Bradford-White U130T'FRN User Manual

Size:
1.64 Mb
Download

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.

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.

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

10

SERVICE PROCEDURE ED-II

Thermopile Testing and Replacement

THERMOPILE REPLACEMENT

Step 1. Turn off gas supply to water heater. Rotate gas control knob to the “OFF” position.

Gas Control Knob Shown In

“OFF” Position

Step 2. Remove outer jacket door.

Step 3. Remove right side inner door and burner door per SERVICE PROCEDURE RG-I,steps 3a through 3g.

Step 4 Disconnect the red thermopile wire from the wire harness and the white thermopile wire from the resettable thermal switch. Follow the thermopile leads to the pilot bracket. Disconnect the thermopile from the pilot bracket (7/16" wrench).

Step 5. Install new thermopile into pilot bracket and tighten the nut to the pilot bracket (7/16" wrench). Position thermopile wire against left side inner door flange at its original position. Connect the red thermopile wire to the red lead from the wire harness. Connect the white thermopile wire to the resettable thermal switch.

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

Step 7. Install right side inner door and burner door per SERVICE PROCEDURE ED-I,Step 7 through Step 16.

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

Thermopile Position

Page 11

11

SERVICE PROCEDURE ED-III
Pilot Assembly Inspection, Cleaning
and Replacement
Primary Air
Opening

PILOT/ELECTRODE ASSEMBLY INSPECTION,

CLEANING AND REPLACEMENT

Step 1. Turn off gas supply to water heater. control knob to the “OFF” position.

Step 2. Remove outer jacket door.

Step 3. Remove burner and right side of inner per SERVICE PROCEDURE ED-I,3a through 3g.

Step 4. Remove burner assembly from combustion Step 5. Remove pilot/electrode assembly from Step 6. Inspect pilot for the following:

a)Primary air openings for blockage debris (dirt, lint, etc).

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

Step 7. Inspect pilot orifice:

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

b)Remove pilot tube and pilot orifice.

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

Pilot Orifice

Step 8. Install pilot/electrode assembly to burner, secure with screw from step 5.

Step 9. Install burner and inner door per SERVICE PROCEDURE ED-I,step 4 through 16.

Step 10. To resume operation follow the instructions located on the lighting instruction label or the lighting instruction located in the installation and operation manual.

Page 12

12

SERVICE PROCEDURE ED-IV

Igniter and Electrode Testing

and Replacement

IGNITER, ELECTRODE TESTING AND REPLACEMENT

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

Step 1. Remove outer jacket door.

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

View spark Action through

Repeatedly Sight glass Depress

Igniter

Step 3 Remove white wire from igniter. Hold the igniter lead from the gas valve to an unpainted surface such as the feed line or gas valve and depress the igniter. If there is a spark, the igniter is OK, the pilot is not functioning and must be replaced, see SERVICE PROCEDURE ED-IIIfor pilot replacement. If no spark is present the igniter is not functioning and the control must be replaced, see SERVICE PROCEDUREED-V

Igniter Lead

Page 13

13

SERVICE PROCEDURE ED-V

Gas Control Replacement Thermal

Well and Chamber Door Sensor

Testing and Replacement

Thermal Well Testing

If Control has gone into lockout due to excessive tank temperature (four flash, 3 second pause) reset control by rotating gas control knob to “OFF” position. Then follow lighting instructions and return gas control knob to desired setpoint.

Observe heater operation. If control

 

 

continues to lockout due to

 

 

excessive tank temperature,

1

2

proceed to thermal well testing to

 

 

determine cause.

 

 

Thermal well testing

 

 

Position gas control knob to the

 

 

“OFF” position and disconnect

 

 

thermal well harness from gas

CAUTION

 

control.

 

 

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, determine the

Using a multi-meterset to the ohms setting, insert one meter probe (see caution)

resistance of thermal well sensor

(see caution photos 1 & 2)

into center wire position of thermal well connector, insert the second probe (see

 

 

caution) into either of the outside wire positions (see photo 1).

 

 

Alternate the probe on the outside position to the opposite outside wire position

 

 

(see photo 2).

 

 

 

 

 

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 15 to obtain water temperature.

 

(see page 16)

 

 

 

Are thermal well resistance values correct?

 

 

 

Y

 

 

 

 

 

 

 

 

 

Replace gas control

 

 

(see page 16)

 

 

Page 14

14

SERVICE PROCEDURE ED-V

Gas Control Replacement Thermal

Well and Chamber Door Sensor

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 14, 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 4 gallons 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 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

1953

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

Page 15

15

Thermal Well

SERVICE PROCEDURE ED-V

Gas Control Replacement Thermal

Well and Chamber Door Sensor

Testing and Replacement

Gas Control & Thermal Well Removal From Water Heater

Gas Control

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

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. Turn the gas control knob to the “OFF” position.

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

Service tool shown

back of control

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". Hold control in position and remove tool. 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 16

16

SERVICE PROCEDURE ED-V

Gas Control Replacement Thermal

Well and Chamber Door Sensor

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 3 for proper control alignment.

