure. Also used to determine tank

 

pressure by adapting to the drain valve of the heater.

Gas Control Service Tool: BWC part number 239-45991-00.A specialized tool designed to remove the gas control from gas control thermal well. Available from

your Bradford White parts supplier.

Various Hand Tools:

Pipe wrench, channel locks, open end wrenchs (3/8",7/16",½"),

 

12" crescent wrench, Allen wrench set, screw drivers (common &

 

Phillips), ¼" nut driver, pliers (common & needle nose), socket set, side

 

cutters wire cutters, wire strippers, wire crimpers, torpedo level, small

 

shop vac, step ladder, and flashlight, 5 gallon pail.

PagePage55

5

Specifications

Power supply

Dedicated 115VAC, 60 Hz, 15A

 

 

Gas Supply Pipe

Minimum 1/2" NPT (schedule 40 black iron pipe recommended)

 

 

Approved Gas Type

Natural or Propane. Unit must match gas type supplied.

 

 

Gas Pressure

5.0" W.C. min. for Nat gas, 11.0" W.C. min. for L.P. gas, 14.0" W.C. maximum (Nat. & L.P.)

 

 

Venting System

Power vent through the wall or vertical through the roof

 

 

Approved Vent Materials

PVC, CPVC or ABS

 

 

Minimum Clearance

18" from top, 24" from front, 4" sides and rear.

for Servicing

 

 

 

Water Supply Pressure

150 PSI maximum allowable working pressure. Check local codes for supply pressure

 

 

Thermal well TCO Limit

Residential 188°F (87°C), Commercial 199°F (93°C)

 

 

Residential Temperature

60°F (16°C) to 160°F (71°C) (Approximate temperatures)

Set Point Range

 

Commercial Temperature

80°F (27°C) to 180°F (82°C) (Approximate temperatures)

Set Point Range

 

Blower Temperature

Normally closed, opens @ 165°F (74°C), auto reset @ 130°F (54°C).

Switch

 

 

TTW1 (M1TW) Models:

 

 

Normally open, closes on vacuum increase @ -.68,opens on vacuum decrease @-.65

Pressure switch

TTW1 (M4TW) Models:

Normally open, closes on vacuum increase @ -.83,opens on vacuum decrease @-.80

 

 

TTW2 (M2TW & TW4) Models:

 

Normally open, closes on vacuum increase @ -1.28,opens on vacuum decrease @-1.25

 

TTW1 (M1TW & M4TW) Models:

 

Blower

115VAC, 60Hz, 3.1 amps, 3000 RPM, 42CFM@1.5" W.C.

TTW2 (M2TW & TW4) Models:

 

 

115VAC, 60Hz, 3.1 amps, 3000 RPM, 68CFM@0.4" W.C.

 

 

Page 6

6

Specifications

Vent Tables

Venting Specifications for:

40 Gallon

50 Gallon

60 Gallon

2" Diameter (5.1 cm) PVC Vent Connector Lengths

Terminating

# of

 

Maximum Straight

 

Minimum Straight

 

Elbows

 

Length ft (m)

 

Length ft (m)

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Wall

1

 

45 (13.7)

 

2

(.6)

 

 

 

 

 

 

 

 

 

Through the Wall

2

 

40 (12.2)

 

2

(.6)

 

 

 

 

 

 

 

 

 

Through the Wall

3

 

35 (10.7)

 

2

(.6)

 

 

 

 

 

 

 

 

 

 

Through the Wall

4

 

30

(9.2)

 

2

(.6)

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Roof

0

 

50 (15.2)

 

7 (2.1)

 

 

 

 

 

 

 

 

Through the Roof

1

 

45 (13.7)

 

7 (2.1)

 

 

 

 

 

 

 

 

Through the Roof

2

 

40 (12.2)

 

7 (2.1)

 

 

 

 

 

 

 

 

Through the Roof

3

 

35 (10.7)

 

7 (2.1)

 

 

 

 

 

 

 

 

 

Through the Roof

4

 

30

(9.2)

 

7 (2.1)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3" Diameter (7.6 cm) PVC Vent Connector Lengths

 

 

# of

 

Maximum Straight

 

Minimum Straight

 

Terminating

 

 

 

Elbows

 

Length ft (m)

 

Length ft (m)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Wall

1

 

115

(35.0)

 

10

(3.1)

 

 

 

 

 

 

 

 

 

 

Through the Wall

2

 

110

(33.5)

 

10

(3.1)

 

 

 

 

 

 

 

 

 

 

Through the Wall

3

 

105

(32.0)

 

10

(3.1)

 

 

 

 

 

 

 

 

 

 

Through the Wall

4

 

100

(30.5)

 

10

(3.1)

 

 

 

 

 

 

 

 

 

Through the Wall

5

 

95 (29.0)

 

10

(3.1)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Through the Roof

0

 

120

(36.6)

 

15

(4.6)

 

 

 

 

 

 

 

 

 

 

Through the Roof

1

 

115

(35.0)

 

15

(4.6)

 

 

 

 

 

 

 

 

 

 

Through the Roof

2

 

110

(33.5)

 

15

(4.6)

 

 

 

 

 

 

 

 

 

 

Through the Roof

3

 

105

(32.0)

 

15

(4.6)

 

 

 

 

 

 

 

 

 

 

Through the Roof

4

 

100

(30.5)

 

18

(5.5)

 

 

 

 

 

 

 

 

 

 

PagePage77

7

 

 

 

 

Specifications

 

Vent Tables

 

 

Venting Specifications for:

 

 

 

 

48 Gallon

 

 

 

 

65 Gallon

 

 

 

 

3" Diameter (7.6 cm) PVC Vent Connector Lengths

Terminating

# of

Maximum Straight

Minimum Straight

Elbows

Length ft (m)

Length ft (m)

 

Through the Wall

1

55 (16.8)

2

(.6)

Through the Wall

2

50 (15.2)

2

(.6)

Through the Wall

3

45 (13.7)

2

(.6)

Through the Wall

4

40 (12.2)

2

(.6)

Through the Roof

0

60 (18.3)

7 (2.1)

Through the Roof

1

55 (16.8)

7 (2.1)

Through the Roof

2

50 (15.2)

7 (2.1)

Through the Roof

3

45 (13.7)

7 (2.1)

4" Diameter (10.2 cm) PVC Vent Connector Lengths

Terminating

# of

Maximum Straight

Minimum Straight

Elbows

Length ft (m)

Length ft (m)

 

Through the Wall

1

175 (53.3)

10

(3.1)

Through the Wall

2

170 (51.8)

10

(3.1)

Through the Wall

3

165 (50.3)

10

(3.1)

Through the Wall

4

160 (48.8)

10

(3.1)

Through the Wall

5

155 (47.2)

12

(3.6)

Through the Roof

0

180 (54.9)

15

(4.6)

Through the Roof

1

175 (53.3)

15

(4.6)

Through the Roof

2

170 (51.8)

15

(4.6)

Through the Roof

3

165 (50.3)

