Bradford-White TW45565 User Manual

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The Bradford White

Through-The-WallGas Water Heaters

SERVICE

MANUAL

(To be performed ONLY by qualified service providers)

Troubleshooting Guide and Instructions for Service

(To be performed ONLY by qualified service providers)

For the Bradford White

For Bradford White

Through-The-WallModels:

TTW Series Models:

M1TW40S*(BN,CX)(1)

M1TW40S*(BN,CX)1

M1TW50S*(BN,CX)(1)

M1TW50S*(BN,CX)1

M2TW50T*(BN,CX)(1)

M2TW50T*(BN,CX)1

M2TW65T*(BN,CX)(1)

M2TW65T*(BN,CX)1

TW450S65(B)*(N,X)

TW450S65(B)*(N,X)

TW465S65(B)*(N,X)

TW465S65(B)*(N,X)

(*) Denotes Warranty Years

(*) Denotes Warranty Years

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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

15I

 

 

Pilot Testing, Cleaning and Replacement

17II

 

 

 

Pressure Switch Testing and Replacement

1

 

8III

 

Blower Testing and Replacement

 

 

 

20IV

 

Blower Temperature Switch Testing and Replacement

22V

 

Gas Control & Thermal well Testing & Replacement

24VI

 

Simulated Resistive Device Testing and Replacement

28VII

 

Safety Circuit Voltage Trace

29VI

 

 

 

 

II

115VAC Circuit Trace

30IX

 

 

 

 

 

 

Dip Tube inspection and Replacement

 

31X

 

 

 

Anode Inspection and Replacement

32XI

 

 

 

Flue Baffle Inspection and Replacement

 

 

33X

II

Glossary of Terms

34--

 

 

 

 

 

 

-

Parts List

35-

 

 

 

 

 

 

 

--

Page 2

Page 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

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, TTW2 & 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

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:I

n 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.

 

Thesepr obes are available at most electronic wholesale outlets.

Thermometer:Us

ed to measure water temperature. An accurate thermometer is

 

recommended.

Water Pressure Gage:U

sed 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:Pi

pe 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.

Page 5

Page 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 Models:

 

Pressure switch

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

TTW2 Models:

 

 

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

 

 

 

TTW1

Blower

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

TTW2

 

 

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

 

 

Page 6

Page 6

 

 

Specifications

Vent Tables

Venting Specifications for:

40 Gallon

50 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)

 

 

 

 

 

 

 

 

 

 

PagPage77

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

85 (25.9)

10 (3.1)

 

 

 

 

 

 

Through the Wall

2

80 (24.4)

10 (3.1)

 

 

 

 

 

 

Through the Wall

3

75 (22.9)

10 (3.1)

 

 

 

 

 

 

Through the Wall

4

70 (21.3)

10 (3.1)

 

 

 

 

 

 

Through the Wall

5

65 (19.8)

12 (3.6)

 

 

 

 

 

 

 

 

 

 

 

Through the Roof

0

90 (27.4)

15 (4.6)

 

 

 

 

 

 

Through the Roof

1

85 (25.9)

15 (4.6)

 

 

 

 

 

 

Through the Roof

2

80 (24.4)

15 (4.6)

 

 

 

 

 

 

Through the Roof

3

75 (22.9)

15 (4.6)

 

 

 

 

 

 

Through the Roof

4

70 (21.3)

15 (4.6)

 

 

 

 

 

 

Page 8

Page 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 (cycle power to restart)

 

Verify Resistive Delay

Retry after 2 Minutes (repeats 5 times)

 

Simulated Resistive Load Lockout

Indefinite (cycle power to restart)

 

Hardware Error Lockout

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

 

Wiring Diagram

 

 

 

Blower

Blower

 

 

Motor

 

 

Temperature

 

 

 

 

 

Switch

 

 

Pressure

 

 

Blower

Switch

 

 

 

 

 

Housing

 

 

Pilot

 

 

 

B C

A

Simulated

Resistive

Device

Thermal

Well

Page 9

Page 9

Sequence of Operation

1 Start Up.

Upon power up, the control runs a safe-startcheck with a typicalstart-updelay of1-5seconds.

2 Simulated Resistive Device Check.

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

1 Thermostat calls for heat.

2

3

4

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.

