Bradford-White U130T'FRN User Manual

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The Bradford White

R

(To be performed ONLY by qualified service providers)

 

R

U130T*FRN

U150L*FRN

U130S*FRN

U1504S*FRN

U140T*FRN

U430T*FRN

U1403T*FRN

U440T*FRN

U1403S*FRN

U4403S*FRN

U1404T*FRN

U4503*FRN

U1503*FRN

U1XR403S*FRN

 

(*) Denotes Warranty Years.

Manual 47132A

Save this manual for future reference

The Bradford White

R

Ultra Low NOx Gas Water Heaters

 

Page

Service Procedure

Introduction

3

- - -

Gas Control Troubleshooting Chart

5

- - -

Tools Required for Service

4

- - -

Burner and Inner Door Gasket Removal, Inspection, Replacement

 

 

and Installation

7

ED-I

Thermopile Testing and Replacement

10

ED-II

Pilot Assembly Inspection, Cleaning and Replacement

12

ED-III

Igniter and Electrode Testing and Replacement

13

ED-IV

Gas Control Replacement Thermal Well and Chamber Door Sensor

 

 

Testing and Replacement

14

ED-V

Burner Operation Inspection, Cleaning and Replacement

19

ED-VI

Resettable Thermal Switch Testing and Replacement

21

ED-VII

ScreenLok R Flame Arrestor Cleaning

23

ED-VIII

Dip Tube and Anode Inspection and Replacement

24

ED-IX

Generic Parts List

26

- - -

Page 2

2

INTRODUCTION

The Bradford White ECO-DEFENDER Safety System R

The Bradford White ECO-DEFENDERSafety System was designed to resist the ignition of flammable vapors that can occur outside of the water heater. In addition, theECO-DEFENDERSafety System is designed to meet the stringent NOx emissions standards required in the South Coast Air Quality Management District (SCAQMD) Rule 1121. Use and installation are nearly identical to previous versions of atmospherically fired and vented water heaters. A number of exclusive design features are incorporated in the system that will require additional knowledge on the part of the qualified service provider. The following information will instruct service professionals on the function, proper diagnosis and repair of water heaters employing the Bradford WhiteECO-DEFENDERSafety System.R

How the Safety System Works

During normal operation, most air for combustion is drawn into the water heater through the openings in the jacket door. This air travels into the burner venturi, mixing with the gas jet. This air is then mixed with gas inside the burner and drawn to the burner screen and is efficiently combusted producing Ultra Low NOx emissions. Additional air is drawn through the openings in the jacket. This air travels down and around the combustion chamber and enters through holes in the bottom of the corrosion-resistantcombustion chamber. The air then travels up through the oriented flame arrestor plate louvers, where the velocity of the air is increased and its direction altered. The air then mixes in a normal manner with the combustion products from the burner.

In the case where trace amounts of flammable vapors are present in the air flowing into the combustion chamber and burner venturi, the vapors are harmlessly ignited by the burner / pilot flame. If flammable vapors are in sufficient quantity to prevent normal combustion, the burner and pilot flames are designed to shut down.

Should the flammable vapors continue to the burner, the flame arrestor plate and burner screen prevent the flames from traveling backwards and igniting vapors outside of the combustion chamber. This causes the thermopile to overheat and shuts down the main pilot and burner. The thermopile powers the intelligent diagnostic control which is capable of recognizing restricted airflow conditions caused by severe lint, dust and oil accumulation on the burner screen and arrestor plate. The intelligent diagnostic control will deactivate the burner and pilot in the unlikely event of restricted airflow.

Page 3

3

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 ECO-DEFENDERSeries of water heaters.

The Honeywell WV8860Q Gas Control will display error codes in the event of abnormal operation. Error codes are listed in the troubleshooting chart beginning on page 5 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.

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, flashlight and 5 gallon pail.

Page 4

4

Gas Control Troubleshooting

Observe red LED indicator on 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.

Red LED

Indicator

LED Status

Control Status

Probable Cause

Service Procedure

 

 

Gas valve is operating

 

If the pilot will not stay lit

 

 

normally. Pilot flame

1. Gas valve is

 

None (LED not on

replace thermopile, see

 

may not be present.

functioning normally

 

page 10. If problem

 

or flashing)

Check for pilot flame

2. Gas valve is not

 

persists replace gas

 

 

through sight glass and

powered. Light pilot

 

 

valve, see page 16.