15

(4.6)

Through the Roof

4

160 (48.8)

15

(4.6)

Page 8

 

 

 

Page 8

 

 

 

 

8

Specifications

Control Timings

Ignition State

Timing

 

Pre-purge

2 Seconds

 

Trial for Ignition

90 Seconds

 

Flame Stabilization Period

3 Seconds

 

Inter-purge

15 Seconds

 

Flame Failure Response Time

1.5 Seconds (2 second. Maximum; 1 second minimum.)

Post-purge

15 Seconds

 

PS Fault Delay (failed open/close)

Retry after 2 Minutes

 

Soft Lockout

Retry after 5 Minutes

 

TCO Limit Lockout

Indefinite (See Page 24 to reset)

 

Verify Resistive Delay

Retry after 2 Minutes (repeats 5 times)

 

Simulated Resistive Load Lockout

Indefinite (cycle power to reset)

 

Hardware Error Lockout

Indefinite (self clears if fault clears for at least 15 seconds)

 

Wiriing Diagram

 

 

Blower

Blower

 

Motor

 

Temperature

 

 

 

Switch

 

 

Pressure

 

 

Switch

 

 

Blower

 

 

Housing

 

Pilot

 

 

Pilot

 

 

B C

A B C

A

Simulated

Flammable

Resistive

Vapor

Device

Sensor

Thermal

ThermalWell

Well

PagePage99

9

Sequence of Operation

1 Start Up.

Upon power up, the control runs a safe-startcheck with a typicalstart-updelay of 5 seconds.

2 Flammable Vapor.

To assure no outputs are energized if the “Flammable Vapor Sensor” is out of range, the control will test the “Flammable Vapor Sensor” for proper operating range. If the “Flammable Vapor Sensor” is within range the control resumes normal operation with no perceptible delay. If the “Flammable Vapor Sensor” is out of range, the control LED immediately flashes 7 times with 3 second pause.

1 Thermostat calls for heat.

Prior to energizing blower, gas control checks safety circuit to insure the circuit is open. Normal switch positions in the safety circuit are as follows:

a)Pressure switch normally open.

b)Blower temperature switch normally closed.

If the safety circuit is closed, the control waits 4 seconds, gas control LED flashes 2 times with 3 second pause. Gas control waits 2 minutes then, blower runs for 30 seconds. This cycle repeats until safety circuit opens.

2 Blower energizes.

3 Pressure switch proves blower/vent system operation.

If the pressure switch does not close within 30 seconds, the control LED Flashes 3 times with 3 second pause. The blower runs for 30 seconds every 2 minutes trying to get the pressure switch or blower temperature switch to close. This cycle repeats as long as there is a call for heat.

4 Blower pre-purge period (2 seconds)

5Trial for pilot ignition (90 seconds).

a)The gas control lights the pilot by activating spark igniter and gas flow to pilot burner.

b)If flame is not sensed within 90 seconds, igniter and gas flow are deactivated, blower will post purge and control LED flashes 6 times with 3 second pause.

6 Main burner Ignition

After pilot flame is sensed, gas control activates main valve for main burner ignition. The gas control will ignore flame and pressure switch signals for 3 seconds allowing for main burner to stabilize.

Page 10

Page 10

10

Sequence of Operation

Steady state operation.

7During Steady State Operation the Control Monitors:

Thermostat temperature sensor- When set point temperature is satisfied, gas valve is shut down and blower will post purge for 15 seconds. Control LED flashes a short flash once every 4 seconds(idle) status code.

Pressure switch / Blower temperature switch- If either switch opens, pilot valve and main valve is shut

down. The blower continues to runs for 30 seconds attempting to close the circuit. The control LED Flashes 3 times with 3 second pause.

Flame Sensor- If flame is lost, pilot & main valve are shut down, blower runs for 15 seconds. Control attempts tore-lightpilot 4 times. If unsuccessful, Blower is shut down and control proceeds to 5 minute lockout. Controlre-attemptsto light pilot starting at normal heating sequence #2.

8Thermostat satisfies (Control LED flashing once every 4 seconds).

9Burner off.

10 Blower post purge (15 seconds).

1. Flammable Vapor Sensor Fault:

a)If the resistance is greater than 70,000 Ohms - the gas control immediately turns off all outputs. Control waits

and monitors resistance for 30 seconds. If the resistance is greater than 65,000 ohms after 30 seconds, the gas control proceeds to verify resistive delay for 2 minutes and flashes 7 times then once with a three second pause. This process is repeated 5 times until the control either returns to normal operation or proceeds to flammable vapor lockout.

b)If the resistance is below 3000 ohms - The gas control immediately turns off all outputs and proceeds to flash8 times then once with three second pause. The error self clears if the resistance returns to normal range for at least 15 seconds.

2. Temperature Sensor Fault:

a)Temperature sensor detected open circuit - The gas control Immediately turns off all outputs and proceeds to flash8 times then three times with three second pause. The error self clears if the fault clears for at least 15 seconds.

b)Thermal well sensors not reading the same temperature within ±5.5 °F - The gas control Immediately turns off all outputs and proceeds to flash 8 times then three times with three second pause. The error self clears if the fault clears for at least 15 seconds.

c)Water temperature in excess of TCO (Temperature Cut Off) limit - The gas control immediately turns off pilot main valve and proceeds to flash 4 times with 3 second pause. Blower continues to run until gas control is reset. To reset control, rotate knob of temperature control to the minimum setting for at least 6 seconds before returning to desired temperature setting.

Page1111

11

Sequence of Operation

3. Pressure Switch/Blower Temperature Fault:

a)Pressure switch closed at start of call for heat - The gas control waits four seconds then, proceeds to flash2 times with 3 second pause. The control waits 2 minutes and then turns on blower for 30 seconds. The blower turns off after 30 seconds and the control waits for pressure switch to open. Any time the Pressure switch opens, the blower turns on (or stays on) and the control proceeds to waiting for pressure switch to close.

b)Pressure switch or blower temperature switch failed to close- The gas control runs the blower for 30 seconds

waiting for the pressure switch and/or blower temperature switch to close. If either switch does not close in 30 seconds, the blower turns off and the control flashes 3 times with 3 second pause. The gas control waits two minutes before turning on the blower for another 30 seconds to see the circuit close. This cycle repeats as long as there is a call for heat or until the circuit closes.

c)Pressure switch or blower temperature switch opens during burner operation - The gas control turns off the pilot and main valve, runs blower for 15 seconds (inter-purge) waiting for pressure switch and/or blower temperature switch to close. If either switch fails to close, the control proceeds as described in 3b above. If the circuit closes again by the end of the inter-purge, the recycle counter is incremented, if the recycle count has

not reached its limit (4), another trial for ignition begins. If the recycle count has been reached, the gas control turns off the blower and flashes 6 times then 2 times with 3 second pause. The gas control waits 5 minutes before repeating ignition sequence.