Blower energizes.

Blower pre-purgeperiod (2 seconds)

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.

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.

6Main 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

 

 

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 Flashes3 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.

9Burner off.

10 Blower post purge (15 seconds).

1. Simulated Resistive Device 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 70,000 ohms after 30 seconds, the gas control proceeds to verify resistive delay for 2 minutes and flashes8 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 flashing 7 times with a 3 second pause.

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 twice with three second pause. The error self clears if the fault clears for at least 15 seconds.

b)Temperature 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 twice 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. Power needs to be cycled to remove gas control from TCO lockout.

PPagege 111

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 open - 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)Pr essure 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. Trail For Ignition Fault:

a)Pres sure 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 flashes6 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 flashes6 times then 3 times with 3 second pause. The gas control waits 5 minutes before repeating the ignition sequence.

c)Fl ame 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

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.

 

 

 

 

 

 

Stand-bymode,

 

 

Normal operation.

 

 

Short flash, once every

 

 

 

 

Waiting for call for

Temperature demand is satisfied

Adjust thermostat to

 

 

four seconds

heat (no fault).

 

 

temp level

 

 

 

 

 

 

 

 

 

 

 

Normal operation.

 

 

“Heartbeat”, alternates

Thermostat calling

 

 

 

 

Tank temperature below set point of thermostat.

Adjust thermostat to

 

 

bright/dim

for heat (no fault).

 

 

temp level

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.

Unstable pilot.

1. Page 15

 

 

Short flash once every

Weak pilot signal

2.

Pilot tube block or restricted.

 

 

 

 

 

on last call for

3.

Oxidation build up on pilot electrode.

2-4.Page 17

 

 

3 second

 

 

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

Page 18

 

 

not working-

2.

Blocked pressure tap on switch or blower.

 

 

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.

2 & 3 Page 18

 

 

Three flash, three

or blower temp.

3.

Faulty pressure switch.

 

 

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

2. Replace gas control,

 

 

3.

Pluming leak

 

 

 

reset.

page 24

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Five flash, three

Undesired-false

 

 

Replace gas control,

 

 

pilot flame

1.

Pilot valve stuck in open position.

 

 

second pause

page 24

 

 

present.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pag 13

 

 

 

 

 

Page 13

 

 

 

 

 

 

 

Troubleshooting

 

LED Status

Control

 

Probable Cause

Service

 

 

Status

 

Procedure

 

 

 

 

 

 

 

 

 

1.

Unstable pilot.

 

 

 

 

Failed to light

1. Page 15

 

 

 

2.

Pilot tube blocked or restricted.

 

 

Six-oneflash, three

pilot.

 

 

 

3.

Oxidation build up on pilot electrode.

2-4.Page 17

 

 

second pause

System auto

 

 

4.

Wire damage to pilot assembly or bad

 

 

 

resets.

 

 

 

 

 

connection at gas valve.

 

 

 

 

 

 

 

 

 

 

Pressure switch

1.

Vent blockage or improper vent configuration.

1. Check vent or vent tables.

 

 

 

 

 

 

 

 

 

 

or blower temp

2.

Pressure switch tubing kinked or blocked.

2 & 3 Page 18

 

 

Six-twoflash, three

switch opened

3.

Faulty pressure switch.

4. Refer to venting section of

 

 

during burner

4.

Vent termination being affected by wind

 

 

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.

2-4.Page 17

 

 

4.

Wire damage to pilot assembly or bad

 

 

second pause

System auto

 

 

 

 

connection at gas valve.

5. Refer to installation manual

 

 

 

resets.

 

 

 

 

5.

Insufficient combustion air.

 

 

 

 

 

 

 

 

 

 

6.

Gas pressure is out of specification.

 

 

 

 

Undesired-false

 

 

 

 

 

 

 

 

 

 

 

Six-fourflash, three

pilot flame

 

 

Replace gas control,

 

 

sensed.

Pilot valve stuck in open position.

 

 

second pause

page 26

 

 

System auto

 

 

 

 

 

 

 

 

 

 

 

resets.

 

 

 

 

 

 

 

 

 

 

 

 

 

Simulated

 

 

 

 

 

Seven flash, three

Resistive Device

Simulated resistive device out of specification.