 

 

light if necessary.

 

 

 

 

 

 

One flash and

If set point knob is in

Gas valve is powered

 

 

"PILOT" position then

and waiting for the set

Normal operation. Adjust

 

three second

pilot flame is detected.

point knob to be turned

thermostat to desired

 

pause.

Turn set point knob to

to a water temperature

temperature level.

 

 

desired setting

setting.

 

 

 

Set point knob has

 

 

 

LED on

been recently turned to

Set point knob was

LED will go out and the

 

the "OFF" position.

turned to "OFF"

control will function

 

continuously.

Wait until LED goes out

normally when the pilot is

 

 

before attempting to

position.

lit.

 

 

 

 

 

relight

 

 

 

 

Weak pilot flame

1. Thermopile failure

 

 

Two flashes and

2. Unstable pilot.

1. See page 10.

 

detected. System will

3. Pilot tube block or

 

three second

2&3. See page 12.

 

reset when pilot flame

restricted.

 

pause.

4. See page 21.

 

is sufficient.

4. Resettable thermal

 

 

 

 

 

 

switch has opened.

 

 

Three flashes and

Insufficient water

1. Thermowell sensor

 

 

and chamber

1&2. See pages 14 and

 

three second

heating. System will

temperature sensor out

 

pause.

reset.

of calibration.

18.

 

 

 

 

 

2. Possible short.

 

 

Four flashes and

Excessive tank

1. Thermowell sensor

1. See page 14.

 

three second

temperature. System

out of calibration.

 

2. See page 16.

 

pause.

must be reset.

2. Faulty gas valve.

 

 

 

Page 5

5

Gas Control Troubleshooting

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LED Status

Control Status

Probable Cause

Service Procedure

 

 

 

Five flashes

 

1. Damage to the

 

 

 

 

 

thermowell wire.

 

 

 

 

 

and three

Thermostat well fault.

 

 

 

 

 

2. Thermowell

See page 14.

 

 

 

 

second

 

 

 

 

 

sensor resistance

 

 

 

 

 

pause.

 

 

 

 

 

 

 

out of range.

 

 

 

 

 

 

 

 

 

 

 

Six flashes

Chamber door

1. Chamber door

 

 

 

 

temperature sensor out

temperature sensor

 

 

 

 

 

and three

 

 

 

 

 

of specification.

out of calibration.

See page 18.

 

 

 

 

second

 

 

 

 

Possible electrical

2. Possible

 

 

 

 

 

pause.

 

 

 

 

 

short.

electrical short.

 

 

 

 

 

 

 

 

 

Seven flashes

 

1. Control needs to

1.Turn gas control knob

 

 

 

to "OFF" position and

 

 

 

 

and three

Gas valve electronic

be reset

then follow lighting

 

 

 

 

second

fault detected.

2. Control is wet or

instructions.

 

 

 

 

pause.

 

physically damaged

2. Replace gas control,

 

 

 

 

 

 

 

see page 16.

 

 

 

Eight flashes

False pilot flame

Pilot valve stuck in

Replace gas control, see

 

 

 

 

and three

 

 

 

 

present.

open position.

page 16.

 

 

second pause

 

 

 

 

 

 

 

 

Ten flashes

Insufficient combustion

Insufficient

See page 19 and 23.

 

 

 

 

and three

air detected. Reset

combustion air.

 

 

second pause

system.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 6

6

SERVICE PROCEDURE ED-I

Burner and Inner Door/Gasket Removal,

Inspection, Replacement and

Reinstallation

Inner Door Removal Procedure

Step 1. Rotate the gas control knob to the “OFF” position.

Step 2. Remove outer jacket burner access door Step 3. Inner Door Removal.

Gas Control Knob Shown In

“OFF” Position

a)Disconnect chamber door temperature sensor wire harness from the gas valve.

b)Disconnect resettable thermal switch white wire lead (leading from gas valve). Disconnect the red wire leading from the gas valve from the red thermopile wire.

c)Disconnect main burner feed line (¾” wrench), pilot tube (7/16" wrench) and igniter wire from gas valve.

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

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

f)Remove (3) 1/4" drive screws from burner door. The burner door and burner are one-piece.

g)Remove burner and inner door and inspect per step 4.