4. Trial For Ignition Fault:

a)Pressure switch opens during trial - The gas control turns off igniter and pilot valve. The gas control proceeds as described in 3b above. If the pressure switch closes within 30 seconds the gas control will continue with trial for ignition starting at blowerpre-purge.

b)Flame Not Sensed - The gas control energizes the spark igniter attempting to light the pilot and prove flame. If

flame is not sensed within 90 seconds, the igniter turns off, the pilot valve is closed and the gas control runs the blower through post purge and flashes 6 times then once with 3 second pause. The control waits 5 minutes before repeating the ignition sequence.

5. Flame Sensing Fault:

b)Flame lost during run - The gas control turns off pilot and main valves, runs blower for 15 seconds (inter purge).

The gas control increments the recycle count, if the recycle count has not reached its limit (4), another trial for ignition begins. If the recycle count has been reached, the gas control turns off the blower and flashes 6 times then 3 times with 3 second pause. The gas control waits 5 minutes before repeating the ignition sequence.

c)Flame sensed out of sequence - the gas control only looks for pilot flame when the blower is running. If flame is present when the pilot valve is not open, the gas control proceeds to wait for flame loss and flashes5 times with 3 second pause. This continues until flame is lost, once the flame signal is lost, the control flashes6 times then 4 times with 3 second pause. The control waits 5 minutes before repeating the ignition sequence.

Page 12

Page 12

12

Troubleshooting

Observe green LED indicator on Electronic gas control. Error flash codes are displayed with a three second pause before repeating. Check and repair the system as noted in the troubleshooting table below.

Green LED

Indicator

 

LED Status

Control

 

Probable Cause

Service

 

 

Status

 

Procedure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

None, control LED not

No electrical

Control power switch in “OFF” position.

Turn power on

 

 

on or flashing

power

Supply voltage interrupted.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Short flash, once every

Stand-bymode,

 

 

Normal operation.

 

 

Waiting for call for

Temperature demand is satisfied

Adjust thermostat to

 

 

four seconds

heat (no fault).

 

 

temp level

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

“Heartbeat”, alternates

Thermostat calling

 

 

Normal operation.

 

 

Tank temperature below set point of thermostat.

Adjust thermostat to

 

 

bright/dim

for heat (no fault).

 

 

temp level

 

 

 

 

 

 

 

 

 

 

 

 

1.

Unstable pilot.

 

 

 

 

 

 

 

 

1. Page 15

 

 

 

 

Weak pilot signal

2.

Pilot tube block or restricted.

 

 

Short flash once per

 

 

 

 

 

on last call for

3.

Oxidation build up on pilot electrode.

 

 

 

 

 

second

2-4.Page 17

 

 

heat.

4.

Wire damage to pilot assembly or bad

 

 

 

 

 

 

 

 

 

 

 

 

 

connection at gas valve.

 

 

 

 

 

 

 

Pressure switch

1.

Pressure switch tubing kinked or blocked.

 

 

 

 

 

Two flash, three

 

 

 

 

 

not working-

2.

Blocked pressure tap on switch or blower.

Page 18

 

 

second pause

 

 

closed position.

3.

Faulty pressure switch.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.

Vent blockage or improper vent configuration.

1. Check vent or vent tables.

 

 

 

 

Pressure switch

2.

Pressure switch tubing kinked or blocked.

 

 

 

 

 

Three flash, three

or blower temp.

3.

Faulty pressure switch.

2 & 3 Page 18

 

 

 

 

 

 

 

second pause

switch not working

4.

Blower not spinning up to speed.

4. Page 20

 

 

 

 

 

 

 

 

 

 

 

-openposition.

5.

Blower temp or exhaust temp too high

 

 

 

 

 

 

 

 

6.

Faulty blower temperature switch.

5 & 6 Page 22

 

 

 

 

Excessive tank

1.

Thermal well sensor out of calibration.

 

 

 

 

 

 

 

1. Page 24

 

 

 

 

 

 

 

 

 

Four flash, three

temperature.

2.

Faulty gas control.

 

 

 

 

 

second pause

System must be

3.

Pluming leak.

2. Replace gas control,

 

 

 

 

reset. (See Pg. 24)

4.

Tank not filled with water.

page 24

 

 

 

 

 

 

 

 

 

 

 

Undesired-false

 

 

 

 

 

 

 

Five flash, three

 

 

 

 

 

 

 

pilot flame

1.

Pilot valve stuck in open position.

Replace gas control,

 

 

second pause

page 24

 

 

present.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 13

 

 

 

 

 

 

 

Page 13

 

 

 

 

 

 

 

 

13

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Troubleshooting

LED Status

Control

 

 

Probable Cause

Service

Status

 

 

Procedure

 

 

 

 

 

Failed to light

 

1.

Unstable pilot.

 

 

 

1. Page 15

 

 

2.

Pilot tube blocked or restricted.

Six-oneflash, three

pilot.

 

 

 

3.

Oxidation build up on pilot electrode.

 

second pause

System auto

 

2-4.Page 17

 

4.

Wire damage to pilot assembly or bad

 

resets.

 

 

 

 

 

connection at gas valve.

 

 

 

 

 

 

 

 

 

 

 

1. Check vent or vent tables.

 

 

 

 

 

 

Pressure switch

 

1.

Vent blockage or improper vent configuration.

 

 

or blower temp

 

2.

Pressure switch tubing kinked or blocked.

2 & 3 Page 18

Six-twoflash, three

switch opened

 

3.

Faulty pressure switch.

 

during burner

 

4.

Vent termination being affected by wind

4. Refer to venting section of

second pause

 

installation manual

operation.

 

5.

Blower not spinning up to speed.

 

 

 

 

System auto

 

6.

Blower temp or exhaust temp too high

5. Page 20

 

resets.

 

7.

Faulty blower temperature switch.

6 & 7 Page 22

 

 

 

1.

Unstable pilot.

 

 

 

 

 

 

Pilot flame

 

2.

Pilot tube blocked or restricted.

1. Page 15

 

 

3.

Oxidation build up on pilot electrode.

 

Six-threeflash, three

extinguished.

 

 

 

4.

Wire damage to pilot assembly or bad

2-4.Page 17

second pause

System auto

 

 

 

 

connection at gas valve.

 

 

resets.

 

 

5. Refer to installation manual

 

 

 

 

 

 

5.

Insufficient combustion air.

 

 

 

 

 

 

 

 

6.

Gas pressure is out of specification.

 

 

 

 

 

 

 

 

Undesired-false

 

 

 

 

Six-fourflash, three

pilot flame

 

 

 

 

sensed.

 

Pilot valve stuck in open position.

Replace gas control,

second pause

 

page 26

System auto

 

 

 

 

 

 

 

 

 

resets.

 

 

 

 

 

 

 

 

 

 

Seven flash, three

Flammable

 

 

WARNING: EXPLOSION HAZARD

 

Vapor Sensor

 

• Indicates gasoline vapors were detected at potentially

Page 28

 

 

 

 

second pause

 

 

explosive levels.

fault detected.