Page 28

 

 

second pause

Harness out of

 

 

 

 

 

 

 

 

specification.

 

 

 

 

 

 

Simulated

 

 

 

 

 

 

 

 

 

 

 

Eight-oneflash, three

Resistive Device

 

 

Page 28

 

 

Harness

Simulated resistive device out of specification.

 

 

second pause

 

 

specification

 

 

 

 

 

 

 

 

 

 

 

 

check.

 

 

 

 

 

 

Thermal well

 

 

 

 

 

Eight-twoflash, three

1.

Damage to thermal well wire.

Page 24

 

 

sensor damaged

 

 

second pause

2.

Thermal well sensor resistance out of range.

 

 

or unplugged

 

 

 

 

 

 

 

 

 

 

Gas valve

 

 

1. Interrupt power supply

 

 

Eight-threeflash, three

1.

Control needs to be reset.

 

 

electronics fault

2. Replace gas control,

 

 

second pause

2.

Control is wet or physically damaged.

 

 

detected

page 26

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

TTW SERVICE PROCEDURE I

Burner Operation Inspection,

Adjustment, Cleaning and Replacement

Burner Inspection and Air Shutter Adjustment.

At periodicintervals (every6 months) a visual inspection should bemade of the pilot and main burnerfor proper operationand to assure nodebris is accumulating.

Pilotflameshould be stable, some causes foran unstable pilot flame are:

a)Water heater vent is less than theallowablevent 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 flamewith aminimum of yellowtips.

Steel burner models self adjust air to gas ratio mixture and do not have an adjustable air shutter. Cast ironburnercan have the gas and air mixture properly proportionedby adjusting the air shutter on the mixer face of the main burner (see cast iron burneradjustmentbelow).

Main burner must be free fromany debris accumulation that may effect burner operation(see burner cleaning procedure on page 15).

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.W

ith main burner in operation, remove outer jacket door and slide inner door from left to ightr to open.

Step 2.To

adjust for proper burning,loosen the air shutter nut, rotateethair shutter to close theopening ni the

 

burner,then slowly rotate the airshutter open until flame becomesas blue as possiblewith a minimumof

 

yellow tips.Tighten the air shutter nut.

 

Too much air will causethe flame to lift off the burner ports and create noisy burner operation.

 

Too little air will result in sootformation.

Step 3.Clo

se inner door and observe burner operation. Burner shouldoperate as adjusted in step 2. If not,

 

repeat air shutter adjustmentcompensatingfor proper burneroperation with inner door closed.

Air Shutter Nut

Air Shutter

PagPage15 15

Main burner orifice

TTW SERVICE PROCEDURE I

Burner Operation Inspection,

Adjustment, Cleaning and Replacement

Burner Cleaning

Remove Outer

Step 1.Pos

 

ition gas controlpower switch to the

door.

 

 

 

 

“OFF” position andunplug heater fromwall

 

outlet.

 

 

Step 2.T

urn off gas supply to water heater.

 

 

Step 3.Re

 

move outer jacket door and slide inner door open fromeftl to

 

right.

Igniter/flame

Step 4.Disc

onnect pilot tube (7/16 wrench) and

sense wire

 

 

feedline (¾ wrench) fromgas control.

 

 

Step 5.D

isconnect igniter/flame sensor wirefrom gas control.

Step 6.R

emove burner assembly fromcombustion chamber.

Step 7.Thoro

ughly inspect burner surface area and burner portarea and

 

removeany loose debris.

 

 

Step 8.

For cast iron burners,inspect for any debrisbuild up inside

 

burner casting.

 

 

Burner surface area

Slide inner door open from left to right.

Feedline nut

Pilot tubing nut

Burner port area

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

Step 10.Re move main burnerorifice from feedline(½" wrench on steel burners, 3/8" wrenchon cast iron) inspect orifice,cleanor replace if necessary.

Step 11.Rea

ssemble burner and reinstall into water heater. Restore gas supply

and check for gas leaks.

Step 12To

resume operationfollow the instruction located on thelighting

instruction label or the lighting instruction located in the installation and operating manual.

L.P. Main burner orifice. Left hand thread

Page 16

Page 16

 

 

Remove Outer door.