Step 2. Route wire leads back into relief opening. (see photo 3).

Step 3. Align slots located on thermal well flange with tabs located on back of gas control (see photos 3 & 4).

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 feed line to gas control.

3

4

Route wires through relief opening

Thermopile

Wire Harness

Connection

Igniter Connection

3 Pin Thermal Well

Connection

Chamber Door

Temperature

Sensor

Gas control Tabs

Step 6. Reconnect wire harnesses and igniter wire to gas control per the illustration to the left.

Step 7. Reconnect gas piping to gas control. Restore gas supply and check for gas leaks.

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

Page 17

17

SERVICE PROCEDURE ED-V

Gas Control Replacement Thermal

Well and Chamber Door Sensor

Testing and Replacement

CHAMBER SENSOR TESTING

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

Step 2. Disconnect the chamber sensor wire harness from the gas valve.

Step 3. Remove the chamber door temperature sensor from the right side inner door (Phillips screw driver).

Step 4. Make sure that the ring terminal of the chamber door temperature sensor is not touching any surface. Using a multi-meterset to the ohms setting, insert one meter probe (see caution) into each of the wire positions (see photo 5).

Step 5. Measure the ambient air temperature near the sensor. Compare the ambient temperature range to the expected resistance range on the chart below. Note that resistance increases as temperature decreases.

5

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.

Sensor Resistance at Various Temperatures

Temperature Range (oF)Resistance Range (kOhms)

41-50

279-175

50-59

219-139

59-68

173-112

68-77

137-90

77-86

110-72

86-104

89-59

104-113

73-48

113-122

60-39

122-131

49-32

Step 6. Replace the chamber door temperature sensor if it it out of specification.

Step 7. Secure the chamber door temperature sensor to the right side inner door using the screw from step 3. Step 8. Connect the chamber door temperature sensor wire harness to the gas valve.

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

Page 18

18

SERVICE PROCEDURE ED-VI

Burner Operation Inspection,

Cleaning and Replacement

MAIN BURNER: Inspection,

Cleaning and Replacement

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

Main burner should light smoothly from pilot and burn with a blue flame with a minimum of yellow tips. After 5 minutes of operation the burner screen will become radiant and the flame will soften and turn orange. If the burner screen does not become radiant after 5 minutes of operation it must be cleaned (see burner cleaning procedure below).

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

DANGER

Under no circumstances shall flammable materials be used or stored in the vicinity of the water heater. With the inner door removed the Bradford White Defender Safety System will be inactivated. If flammable vapors are present, a fire or explosion may result causing property damage, personal injury or death.

WARNING

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

BURNER CLEANING

Step 1. Remove burner and inner door assembly per SERVICE PROCEDURE ED-I,steps 1 through 3g. Step 2. Remove manifold mount from burner inner door by removing (2) ¼” hex drive screws.

Step 3. Thoroughly inspect burner screen and burner venturi and remove any loose debris accumulation. Inspect burner screen for any openings larger than the normal screen openings.

Step 4. Use compressed air and/or a vacuum to remove any scale or other debris accumulation from the burner screen and venturi.

Burner Screen

¼” Hex Drive Screws

Burner Venturi

Page 19

19

SERVICE PROCEDURE ED-VI

Burner Operation Inspection,

Cleaning and Replacement

BURNER CLEANING (Cont.)

Step 5. Disconnect (unscrew) manifold mount from feed line. Use a stiff brush, compressed air and/or shop vacuum to remove any debris build up from the manifold mount.

Step 6. Remove main burner orifice from feed line (3/8" wrench). Inspect and clean if necessary

Step 7. Remove pilot assembly, refer to SERVICE PROCEDURE ED-IIIfor cleaning and inspection. Step 8. Reassemble burner.

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

Step 10. Reinstall burner and inner door per SERVICE PROCEDURE ED-I,steps 4 through 16.

Step 11. To resume operation, follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual.

Page 20

20

SERVICE PROCEDURE ED-VII

Resettable Thermal Switch

Testing and Replacement

RESETTABLE THERMAL SWITCH CONTINUITY TESTING

Step 1. Remove outer jacket door.

Step 2. Disconnect white wire leads from resettable thermal switch.

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

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

Step 5. If continuity is not indicated, the switch is open, possibly due to an over heating condition. The switch is designed to open at predetermined temperatures. An open switch can be reset by depressing the red colored button located at the center of the switch. The overheating condition must be determined prior to putting the water heater back in service.

PROBABLE CAUSE FOR RESETTABLE THERMAL SWITCH ACTIVATION

PROBABLE CAUSE

CORRECTIVE ACTION

 

 

1. Inspect burner per SERVICE PROCEDURE

 

 

 

 

ED-VI

 

Burner Failure

2. Replace burner per SERVICE PROCEDURE

 

 

 

 

ED-VI

 

 

 

 

 

Weak switch or switch

1.

Replace resettable thermal switch

 

 

out of calibration.