 

 

 

 

 

 

 

 

• Verify no gasoline vapors are still present.

 

 

 

 

 

 

 

 

• Reset the control by cycling power to the appliance or by

 

 

 

 

cycling the ON/OFF switch.

 

 

 

 

• Replace the Flammable Vapor Sensor element if a gasoline

 

 

 

 

spill event occurred.

 

 

Flammable

 

• Very Flammable Vapor Sensor (FVS) resistance is not below

 

 

 

 

 

 

 

 

Eight-oneflash, three

Vapor Sensor

 

25 KΩ.

 

out of

 

• Check wiring to FVS and insure it is not shorted.

Page 28

 

 

second paus

 

 

 

specification.

 

• Replace control if everything above checks out OK.

 

 

 

 

 

 

 

 

 

 

Thermal well

 

 

 

 

Eight-threeflash, three

 

1.

Damage to thermal well wire.

 

second pause

sensor damaged

 

2.

Thermal well sensor resistance out of range.

Page 24

or unplugged

 

 

 

 

 

 

 

 

 

 

 

 

 

Eight-fourflash, three

Gas valve fault

 

1.

Control needs to be reset.

1. Interrupt power supply

 

 

second pause

detected.

 

2.

Control is wet or physically damaged.

2. Replace gas control,

 

page 26

 

 

 

 

 

 

 

 

 

 

 

Page 14

Page 14

14

TTW SERVICE PROCEDURE I

Burner Operation Inspection,

Adjustment, Cleaning and Replacement

Burner Inspection and Air Shutter Adjustment.

At periodic intervals (every 6 months) a visual inspection should be made of the pilot and main burner for proper operation and to assure no debris is accumulating.

Pilot flame should be stable, some causes for an unstable pilot flame are:

a)Water heater vent is less than the allowable vent length.

b)Gas pressure is out of specification.

c)Pilot flame not fully engulfing spark/flame sensor.

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

Steel burner models self adjust air to gas ratio 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 cast iron burner adjustment below).

Main burner must be free from any debris accumulation that may effect burner operation (see burner cleaning procedure on page 16).

Cast Iron Burner Air Shutter Adjustment

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 outer jacket door and inner door per service procedure XIII on page 34.

Step 2. To adjust for proper burning, loosen the air shutter nut, rotate the air shutter to close the opening in the burner, then slowly rotate the air shutter open until flame becomes as blue as possible with a minimum of yellow tips. 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 will result in soot formation.

Step 3. Reinstall inner door and observe burner operation. Burner should operate as adjusted in step 2. If not, repeat air shutter adjustment compensating for proper burner operation with inner door closed.

Air Shutter Nut

Air Shutter

PagePage1515

15

TTW SERVICE PROCEDURE I

Burner Operation Inspection,

Adjustment, Cleaning and Replacement

Burner Cleaning

Step 1. Position gas control power switch to the “OFF” position and unplug heater from wall outlet.

Step 2. Turn off gas supply to water heater.

Step 3. Remove outer jacket door and inner door per service procedure XIII on Page 34.

Step 4. Disconnect pilot tube (7/16 wrench) and feedline (¾ wrench) from gas control.

Step 5. Disconnect igniter/flame sensor wire from gas control.

Step 6. Remove burner assembly from combustion chamber.

Step 7. Thoroughly inspect burner surface area and burner port area and remove any loose debris.

Burner surface area

Burner port area

Step 9. Unscrew burner from main burner orifice. On cast iron burners, loosen air shutter nut and unscrew feedline from burner.

Step 10. Remove main burner orifice from feedline (½" wrench on steel burners, 3/8" wrench on cast iron) inspect orifice, clean or replace if necessary.

Main burner orifice

Step 11. Reassemble burner and reinstall into water heater. Restore gas supply and check for gas leaks.

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

Page 16

L.P. Main burner orifice. Left hand thread

Page 16

16

TTW SERVICE PROCEDURE II

Pilot testing, Cleaning and Replacement

Pilot Inspection, Testing and Replacement

Step 1. Position gas control power switch to the “OFF” position and unplug heater from wall outlet.

Remove Outer

door.

Step 2. Turn off gas supply to water heater.

Step 3. Remove outer jacket door and slideinnerinnerdoo doorper serviceopen from left to rightprocedure. XIII on page 34.

Igniter/flame sense wire

Step 4. Disconnect pilot tube nut (7/16 wrench) and feedline nut (¾ wrench) from gas control.

Step 5. Disconnect igniter/flame sense wire from gas control.

Step 6. Remove burner assembly from combustion chamber.

Step 7. Remove pilot assembly from feedline (¼" nut driver).

Step 8. Visually inspect igniter/flame sense wire for damage. Replace pilot if damage is found.

Step 9. With a multi-meterset to the ohms setting, check continuity through igniter/flame sense wire. Replace pilot if no continuity.

Step 10. Visually inspect igniter/flame sense electrode for deterioration. Replace pilot as necessary. Electrode should not be in contact with pilot hood, If so, carefully adjust electrode to a gap distance of 3/32" (.09) from pilot hood.

Step 11. Visually inspect igniter/flame sense electrode for oxidation build up. Carefully clean any oxidation using very fine emery cloth.

Slide inner door open from left to right.

Feedline nut

Pilot tubing nut

Ferrule

Pilot

Pilot

Pilot

nut

tubing

orifice

hood

Igniter/flame

Igniter/flame

sense wire

sense electrode

Step 12. Visually inspect pilot tubing for kinks or cracks. If damage is found replace pilot.

Step 13. Inspect pilot tubing and pilot orifice for blockage:

a)Remove ferrule nut from bottom of pilot assembly (7/16" wrench).

b)Remove pilot tube and pilot orifice.

c)Inspect pilot tubing and pilot orifice for blockage. Clean or replace as necessary.

Step 14. Reassemble pilot and install to feedline. Reinstall burner assembly to water heater. Restore gas supply and check for gas leaks.

Step 15 To resume operation follow the instruction located on the lighting instruction label or the lighting instruction located in the installation and operating manual.

PagePage1717

17

TTW SERVICE PROCEDURE III

Pressure Switch Testing and

Replacement

Pressure Switch Testing

Step 1. Position power switch on gas control to the “OFF” position.

WARNING

115 volt potential exposure. Use caution making voltage checks to avoid personal injury.

Step 2. Remove the three screws (Phillips screw driver) from control access cover on blower assembly and remove cover (see photo 1).

Step 3. Carefully remove pressure switch from blower housing (see photo 2)

With steps 1,2 & 3 complete,

disconnect wire leads from pressure switch.

Use a multi-meterset to the

 

 

 

 

 

ohms setting. With blower off,

 

 

 

 

 

check across pressure

 

N

 

 

 

switch terminals.

 

 

 

 

 

Are switch contacts open?

 

 

 

 

 

(no electrical continuity)

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Position gas valve power

 

 

 

Y

switch to the “ON” position

 

 

 

 

 

 

 

 

and adjust thermostat

 

 

Check tubing and

to call for heat,

N

pressure tap on

this will start the blower.