TTW SERVICE PROCEDURE II

Pilot testing, Cleaning and Replacement

Pilot Inspection, Testing and Replacement

Step 1. Positiongas control power switch to the “OFF” position andunplug heater from wall outlet.

Step 2. Turnoff gas supply to water heater.

Step 3. Remove outer jacketdoor and slide inner dooropen fromleft to right.

Slide inner door open from left to right.

Igniter/flame

sense wire

Step 4.Di

 

sconnect pilot tube nut (7/16 wrench) and feedline nut

 

 

 

 

 

 

 

 

Feedline nut

 

(¾ wrench) from gas control.

 

 

 

 

 

 

 

 

 

Step 5.D

 

isconnect igniter/flame sense wire from gas control.

 

 

 

 

 

 

 

Pilot tubing nut

Step 6.R

 

emove burner assembly fromcombustion chamber.

 

 

 

 

 

 

 

 

 

Step 7.

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

 

 

 

 

 

 

 

 

 

Step 8.

Visuallyinspectigniter/flame sense wire for damage. Replace

 

 

 

 

 

 

 

 

 

 

pilot if damage is found.

 

 

 

 

 

 

 

 

 

Step 9.With

a multi-metersetto the ohms setting, check continuity

Ferrule

Pilot

Pilot

Pilot

 

through igniter/flame sensewire. Replace pilot if no continuity.

nut

tubing

orifice

hood

 

 

 

 

 

 

 

 

 

 

Step 10.Visua lly 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) frompilot hood.

 

 

 

 

 

 

 

 

 

 

 

Igniter/flame

 

 

Igniter/flame

 

 

 

 

 

 

Step 11.V

 

isually inspect gniter/flamei sense electrode for oxidation

 

sense wire

 

 

sense electrode

 

build up. Carefully clean any oxidation usingvery fine emery

 

 

 

 

 

 

 

 

 

 

cloth.

 

 

 

 

 

 

 

 

 

Step 12.Vi

 

sually inspect pilot tubing for kinks orcracks. Ifdamage is

 

 

 

 

 

 

 

 

 

 

found replace pilot.

 

 

 

 

 

 

 

 

 

Step 13.In

spect pilot tubingand pilot orifice for blockage:

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

b) Remove pilottube and pilot orifice.

 

 

 

 

 

 

 

 

 

 

c) Inspect pilottubing and pilot orifice forblockage. Clean

 

 

 

 

 

 

 

 

 

 

 

or replace as necessary.

 

 

 

 

 

 

 

 

 

Step 14.R

eassemble pilotand install to feedline. Reinstall burner assembly to water heater. Restore gas supply

 

and check for gas leaks.

 

 

 

 

 

 

 

 

 

Step 15To

 

resume operation follow the instruction located onthe lighting instruction label or thelighting

 

instructionlocatedin theinstallation and operating manual.

 

 

 

 

 

 

 

 

 

PagPage17 17

TTW SERVICE PROCEDURE III

Pressure Switch Testing and

Replacement

Pressure Switch Testing

WARNING

Step 1.Po

sition power switch on g as control

115 volt potential exposure. Use caution

making voltage checks to avoid personal injury.

 

to the “OFF” position.

 

Step 2.Rem

ove the three screws (Phillips screw driver) from control a ccess cover on blower assembly and

 

remove cover (see photo 1).

 

Step 3.C

arefully remove p ressure swi tch from blower housing (s ee phot o 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

 

 

TTW SERVICE PROCEDURE III

Pressure Switch Testing and

Replacement

Pressure Switch Replacement

WARNING

 

 

115 volt potential exposure. Use caution

Step 1.Posi

tion gas control power switch

to avoid personal injury.

 

to “OFF” position.

 

Step 2.Rem

ove the three screws (Phi llips screw d river) from control access cover on blower assembly and

remove cover (see photo 3).

 

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

Step 4.D isconnect tubing from pressure switch.

(seephoto 5)

Pressure Switch

3

4

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

5

6

Step 5.D isconnect yellowwires from pressureswitch (seephoto 6)

Step 6.R

econnect wires from step 5 to new pressure switch.

Step 7.R

econnect tubing to new pressure switch.

Step 8.C

arefully position pressure switch into blower housing.

Step 9.