Chamber Door

Temperature

Sensor

¼” Hex Drive Screws Right and Left Side Inner Door

¼” Hex Drive Screws at Flange Area of Inner Door

White Wire Lead

White Thermopile

Wire

Chamber Door

 

 

 

Temperature Sensor

 

Feed Line Nut

Red Thermopile

Wire Harness

Pilot Nut

Red Wire Lead

Wire

 

 

 

Step 4. Fully inspect burner and 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.

Page 7

7

SERVICE PROCEDURE ED-I

Burner and Inner Door/Gasket Removal,

Inspection, Replacement and

Reinstallation

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 burner 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 & burner). The burner door gasket must be sliced in the location shown on the illustration below in order to slide the gasket over the burner venturi. Refer to illustration below for proper RTV sealant application. Note the overlap configuration in the flange area of the inner door. Set the flange section first, this will help to achieve the proper over lap position.

Installation of Inner Door With Gasket.

 

Step 7.

Clean any residual gasket residue or other debris

WARNING

 

from combustion chamber surface before

 

Stripped fastener connections may allow

 

installing the inner door/gasket assembly.

Step 8.

Place the burner door into position first. Tighten

for seal breach of inner door. A seal

breach may result in a fire or explosion

 

the feed line nut to the gas valve. Use the ¼” hex

causing property damage, personal injury

 

drive screw without the built-inwasher to secure

 

or death. Do not over tighten screws in

 

the right side of the burner door to the chamber.

 

Use the ¼” hex drive screws with the built-in

steps 8, 10 and 11.

 

washer to secure the left side of the burner door in

 

 

place. DO NOT OVER TIGHTEN SCREWS.

If a fastener connection is stripped,

Step 9.

Position thermopile wires, pilot tube and igniter wire

contact the manufacturer listed on the

 

against burner door flange gasket.

water heater rating plate.

 

Page 8

 

8

SERVICE PROCEDURE ED-I

Burner and Inner Door/Gasket Removal,

Inspection, Replacement and

Reinstallation

Position Thermopile Wire,

Pilot Tube and Igniter Wire

Step 10. Firmly place right side inner door flange against the burner door flange and secure with two ¼” drive screws from step 3e. 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 3b. DO NOT OVER TIGHTEN SCREWS. Verify both burner 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. Reconnect lead wires from gas valve to resettable thermal switch (See photo in step 3). Note, the white wire needs to be connected to the thermal switch and the red wire needs to be connected to the red wire from the thermopile.

Step 13. Reconnect the wire harness from the chamber door temperature sensor to the gas valve (See photo in step 3). Step 14. Tighten the pilot nut to the gas valve.

Step 15. Replace outer jacket burner access door.

Step 16. To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual.

Page 9

9

SERVICE PROCEDURE ED-II

Thermopile Testing and Replacement

CLOSED CIRCUIT THERMOPILE TESTING (Honeywell Control)

Step 1. Closed circuit testing is the preferred method for testing thermopile. Following the lighting instruction label on the heater, proceed to light the pilot and allow to operate for three minutes. If the pilot will not stay lit, hold the pilot button (rotate the gas control knob to the pilot position, push and hold in) during this test

Step 2. Using a multimeter capable of measuring millivolts, place one lead of the multi meter on the left side of the wire harness and place the second lead of the multi meter on the right side of the wire harness.

Step 3. If meter reads 300 millivolts or higher, the thermopile is OK. If reading is below 300 millivolts, replace the thermopile. For maximum thermopile life the thermopile should be replaced with a genuine Honeywell thermopile (BWC P/N 233-47063-00).

Left Side of Wire Harness

Right Side of Wire Harness

 

OPEN CIRCUIT THERMOPILE TESTING

Step 1. Disconnect red thermopile wire from wire harness leading to the gas valve. Disconnect the white thermopile wire from the resettable thermal switch

Step 2. Using a multimeter capable of measuring millivolts, connect one lead to the red thermopile wire and one lead to the white thermopile wire.

Step 3. Following the lighting instruction label on the heater, proceed to light the pilot and allow to operate for

three minutes. It will be necessary to hold gas control knob down in the “PILOT” position continuously throughout this test.Any reading over 400 millivolts indicates good thermopile output.

Page 10

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