 

 

switch for blockage.

Check with multi-meter,do

 

 

Is there blockage?

pressure switch contacts

 

 

 

 

 

close with blower running?

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Switch contacts are OK.

 

 

 

 

 

See safety circuit trace

 

 

 

 

 

(page 29)

 

 

 

 

 

1

Pressure switch wire leads

Check tubing and pressure tap on switch for blockage.

Is there blockage?

Y

Clear blockage

 

 

Y

 

N

Is vent

N

system

 

 

 

blocked

 

2

Pressure Switch

Slide pressure switch in direction of arrow while tilting slightly away from blower housing.

NReplace switch (see page 19)

Is vent system length

 

 

Y

 

See blower testing

within vent table

Y

(page 20)

specifications

 

 

Is blower OK?

listed on pages 7 & 8

 

 

 

N

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Reconfigure vent

 

Correct blower

system to be

 

compliant with

 

problem.

vent tables.

 

 

 

Page 18

Page 18

18

TTW SERVICE PROCEDURE III

Pressure Switch Testing and

Replacement

Pressure Switch Replacement

Step 1. Position gas control power switch to “OFF” position.

WARNING

115 volt potential exposure. Use caution to avoid personal injury.

Step 2. Remove the three screws (Phillips screw driver) from control access cover on blower assembly and remove cover (see photo 3).

Pressure Switch

3

4

Step 3. Carefully remove pressure switch from blower housing (see photo 4)

Slide pressure switch in direction of arrow while tilting slightly away from blower housing.

5

6

Step 4. Disconnect tubing from pressure switch.

(see photo 5)

Step 5. Disconnect yellow wires from pressure switch (see photo 6)

Step 6. Reconnect wires from step 5 to new pressure switch.

Step 7. Reconnect tubing to new pressure switch.

Step 8. Carefully position pressure switch into blower housing.

Step 9. Position gas control power switch to “ON” position and verify proper heater operation.

Step 10. Replace control access cover from step 2.

PagePage1919

19

TTW SERVICE PROCEDURE IV

Blower Testing and Replacement

 

WARNING

Blower Testing

115 volt potential exposure. Use caution when

 

 

making voltage checks to avoid personal injury.

Step 1. Position gas control power switch

 

to “ON” position and adjust control to call for heat.

7

Step 2. Remove the three screws (Phillips Screw driver) from control access cover on blower assembly and remove cover (see photo 7).

 

 

 

 

 

 

 

 

 

 

Disconnect

 

 

 

 

 

 

Connect

 

Disconnect vent

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

manometer to

system from top of

 

 

Does blower energize

 

 

 

 

 

Y

 

pressure switch

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

pressure tap of

 

 

 

blower and remove

 

 

Within 2 minutes?

 

 

 

 

 

 

 

tubing from blower.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

blower.

 

vent adapter.

 

 

 

 

 

 

 

 

 

 

 

 

(see photo 8)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see photo 8)

 

(see photo 10)

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8

 

 

 

 

 

 

 

 

Pressure tap

9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

With blower running, and exhaust

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

adapter removed from top of

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

blower, is there a negative

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

pressure of -2.15"to-2.30"W.C.?

 

 

 

 

 

 

 

 

 

 

Pressure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

switch tubing

 

 

 

 

 

Determine voltage

 

N

 

Is there 115vac across

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

blue and green wires

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

problem and correct.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see photo 13)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Does blower energize after

 

 

 

Y

 

See pressure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2 minutes, run for 30

 

 

 

 

 

 

switch testing

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

11

 

 

 

 

 

12

 

 

seconds and shut down?

 

 

 

 

 

Page 18

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Disconnect cord set

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

shown in photo 9. Is

 

 

Y

 

Is there 115VAC

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

there 115VAC across

 

 

 

across terminals

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

terminals shown in

 

 

 

 

 

 

 

shown in photo 12 ?

 

 

 

Reconnect cord set

 

 

 

 

 

 

 

photo 11

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

shown in photo 9, is

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

there 115VAC between

 

 

 

 

N

 

 

 

 

 

 

 

Incorrect supply

 

 

 

 

 

 

 

blue wire and green

 

 

 

 

Replace blower

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ground wire

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

voltage polarity

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(see photo 13)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

Green ground

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Determine

Replace

 

 

N

Does cord set

 

 

 

 

wire

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is there 115 VAC

N

 

 

 

 

power source

 

 

have electrical

 

 

 

 

 

 

 

 

 

 

 

cord set

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

problem and

 

 

 

continuity?

 

 

 

 

 

 

 

 

 

at wall outlet?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

correct.

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Check power cord

Y

 

 

 

 

Repair or replace

 

 

 

 

 

 

 

 

Replace

 

 

 

 

 

 

 

 

 

for damage.

 

 

 

 

 

 

 

 

power cord

 

 

 

 

 

 

 

 

gas control

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

Remove exhaust adapter

10

Y

Blower OK

Replace blower

13

Blue wire

Replace blower

Shown with pressure

switch removed.

Page 20 Page 20

20

TTW SERVICE PROCEDURE

Blower Testing and Replacement

Step 1. Position gas control power switch to the “OFF” position.

Step 2. Unplug blower power cord from wall outlet.

Remove exhaust adapter and retain for use on new blower.

Step 3. Disconnect vent system from exhaust adapter on top of blower.

Step 4. Remove exhaust adapter from blower (blade screw driver) and retain for use on new blower

Step 5. Unplug cord sets from blower.

Step 6. Remove the three blower mounting screws (¼" nut driver).

Step 7.

Remove blower with gasket from water heater.

Blower

 

 

 

 

Cord Sets

Blower Mounting

Screws

Step 8. Clean any debris from jacket head of water heater.

Step 9. Set new blower with gasket in place using locating pins on blower flange to line up with location holes in jacket head. Be sure not to damage gasket.

Step 10 Secure blower in place using mounting screws from step 6.

Step 11. Re-installexhaust adapter from step 4.

Step 12. Reconnect vent system to exhaust adapter.

Locating Pins on blower flange

Step 13. Reconnect cord sets from step 5.

Step 14. Plug blower power cord into wall outlet.

Pin location holes in jacket head

Step 15. Position gas control power switch to the “ON” position.

Step 16. Verify proper blower operation.

PagePage2121

21

TTW SERVICE PROCEDURE V

Blower Temperature Switch Testing

and Replacement

Blower Temperature Switch

Testing.

Step 1. Position power switch on gas control to the “OFF” position.

WARNING

115 volt potential exposure. Use caution to avoid personal injury.

14

Step 2. Remove the three screws (Phillips screw driver) from control access cover on blower and remove cover (see photo 14).