Position gas contro l power switch to “ON” position and verify proper heater operation.

Step 10.Re

place control access cover from step 2.

PagPage19 19

TTW SERVICE PROCEDURE IV

Blower Testing and Replacement

Blow er T esti ng

WARNING

 

115 volt potential exposure. Use caution when

Step 1.Position gas control power switch

making voltage checks to avoid personal injury.

 

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

7

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

 

 

 

 

 

 

 

 

 

 

Disconnect

 

 

 

 

 

 

Connect

 

Disconnect vent

 

 

Does blower energize

 

 

 

 

 

 

 

 

 

 

 

 

manometer to

system from top of

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace blower

 

 

 

 

 

 

 

 

Incorrect supply

 

 

 

 

 

 

 

blue wire and green

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

problem and

cord set

 

 

 

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

 

 

Blower
Cord Sets

TTW SERVICE PROCEDURE IV

Blower Testing and Replacement

Blower removal

Step 1. Position gas control power switch to the “OF” position. Step 2.U nplug blower power cord from wall outlet.

Remove exhaust adapter and retain for use on new blower.

Step 3.D isconnect vent system from exhaust adapter ontop of blower.

Step 4.R emove exhaustadapter from blower (blade screw driver) and retain for useon new blower

Step 5. Unplugcord sets from blower.

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

Step 7.R emove blower with gasket fromwater heater.

Blower Mounting

Screws

Blower Installation

Step 8.

Clean any debris fromjacket head of water heater.

Step 9.Set

new blower with gasket in place using locating pins on

 

blower flange to line up with location holesin jacket head.

 

Be sure not to damage gasket.

Step 10S

ecure blower inplace using mounting screws fromstep 6.

Step 11.R

e-installexhaustadapter from step 4.

 

Step 12.R

econnect vent system to

Locating Pins

on blower flange

exhaust adapter.

 

Step 13.Rec

onnect cord sets fromstep 5.

Pin location holes in

jacket head

 

 

Step 14.Pl ug blower power cord into wall outlet.

Step 15.P ositiongas control power switch to the “ON” position. Step 16. V erify proper blower operation.

PagPage21 21

 

 

TTW SERVICE PROCEDURE V

 

 

Blower Temperature Switch Testing

 

 

 

and Replacement

Blower Temperature Switch

 

WARNING

Testing.

 

115 volt potential exposure. Use caution

Step 1.Po sition power switch on gas control

to avoid personal injury.

 

 

to the “OFF” position.

 

14

 

 

 

Step 2.Remov

e the three screws (Phillips screw driver) from

 

control access cover onblower and remove cover (see

 

photo 14).

 

 

Step 3.Locate

blowertemperature switch (seephoto15)

 

 

 

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

N

 

 

 

 

 

 

 

 

 

 

 

 

 

switch. Using a multi-meter

 

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 165°F?

 

 

 

 

 

 

 

 

4.

Missing or deteriorated flue baffle.

 

N

 

 

 

 

 

 

 

 

5.

Gas pressure is out of specification.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Do switch

Y

 

Replace switch

 

 

 

 

 

contacts open?

 

 

 

 

 

(see page 23)

 

 

 

 

 

N

Switch OK

Page 22

Page 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.Po

sition gas control power switch to the “OF F” position

 

and unplug he ater from wall outlet.

Step 2.R

emove the three screws (Phillips screw driver) from the

 

control access cover on blower and remove cover.

 

(see photo 16)

Step 3.Locate b

lower temperature switch (see photo 17)

Step 4.D

isconnect red and yellow wireleadsfromswitch.

Step 5.

Withan 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.In

stallnew switch. Besure switch is properly seated in

 

mountingarea.

Step 8.

Reconnect red andyellows wires to new switch. Wires are

 

interchangeable with either terminal.

Step 9.P

ositiongas control power switch to the “ON” position

 

and verify proper heater operation.

Step 10.Re

place controlaccesscover from step2.

16

17

Blower temperature

 

 

switch location

18

Snip retaining lug

 

 

from blower housing

Page 23

Page 23

TTW SERVICE PROCEDURE VI

Gas Control/Thermal Well Testing and

Replacement

Gas Control Testing

 

See pages 29 & 30 for gas control

 

input & output testing.