 

 

 

 

 

 

 

 

 

Flammable vapor incident

1.

Replace water heater.

 

 

 

 

 

 

Page 21

21

SERVICE PROCEDURE ED-VII

Resettable Thermal Switch

Testing and Replacement

RESETTABLE THERMAL SWITCH REPLACEMENT

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

Gas Control Knob Shown In

“OFF” Position

Step 2. Remove outer jacket door.

Step 3. Disconnect wire leads from resettable thermal switch.

Step 4. Remove (2) ¼” hex drive screws from the manifold mount.

Step 5. Bend the flexible feed line so the resettable thermal switch is easily accessible.

Step 6. Remove resettable thermal switch from manifold mount (Phillips screw driver).

Manifold Mount

Step 7. Place new resettable thermal switch in place. Be sure contact surface of resettable thermal switch and manifold mount are free of any debris. Secure resettable thermal switch into place using screws from step 6.

DO NOT OVER TIGHTEN SCREWS.

Step 8. Bend flexible feed line back in place and secure the manifold mount using the screws from step 4. Step 9. Reconnect wire leads from gas valve and thermopile to resettable thermal switch.

Note: Wire termination are interchangeable with either resettable thermal switch connection. Step 10. Replace outer jacket door.

Step 11. To resume operation follow the instructions located on the lighting instruction label or the lighting instruction located in the installation and operation manual.

Page 22

22

SERVICE PROCEDURE ED-VIII

ScreenLok Flame Arrestor Cleaning

ScreenLok Flame Arrestor Cleaning

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

Gas Control Knob Shown In

“OFF” Position

Step 2. Remove outer jacket door.

Step 3. Remove burner and inner door per SERVICE PROCEDURE

ED-I,step 3a through 3g.

Step 4. Clean ScreenLok Flame Arrestor using stiff brush, compressed air and/or shop vacuum to remove any scale or other debris accumulation. It is only necessary to clean the ScreenLok Flame Arrestor in the areas that are not covered by the secondary air restrictor plate. Using a soft brush, clear jacket openings of any dirt, dust, restrictions or other obstructions.

Step 5. Remove any debris from burner assembly per SERVICE PROCEDURE ED-VIand reinstall burner assembly into combustion chamber.

Step 8 Reinstall burner and inner door per SERVICE PROCEDURE ED-I,steps 4 through 16.

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 23

23

SERVICE PROCEDURE ED-IX

Dip Tube and Anode

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

Gas Control Knob Shown In

“OFF” Position

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

Step 3. Disconnect inlet nipple from plumbing system.

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

Step 5. Visually Inspect inlet nipple/dip tube. Inlet nipple/dip tube should be free of cracks and any blockage. Hydro-jetslocated near the bottom of the dip tube should be open and free of any blockage.Anti-siphonhole located approximately 6" from the bottom of nipple, should be free of any blockage.

Any damage such as cracks, restriction due to deformation or unintentional holes are not field repairable and the inlet nipple/dip tube must be replaced.

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

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

Page 24

24

SERVICE PROCEDURE ED-IX

Dip Tube and Anode

Inspection and Replacement

ANODE INSPECTION AND REPLACEMENT

WARNING

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

Step 1. Turn off water supply to water heater. Rotate gas control knob to the “OFF” position.

Gas Control Knob Shown In

“OFF” Position

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

Step 3. Disconnect outlet nipple from plumbing system.

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

Step 5. Visually Inspect outlet nipple/anode. Outlet nipple/anode should show signs of depletion, this is normal.

If depletion is ½ of the original anode diameter (approximately ¾” diameter), replacement is recommended. If any of thesteel core of the anode is exposed, replacement is recommended.

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

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

Page 25

25

 

 

 

 

 

1

 

Flue Baffle

17

Screw #8-18x ½ Hex Washer Head

2

 

Hot Water Outlet/Anode

18

Resettable Thermal Switch

3

 

Cold Water Inlet Tube

19

Screw #6-20x 3/8 PHCR

4

 

T&P Relief Valve

20

Screw #8-18x ¾ Hex Washer Head

5

 

Thermal Well

21

Manifold Mount

6

 

Brass Drain Valve

22

Complete Right Side Inner Door

7

 

Gas Valve

23

Resistance Temperate Detector (RTD)

8

 

Main Burner Orifice

24

Screw #10-12x ¾ Hex Washer Head

9

 

Heat Trap Inlet

25

¾ NPT Tank Plug (XR Models)

10

Heat Trap Outlet

26

Wire Tie

11

Outer Door

27

ASSE Approved Mixing Valve (Optional)

12

Draft Diverter

28

Thermopile

13

Complete Burner Assembly

29

Inner Door Gasket Set

14

RN Burner and Door

30

Pilot Orifice

15

Flexible Gas Feed Line

31

Kit-HeatTrap Insert

16

Pilot Assembly

32

Intermediate Gas Valve Harness

Page 26

26

27

Email parts@bradfordwhite.com techserv@bradfordwhite.com

www.bradfordwhite.com