Step 3. Locate blower temperature switch (see photo 15)

Switch Setting

 

 

 

 

 

 

15

Blower temperature

Opens on rise @ approximately 165°F

 

 

 

switch location

Auto resets on fall @ approximately 130°F

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Cool switch to

 

 

 

 

 

 

 

 

 

 

below 130°F

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Air mixing inlet

 

 

 

 

 

 

 

 

 

 

 

 

Disconnect wire leads to

 

 

 

 

 

 

 

 

 

 

 

 

 

 

switch. Using a multi-meterN

 

Replace switch

 

 

 

 

set to the ohms setting, is

 

 

 

 

 

 

 

 

 

 

(see page 23)

 

 

 

 

there continuity between

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the switch terminals?

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

Common causes for

 

 

 

 

 

 

 

 

 

 

 

Reconnect wire leads and

 

 

 

 

 

 

high exhaust temperature

observe heater operation.

Y

 

Do switch

Y

Exhaust

 

1. Vent length is below minimum allowable.

Do exhaust gas

 

 

 

temperature is

 

2. Vent diameter not to specification.

 

 

 

 

contacts open?

 

 

temperatures rise to or

 

 

 

 

 

too hot.

 

3. Restricted dilution air inlet.

 

 

 

 

 

 

 

 

above 170°F

 

 

 

 

 

 

 

 

 

4. Missing or deteriorated flue baffle.

with vent connected?

 

 

 

 

 

 

 

 

 

5. Gas pressure is out of specification.

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Do switch

Y

 

Replace switch

 

 

 

 

contacts open?

 

 

 

 

 

(see page 23)

 

 

 

 

N

Switch OK

Page 22

Page 22

22

TTW SERVICE PROCEDURE V

Blower Temperature Switch Testing

and Replacement

Blower Temperature Switch

Replacement.

WARNING

115 volt potential exposure. Use caution to avoid personal injury.

Step 1. Position gas control power switch to the “OFF” position and unplug heater from wall outlet.

Step 2. Remove the three screws (Phillips screw driver) from the control access cover on blower and remove cover.

(see photo 16)

Step 3. Locate blower temperature switch (see photo 17)

Step 4. Disconnect red and yellow wire leads from switch.

Step 5. With an appropriate tool such as side cutters, snip the retaining lug from the blower housing to allow removal of temperature switch (see photo 18).

Step 6. Remove switch from blower housing.

Step 7. Install new switch. Be sure switch is properly seated in mounting area.

Step 8. Reconnect red and yellows wires to new switch. Wires are interchangeable with either terminal.

Step 9. Position gas control power switch to the “ON” position and verify proper heater operation.

Step 10. Replace control access cover from step 2.

16

17

Blower temperature switch location

18

Snip retaining lug

 

 

from blower housing

PagePage2323

23

TTW SERVICE PROCEDURE VI

Gas Control/Thermal Well Testing and

Replacement

Gas Control Testing

See pages 29 & 30 for gas control voltage testing.

Thermal Well Testing

If Control has gone into TCO lockout due to excessive tank temperature (four flash, 3 second pause) reset control by rotating knob of temperature control to the minimum setting for at least 6 seconds before returning to desired temperature setting.

Disconnect thermal well wire harness

Observe heater operation. If control continues to lockout due to excessive tank temperature, proceed to thermal well testing to determine cause.

Thermal well testing Position gas control power switch to the “OFF” position and disconnect

thermal well harness from gas control.

Using a multi-meterset to the Ohms setting, determine the resistance of thermal well sensor (see caution photos 19 & 20)

19

20

CAUTION

DO NOT use standard multimeter probes for this test. Doing so will damage connector. Use special pin type electronic probes or small diameter wire pins inserted into connector.

Using a multi-meterset to the ohms setting, insert one meter probe (see caution) into center wire position of thermal well connector, insert the second probe (see caution) into either of the outside wire positions (see photo 19).

Alternate the probe on the outside position to the opposite outside wire position (see photo 20).

Once the thermal well resistance values are known, the water

 

 

temperature must also be known to determine if the resistance

N

Replace thermal well

values are correct. See page 25 to obtain water temperature.

 

(see page 26)

 

 

 

Are thermal well resistance values correct?

 

 

 

Y

 

 

 

 

 

 

 

 

 

Replace gas control

 

 

(see page 26)

 

 

Page 24

 

Page 24

24

TTW SERVICE PROCEDURE VI

Gas Control/Thermal Well Testing and

Replacement

WARNING

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

Determine Water Temperature Inside Tank

Note: It is important to understand once the resistance for the thermal well is determined from page 24, water flow through the heater should not occur. Prior to performing the steps below, turn off the cold water supply to the water heater. This will prevent cold water flow into the tank affecting the resistance value of thermal well.

Step 1. Position gas control power switch to “OFF” position.

Step 2. Draw approximately 1 quart of water from drain valve into container and immediately measure water temperature using an accurate thermometer. It may be necessary to open a hot water faucet to allow heater to drain.

Step 3. Using the chart below, determine correct resistance value for the water temperature from step 2.

Example:

If temperature of water is 84°F, then the resistance through the sensor would be

 

 

8449 (see shaded area). NOTE: Sensor resistance increases as the temperature

 

 

falls.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Sensor Resistance at Various Temperatures

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

In Degrees F

 

 

 

 

 

°F

0

1

2

3

 

4

5

6

7

8

9

 

40

26109

25400

24712

24045

 

 

23399

22771

22163

21573

21000

20445

 

50

19906

19383

18876

18383

 

 

17905

17440

16990

16553

16128

15715

 

60

15314

14925

14548

14180

 

 

13823

13477

13140

12812

12494

12185

 

70

11884

11592

11308

11032

 

 

10763

10502

10248

1000

9760

9526

 

80

9299

9078

8862

8653

 

 

8449

8250

8057

7869

7685

7507

 

90

7333

7165

7000

6839

 

 

6683

6531

6383

6238

6098

5961

 

100

5827

5697

5570

5446

 

 

5326

5208

5094

4982

4873

4767

 

110

4663

4562

4464

4368

 

 

4274

4183

4094

4006

3922

3839

 

120

3758

3679

3602

3527

 

 

3453

3382

3312

3244

3177

3112

 

130

3048

2986

2925

2866

 

 

2808

2752

2697

2643

2590

2538

 

140

2488

2439

2391

2344

 

 

2298

2253

2209

2166

2124

2083

 

150

2043

2004

1966

1928

 

 

1891

1856

1820

1786

1753

1720

 

160

1688

1656

1625

1595

 

 

1566

1537

1509

1481

1454

1427

 

170

1402

1376

1351

1327

 

 

1303

1280

1257

1235

1213

1191

 

180

1170

1150

1129

1110

 

 

1090

1071

1053

1035

1017

999

 

190

982

965

949

933

 

 

917

901

886

871

857

842

 

200

828

814

801

788

 

 

775

762

749

737

725

713

PagePage2525

25

TTW SERVICE PROCEDURE VI

Gas Control & Thermal Well Testing

and Replacement

Gas Control & Thermal Well Removal From Water Heater

Gas Control

Step 1.

Position gas valve power switch to the “OFF”

Thermal

 

position and Unplug Heater from power supply.

 

Well

 

 

Step 2. Drain heater to a point below the gas control level.