 

Thermal Well Testing

 

Position gas valve power

Disconnect thermal

switch to the “OFF”

well wire harness

position and disconnect

 

thermal well harness from

 

gas control.

 

 

 

 

 

 

Using a multi-meterset to

 

the Ohms setting,

 

determine the resistance of

 

thermal well sensors 1 & 2

 

(see photos 19 & 20)

 

19

20

Using a multi-meterset to theohms setting, insert one meter probe into center wire position of thermal well connector, insert the second probe 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

 

 

 

 

 

 

 

 

 

Thermal well OK

 

 

Page 24

Page 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 resistancefor the thermal well is determined from page 24, water flow throughthe heater should notoccur. Prior to performing the steps below, turnoff thecold water supplyto the water heater.This will preventcold water flow intothe tank affecting the resistance value of thermal well.

Step 1.Positio

n gas controlpower switch to “OFF” position.

Step 2.D

raw approximately 4 galons of water from drain valve into a container and discard. Draw an

 

additional gallon 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 thewater temperature from step 2.

Example: I f 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

012

 

 

34

5

67

8

9

4026

109

254002

47122404523399227712216321

 

5732100020445

 

5019

906

193831

88761838317905174401699016

 

5531612815715

 

6015

314

149251

45481418013823134771314012

 

8121249412185

 

7011

884

115921

1308110321076310502102481000976

 

0

9526

809

29990788

86286538449825080577869

 

76857507

 

907

33371657

00068396683653163836238

 

60985961

 

100582

756975

570

5446

53265208

5094498

248734767

 

110466

345624

464

4368

42744183

4094400

639223839

 

120375

836793

602

3527

34533382

3312324

431773112

 

130304

829862

925

2866

28082752

2697264

325902538

 

140248

824392

391

2344

22982253

2209216

621242083

 

150204

320041

966

1928

18911856

1820178

617531720

 

160168

816561

625

1595

15661537

1509148

114541427

 

170140

213761

351

1327

13031280

1257123

512131191

 

180117

011501

129

1110

10901071

1953103

51017

999

19098

29

659

49933917901

 

886871857842

 

20082

88

148

01788775762

 

749737725713

 

Page 25

Page 25

TTW SERVICE PROCEDURE VI

Gas Control & Thermal Well Testing

and Replacement

Gas Control & Thermal Well Removal From Water Heater

 

 

Gas Control

Step 1.Pos

ition gas valvepower switch to the “OFF”

Thermal

 

position and UnplugHeater frompower supply.

Well

Step 2.D

rain heater toa pointbelow the gas

 

 

control level.

 

Step 3.T

urn offgas supply to water heater and

 

 

disconnect gas piping fromgas control.

 

Step 4.Dis

connect wire harnesses and burner assembly

 

 

from gas control.

 

Step 5.R

emove gas control & thermal wellby rotatingflats of ThermalWellcounter clockwise (1-5/16"wrench).

Gas Control Removal From Thermal Well

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

Step 1.Pos

itiongas control power switch tothe “OFF” positionand unplug water heaterfrom power supply.

Step 2.Tur

n offgas supply to water heater and disconnectgas piping from gascontrol.

Step 3.Di

sconnect wire harnesses & burner assembly from gas control.

Step 4.Us

ing 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

Service tool shown

back of control

 

 

inserted in to back

 

 

of control

Step 5.Piv

ot tool towardsheater as far as possible (seephoto below). Lift straightup on gas control.The

 

control should move about1/8". At this point, remove toolnot 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

 

 

TTW SERVICE PROCEDURE VI

Gas Control & Thermal Well Testing

and Replacement

Gas Control Assembly to Thermal Well

Step 1.In

stallthreaded end of thermal well intotank. Be sure

 

thermal well flangeis square asshown in photo 24 for

 

proper control alignment.

Step 2.R

oute wire leads back into relief opening.

 

(seephoto 24)

Step 3.A

lign slots located on thermal well flangewith tabs

 

located on backof gas control (see photos 24 & 25)

 

Thermal Well

 

flange slots

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

Step 5.Inst all burner andconnect pilot and feedline to gas control.

24

25

Route wires through relief opening

 

Gas control tabs

Igniter/sensor

Step 6.Re

connect wire harnesses to gas control

connection

 

per the illustration.