Step 3. Turn off gas supply to water heater and disconnect gas piping from gas control.

Step 4. Disconnect wire harnesses and burner assembly from gas control.

Step 5. Remove gas control & thermal well by rotating flats of Thermal Well counter clockwise (1-5/16"wrench).

Gas Control Removal From Thermal Well

Follow the steps below allows removal gas control from thermal well without removing thermal well from tank.

Step 1. Position gas control power switch to the “OFF” position and unplug water heater from power supply.

Step 2. Turn off gas supply to water heater and disconnect gas piping from gas control.

Step 3. Disconnect wire harnesses & burner assembly from gas control.

Step 4. Using gas control service tool (239-45991-00)available from your BWC parts supplier, Insert tool into back of gas control (see photos below)

View from back of control for clarity

Insert tool from

back of control Service tool shown inserted in to back

of control

Step 5. Pivot tool towards heater as far as possible (see photo below). Lift straight up on gas control. The control should move about 1/8". At this point, remove tool not allowing the control to fall back. With tool removed, lift straight up on control to remove completely from Thermal Well.

With service tool inserted, pivot tool back towards heater as far as possible. Lift straight up on control, control will move 1/8". Remove tool and continue to lift straight up on control to remove from Thermal Well.

Page 26

Page 26

26

TTW SERVICE PROCEDURE VI

Gas Control & Thermal Well Testing

and Replacement

Gas Control Assembly to Thermal Well

Step 1. Install threaded end of thermal well into tank. Be sure thermal well flange is positioned as shown in photo 24 for proper control alignment.

Step 2. Route wire leads back into relief opening. (see photo 24)

Step 3. Align slots located on thermal well flange with tabs located on back of gas control (see photos 24 & 25)

Thermal well flange slots

Step 4. Carefully push control back onto thermal well flange as far as possible towards water heater. Slide control down to lock into position.

Step 5. Install burner and connect pilot and feedline to gas control.

24

25

Route wires through relief opening

control Tabs

Igniter/sensor

connection

Ground Wire

connection

5 pin

blower harness connection 3 pin

thermal well connection

wire harnesses to gas control illustration.

gas piping to gas control. gas supply and check for gas

resume operation, follow the located on the lighting

label or the lighting instruction in the installation and operation

.

Flammable Vapor

Sensor

PagePage2727

27

TTW SERVICE PROCEDURE VII

Flammable Vapor Device Testing

Flammable Vapor Device Testing

Step 1. Position power switch on gas control to the “OFF” position.

Step 2. Disconnect flammable vapor sensor from gas control.

Step 3. Using a multi-meterset to the ohms setting check resistance of flammable vapor sensor. (see caution below)

Resistance must be within 3,000 ohms and 48,000 ohms. If outside of this range replace flammable vapor sensor.

Flammable Vapor

Sensor

Multi-meterset to

ohms setting

Electronic

CAUTION

DO NOT use standard multimeter probes for this test.

“pin type”

Doing so will damage connector. Use special electronic

Meter Probes

“pin type” probes or small diameter wire pins inserted

 

into connector.

Flammable Vapor

Sensor

Page 28

Page 28

28

TTW SERVICE PROCEDURE VIII

Safety Circuit Voltage Trace

Safety Circuit Voltage

Trace

NOTE: This procedure assumes a cool tank.

WARNING

115 volt potential exposure. Use caution making voltage checks to avoid personal injury.

26

Remove three screws (Phillips Screw driver) from control access cover on blower and remove cover (see photo 26).

Position gas control switch to the “ON”

 

 

 

position and adjust thermostat dial to call

 

 

 

for heat, Is there 10 to 13 VAC between

Is LED on gas valve flashing

 

red wire leading to blower temperature N

Y

 

 

 

the “heartbeat” code

 

switch and green ground wire?

 

(alternating bright/dim)

 

Blower must be running during this

 

 

 

 

voltage check.

 

N

 

 

 

(see photo 27)

 

 

 

 

 

 

Y

Verify 115VAC to gas

 

 

 

 

 

 

 

 

 

 

control (see page 30)

 

 

 

 

 

 

 

No voltage from gas control, call for technical support.

Is there 10 to 13 VAC between yellow

Is there continuity

 

Check for loose or

wire leading from pressure switch and N

through blower

Y

broken wire

green ground wire?

 

temperature switch?

 

connection at switch

(see photo 27)

(see page 22)

 

terminals

 

Y

 

N

 

 

 

 

 

 

 

 

 

Determine cause of blower

 

 

 

Correct igniter/

temperature switch

 

 

 

 

sensor problem.

activation and correct.

 

 

 

 

 

 

 

 

 

Do you hear or can you N see the igniter sparking?

Y

Safety circuit voltage is OK.

If burner does not light, observe LED flash code on gas valve and refer to troubleshooting section on page 13

Check igniter/sensor (see page 17)

Y Faulty cord set or

is igniter/sensor OK?

gas control.

Green ground wire

27

Red wire leading to blower temp. switch

Yellow wire leading from pressure switch

PagePage2929

29

TTW SERVICE PROCEDURE IX

115 VAC Trace

115 VAC Circuit Trace

WARNING

115 volt potential exposure. Use caution making voltage checks to avoid personal injury.

Step 1. Verify 115VAC and proper polarity at wall outlet.

Step 2. With unit plugged in and control power switch in the “ON” position verify LED status.

LED status

LED status

None, Control LED not

Short flash, once every

on or flashing.

four seconds.

 

 

 

 

 

 

Waiting for

 

 

call for heat.

 

 

28

Disconnect cord set as

 

 

shown in photo 28

 

 

Using a volt meter set

to volts AC, is there

N

115VAC across terminals shown in photo 29 ?

Y

Is there 115VAC

Y

across terminals

 

shown in photo 30 ?

 

 

N

 

 

 

 

 

 

Incorrect supply

 

voltage polarity

 

Locate black & white wires at connector, It may be necessary to pull back wire sheath to identify wire colors. (see photo 32)

Reconnect cord set shown in photo 28.

Disconnect wire harness from gas control (see photo 31).

Is there 115VAC

 

across black & white Y

Replace gas

wires as shown in

 

control.

photo 32?

 

 

N

 

 

 

 

 

 

Call for technical

 

support.

 

Page 30

 

LED status

LED status

“Heartbeat”, alternates

Various flashing error

bright/dim.

codes.

 

 

 

 

Thermostat calling

Verify error code as

for heat

listed on page 13

29

30

Check for damage to Y

Repair damage

AC supply power cord.

 

 

 

N

 

 

 

Replace Blower

 

31

Wire harness

32

Wire sheath pulled back to identify wire colors

Check for 115VAC between black & white wires. -NOTE-

Electronic meter probes required. Use care not to damage connector during this check.

Page 30

30

TTW SERVICE PROCEDURE X

Dip Tube

Inspection and replacement

Dip Tube Inspection and Replacement

WARNING

Water 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. Position on/off switch of gas control valve to “OFF” position and unplug water heater from wall outlet.

Step 2. Turn off cold water supply to water heater. Connect hose to drain valve of water heater and route to an open drain. Open a nearby hot water faucet to vent heater for draining. Open drain valve 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 tool such as a pipe 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-jetslots should be open and 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 water heater. Connect nipple to plumbing system, resume water supply and refill 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.

PagePage3131

31

TTW SERVICE PROCEDURE XI

Anode

Inspection and replacement

Anode Inspection and Replacement

WARNING

Water 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. Position on/off switch of gas control valve to the “OFF” position and unplug water heater from wall outlet.

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

Step 3. Disconnect outlet nipple from plumbing system.

Step 4 With an appropriate tool such as a pipe 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 ½ of the original anode diameter (approximately ¾” 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 water heater. Connect nipple to plumbing system, resume water supply and refill 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.

Page 32

Page 32

32

TTW SERVICE PROCEDURE XII

Flue Baffle Inspection and replacement

Disconnect vent

Remove blower to gain access to system from exhaust

adapter.

flue baffle

Step 1.

Position gas control power switch to the “OFF” position

33

 

and unplug blower from wall outlet.

 

Step 2.

Disconnect vent system from exhaust adapter on top of

 

 

blower.

 

Step 3.

Unplug cord sets from blower. (see photo 33).

 

Step 4.

Remove the three blower mounting screws

 

 

(¼" nut driver) (see photo 33).

 

 

 

Blower

Step 5.

Remove blower with gasket from water heater.

Cord Sets

Step 6.

Remove flue baffle from Heater (see photo 34).

34

 

 

Step 7.

Inspect baffle for deterioration, missing restrictors.

 

 

Clean any scale or debris build up. Replace with new

 

 

baffle as necessary.

 

Step 8.

Reinstall baffle into flue tube. Be sure baffle

 

 

hanger tab are inserted into notch location at the

 

 

top of the flue tube (see photos 35 & 36).

 

Step 9

Check Burner to insure no scale has accumulated during

 

 

this operation. See burner cleaning procedure on page 15.

 

Step 10.

Reinstall blower on water heater. Connect vent

35

 

 

system and cord sets to blower. Plug water heater

 

 

into wall outlet.

 

Step 11.

To resume operation follow the lighting instruction

 

 

located on the lighting instruction label or the lighting

 

 

instruction located in the installation and operation

 

manual.

Flue tube notch

36

Blower Mounting

Screws

Flue Baffle

Baffle shown installed in flue tube notch.

PagePage3333

33

TTW SERVICE PROCEDURE XIII

Inner Door/Gasket Removal, Inspection

Replacement and Reinstallation

Inner Door Removal Procedure

Step 1. Position gas control power switch to the “OFF” position.

Step 2. Remove outer jacket burner access door

Step 3. Inner Door Removal.

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

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

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

d)Remove inner door and inspect per step 4.

 

¼" Hex Drive Screws

 

Right and Left Side Inner Door.

 

¼" Hex Drive Screws at

 

Flange Area of 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 theflange section first, this will help to achieve the proper over lap position.

Page 34

Page 34

34

TTW SERVICE PROCEDURE XIII

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. Place the left side inner door into position first. Firmly position the radiused channel of the inner door aroundthe feedline. Using the 1/4” hex drive screws from step 3c, secure left side inner door in place. DO NOT OVER TIGHTEN SCREWS.

Step 9 Position pilot tube and igniter/sensor wire against left side inner door flange gasket.

DO NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE.

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.

Position pilot tubing and igniter/sensor wire.

Radiused Channel

for Feedline

Page 35

Page 35

35

TTW SERVICE PROCEDURE XIII

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 ¼” drive screws from step 3b. 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 opening. Secure right side inner door using 1/4” hex drive screws from step 3a. DO NOT

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

Secure flange with ¼" drive screws.

Verify threaded hole alignment with slotted openings in inner door.

Step 12. Replace outer jacket burner access door.

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.

Page 36

Page 36

 

36

ScreenLok® Flame Arrestor Cleaning

ScreenLok® Flame Arrestor Cleaning:

Step 1. Position Gas Control Power Switch to the OFF position.

Step 2. Remove outer jacket.

Step 3. Remove inner door per TTW SERVICE PROCEDURE XIII, step 3a through step 3d.

Step 4. Disconnect main burner feed line (3/4 wrench), pilot tube (7/16 wrench) and igniter/flame sensor wire from gas control 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 TTW SERVICE PROCEDURE I and reinstall burner assembly into combustion chamber.

Step 7. Reconnect feedline, pilot tube and igniter/flame sensor wire to the gas control.

Step 8. Reinstalll inner door per TTW SERVICE PROCEDURE XIII, step 7 through step 12.

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.

Page 37

37

Glossary of Terms

BTU

British Thermal Units

GPM

Gallons per Minute

Hz

Hertz

KW/h

Killo-wattsper hour

LED

Light Emitting Diode

NPT

National Pipe Thread

Ohms

Ohms of resistance

PSI

Pounds per Square Inch

RPM

Revolutions per Minute

TCO

Temperature Cut Off

VAC

Volts Alternating Current

W.C.

Inches of Water Column

°C

Degrees Centigrade

°F

Degrees Fahrenheit

NOTES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 38

Page 34

38

Parts List

1.

Blower Complete

13.

Heat Trap Inlet

25.

Cast Iron Burner

37.

Brass Drain Valve

2.

Air Mixing Inlet cover

14.

Inlet Dip Tube

26.

Pilot Assy. (L.P.)

38.

Flammable Vapor Sensor Clip

3.

Pressure Switch

15.

Wire Harness

27.

Pilot Orifice (L.P.)

39.

Flammable Vapor Sensor

4.

Blower Temp. Switch

16.

T&P Valve

28.

Feedline

40.

Sensor Harness

5.

Blower Gasket

17.

¾ NPT Plug

29.

Jam Nut

41.

Thermal Well

6.

Blower Power Cord

18.

Burner Assy. (Nat)

30.

Air Shutter

42.

Gas Control

7.

Vent Adapter w/vent term.

19.

Burner Head

31.

Main Burner Orifice (L.P.)

43.

Gas Control Service Tool

8.

Condensate Hose Kit

20.

Main Burner Orifice

32.

Outer Door

44.

Kit-GasControl

9.

Flue Reducer (M2 only)

21.

Pilot Assy. (Nat)

33.

Right Side Inner Door

45.

Inner Door Gasket Kit

10.

Heat Trap Outlet

22.

Pilot Orifice

34.

Screw #8-15x 3/4

46.

ASSE App’vd Mixing Valve

11.

Hot Water Outlet Anode

23.

Feedline

35.

Left Side Inner Door

47.

Kit-HeatTrap Insert

12.

Flue Baffle

24.

Burner Assy. (L.P.)

36.

Screw #10-12x 3/4

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 39

 

 

 

 

 

 

 

 

 

Page 35

 

 

 

 

 

 

 

 

 

 

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