 

 

 

Step 7.

Reconnect gas piping to gas control.

Ground Wire

 

Restore gas supply and check for gas

connection

 

leaks.

 

Step 8.

To resume operation, follow the

5 pin

 

instruction located on the lighting

 

instruction label or the lighting instruction

blower harness connection

3 pin

located in the installation and operation

 

 

thermal well connection

manual.

Simulated Resistive device

PagPage27 27

TTW SERVICE PROCEDURE VII

Simulated Resistive Device Testing

Simulated Resistive Device Testing

Step 1.Po

sition power switch on gas control tothe

 

“OFF” position.

Step 2.Di

sconnect simulated resistive device from

 

gas control.

Step 3.U

sing a multi-metersetto the ohms setting

 

check resistance of simulated resistive

 

device. Resistance must be within 25,000

 

ohms and 45,000 ohms. If outside of this

 

range replace simulated resistive device.

Simulated Resistive device

Multi-meterset to

ohms setting

Electronic “pin type” Meter Probes

Simulated Resistive device

Page 28

Page 28

 

 

TTW SERVICE PROCEDURE VIII

Safety Circuit Voltage Trace

Safety Circuit Voltage

Trace

NOTE: This procedure assumes acool 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 (seephoto26).

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

Y

Faulty cord set or

(see page 17)

 

gas control.

is igniter/sensor OK?

 

 

Green ground wire

 

 

27

 

 

 

 

Red wire leading to

 

 

blower temp. switch

Yellow wire leading from pressure switch

Page 29

Page 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.Veri

fy 115VAC and proper polarity at wall outlet.

Step 2.Wit

h 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

Reconnect cord set

across terminals

 

shown in photo 28.

shown in photo 30 ?

 

 

 

 

 

N

 

 

 

 

 

 

 

 

Disconnect wire harness

 

 

 

Incorrect supply

 

 

from gas control

voltage polarity

 

(see photo 31).

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

Is there 115VAC

Replace gas

across black & white Y

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

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.Positi

on on/off switch ofgas controlvalveto “OFF”position and unplug water heater from wall outlet.

Step 2.

Turn off cold water supply towater heater.Connect hose to drain valve of water heaterandroute to an

 

open drain. Open a nearby hotwater faucetto vent heater fordraining. Open drain valve of water

 

heater and allow heater to drain to a pointbelow the inlet onnectionc nipple.

Step 3.Dis

 

connect inlet nipple from plumbing system.

Step 4With

an appropriate tool such as a pipe wrench, remove inlet nipple/diptube from the waterheater.

 

Use caution not to damage pipe threads.

Step 5.V

 

isuallyinspect inlet nipple/dip tube. Inlet nipple/dip tube should be free ofcracks andany blockage.

 

Hydro-jetslots shouldbe open and freeof any blockage.

 

Any damagesuch as cracks, restrictiondue todeformation or unintentional holes are not field

 

repairableand the inlet nipple/dip tubemust be replaced.

Step 6.

Upon completion ofinspection or subsequentreplacement,reinstall inlet nipple/dip tubeintowater

 

heater. Connect nipple to plumbing system, resume water supply and refill withwater.

Step 7.To

 

resume operation follow the instructions located on thelightinginstruction label or the lighting

 

instructions located in the installation and operationmanual.

Page 31

Page 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.

Positionon/off switch ofgas control valveto the “OFF”position and unplug water heater from wall

 

outlet.

Step 2.Tu

rn off cold water supply to water heater. Connect hose to drainvalve of water heater and route to an

 

open drain. Open a nearby hot water faucet to vent water heaterfor draining. Open drain valve of

 

water heater and allow water heater to drain to a point below the outlet connection nipple.

Step 3.D

isconnect outlet nipple from plumbing system.

Step 4

With anappropriate tool such as a pipe wrench, remove outlet nipple/anode fromthe water heater. Use

 

caution not todamage pipe threads.

Step 5.V

isuallyinspect outlet nipple/anode. Outlet nipple/anode should hows signs of depletion,this is

 

normal. If depletionis ½ of the original anodediameter (approximately ¾” diameter), replacementis

 

recommended. If any of thest eel core of the anode is exposed, replacement is recommended.

Step 6.U

pon completion of inspection orsubsequent replacement, reinstall outlet nipple/anode into water

 

heater. Connect nipple to plumbing system, resume water supply and refillwith water.

Step 7.

To resume operation, follow the instructions located on the lighting instruction label or the lighting

 

instructions locatedin the installation and operationmanual.

Page 32

Page 32

 

 

Flue tube notch

TTW SERVICE PROCEDURE XII

Flue Baffle Inspection and replacement

Remove blower to gain access to

Disconnect vent

system from exhaust

flue baffle

adapter.

 

 

Step 1.P

 

ositiongas control power switch to the “OFF” position

33

 

and unplug blower from wall outlet.

 

 

Step 2.

Disconnect vent system from exhaust adapter ontop of

 

 

blower.

 

 

Step 3.

Unplug cord sets fromblower. (see photo33).

 

 

Step 4.R

 

emovethe three blower mounting screws

 

 

 

(¼" nut driver) (see photo 33).

 

 

Step 5.

Remove blower with gasket from water heater.

 

Blower

 

Cord Sets

Step 6.

Remove flue baffle from Heater (see photo 34).

 

34

 

 

 

 

Step 7.Ins

 

pectbaffle for deterioration,missing restrictors.

 

 

Clean any scale or debris build up.Replace with new

 

 

baffle as necessary.

 

 

Step 8.Rein

stallbaffle into flue tube.Be sure baffle

 

 

 

hanger tab are inserted into notch location atthe

 

 

 

top of the flue tube (seephotos 35 & 36).

 

 

Step 9Ch

 

eck Burner to insureno scalehas accumulated during

 

 

this operation.See burner cleaning procedureon page 15.

 

Step 10.R

 

einstall bloweron water heater. Connect vent

 

35

 

system and cord sets to blower. Plug water heater

 

 

 

into walloutlet.

 

 

Step 11.T

o resume operation follow the lighting instruction

 

 

located on the lighting instruction label or thelighting

 

 

instruction located in the installation and operation

 

 

manual.

 

 

36

Blower Mounting

Screws

Flue Baffle

Baffle shown installed in flue tube notch.

PagPage33 33

Glossary of Terms

BTU

British Thermal Units

GPM

Gallons per Minute

HzHert

z

KW/h

Killo-wattsper hour

LEDLigh

t Emitting Diode

NPTN

ational Pipe Thread

OhmsOh

ms of resistance

PSIPoun

ds per Square Inch

RPMRe

volutions per Minute

TCOTe

mperature Cut Off

VACVo

lts Alternating Current

W.C.In

ches of Water Column

°CDeg

rees Centigrade

°FDe

grees Fahrenheit

NOTES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 34

Page 34

 

 

Parts List

Optionalptional

1.

B

lower Complete

13.

Heat Trap Inlet

25.C ast Iron Burner

37.

Gas Control

2.

A ir Mixing Inlet cover

14.

Inlet Dip Tube

26.

Pilot Assy. (L.P.)

38.

Gas Control Service Tool

3.

P

ressure Switch

15.

Wire Harness

27.P ilot Orifice (L.P.)

39.

Kit-GasControl

4.

B

lower Temp. Switch

16.

T&P Valve

28.Fe edline

40.

ASSE App’vd Mixing Valve

5.

B

lower Gasket

17.¾ NPT Plug

29.

Jam Nut

41.

Kit-HeatTrap Insert

6.

Blower Power Cord

18.

Burner Assy. (Nat)

30.

Air Shutter

42.

Exhaust Termination Elbow

7.

Vent

Adapter

19.

Burner Head

31.M ain Burner Orifice (L.P.)

 

 

8.

Co

ndensate Hose Kit

20.

Main Burner Orifice

32.

Outer Door

 

 

9.

Fl

ue Reducer (M2 only)

21.

Pilot Assy. (Nat)

33.

Inner Door

 

 

10. Heat Trap Outlet

22.

Pilot Orifice

34.B rass Drain Valve

 

 

11.Hot

Water Outlet Anode

23.

Feedline

35.

Resistive Load Device

 

 

12.F lue Baffle

24.

Burner Assy. (L.P.)

36.

Thermal well

 

 

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