Bradford White U-100T-88R-3N User Manual

Atmospheric ECO-MAGNUM SERIES™

Ultra Low NOx Gas Water Heaters

SERVICE

MANUAL

Troubleshooting Guide and Instructions for Service

(To be performed ONLY by qualified service providers)

Models Covered

by This Manual:

U175S*RN

U2XR75S*RN

U100T*RN

U75T80R*N

U100T88R*N

(*) Denotes Warranty Years

Manual 238-50628-00A

Save this manual for future reference

The Bradford White

Atmospheric ECO-MAGNUM

Ultra Low NOx Gas Water

Heaters

Table of Contents

	Page	Service Procedure
Introduction	4	- - -
Tools Required for Service	4	- - -
Gas Control Troubleshooting Chart	5	- - -
Burner and Inner Door Gasket Removal, Inspection, Replacement
and Installation	7	I
Thermopile Testing and Replacement	10	II
Pilot Assembly Inspection, Cleaning and Replacement	12	III
Igniter and Electrode Testing and Replacement	13	IV
Honeywell Gas Control Testing and Replacement	14	V
Burner Operation Inspection, Cleaning and Replacement	16	VI
Resettable Thermal Switch Testing and Replacement	18	VII
Dip Tube and Anode Inspection and Replacement	20	VIII
Generic Parts List	23	- - -

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ECO-MAGNUM

75/100-Gallon Atmospheric

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.

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

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

ξ 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-air intake system. Use proper care to avoid unnecessary contact (especially by children) with the water heater and vent-air intake 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-AIR INTAKE SYSTEM OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER OR VENT-AIR INTAKE 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:

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

ξ Most people recognize this odor as a “sulfur” or

“rotten egg” smell.

ξ Other conditions, such as “odorant fade” can cause the odorant to diminish in intensity, or ”fade”, and not be as readily detectable.

ξ 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.

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How to Use This Manual

ECO-MAGNUM

75/100-Gallon Atmospheric

Introduction

It is intended for this manual to be used by qualified service personnel for the primary purpose of troubleshooting and repair of the Bradford White Atmospheric Ultra Low NOx Series of water heaters.

The Honeywell 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.

Tools Required for Service

Manometer: A liquid “U” tube type or a digital 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-amps and ohms.

Electronic Probes: In some cases, standard multi-meter probes 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-meter probes. 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.

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.

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ECO-MAGNUM

Gas Control Troubleshooting

75/100-Gallon Atmospheric

Observe green 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.

Green LED

Indicator

	LED Status	Control Status	Probable Cause	Service Procedure
				If the pilot will not stay lit
	None (LED not on	Gas valve is not	1. Pilot flame is not	replace thermopile, see
				page 11. If problem
	or flashing)	powered.	present. Light pilot.
				persists replace gas
				valve, see page 15.
		1. If set point knob is in
		"PILOT" position then	1. Gas valve is
		pilot flame is detected.	powered and waiting
	One flash and	Turn set point knob to	for the set point knob to	Normal operation. Adjust
	three second	desired setting	be turned to a water	thermostat to desired
	pause.	2. If set point knob is at	temperature setting.	temperature level.
		desired setting the gas	2. Temperature
		valve is waiting for a	demand is satisfied.
		call for heat (no faults).
	LED strobe (two		Tank temperature
	quick flashes) and	Thermostat calling for
			below setpoint of	Normal operation.
	three second	heat (no faults).	thermostat.
	pause.
		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
			position.
		before attempting to		lit.
		relight
			1. Thermopile failure
	Two flashes and	Weak pilot flame	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 18.
		is sufficient.	4. Resettable thermal
			switch has opened.

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Gas Control Troubleshooting	ECO-MAGNUM
	75/100-Gallon Atmospheric

	LED Status	Control Status	Probable Cause	Service Procedure
	Three flashes		1. Thermowell
		Insufficient water	sensor and chamber
	and three			1&2. Replace gas
	second	heating. System will	temperature sensor	control, see page 15.
	pause.	reset.	out of calibration.
			2. Possible short.
	Four flashes	Excessive tank	1. Thermowell	1. See page 14.
	and three		sensor out of
		temperature. System		2. Replace gas control,
	second		calibration.
	pause.	must be reset.	2. Faulty gas valve.	see page 15.
	Five flashes		1. Damage to the
			thermowell wire.
	and three			1&2. Replace gas
		Thermostat well fault.	2. Thermowell
	second			control, see page 15.
			sensor resistance
	pause.
			out of range.
				1.Turn gas control knob
	Seven flashes		1. Control needs to	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 15.
	Eight flashes	False pilot flame	Pilot valve stuck in	Replace gas control, see
	and three
		present.	open position.	page 15.
	second pause

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	ECO-MAGNUM	SERVICE PROCEDURE I
	75/100-Gallon Atmospheric	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.

Gas Control Knob Shown In

“OFF” Position

Step 2. Remove outer jacket burner access door.

Step 3. Remove wire clip from main burner feedline.

Step 4. Inner Door Removal.

a)Disconnect red thermopile lead and red gas control lead from resettable thermal switch. Disconnect white thermopile lead from the gas valve (see photos 1 and 2).

b)Disconnect main burner feed line (¾” wrench), pilot tube (7/16" wrench) and igniter wire from gas control (see photo 2).

c)Remove (2) ¼” hex drive screws from right side inner door

(see photo 3).

d)Remove (2) ¼” hex drive screws from flange section of

inner door (see photo 3).

Red Gas

Control Lead

1

Red Thermopile Lead

White Thermopile

Lead

e) Remove (3) 1/4" hex drive screws from burner door		2
(see photos 4&5). The burner door and burner are
one-piece.	3	Pilot Tube

Main Burner

Feedline

Flange Hex

Drive

Screws

Igniter Wire

Position #2	5
	Right Side
	Hex Drive
	Screws
	Burner Door
	Hex Drive
	Screws
Position #3	4
	Position #1
f) Remove burner and inner door and inspect per step 5.
Step 5. Fully inspect burner door and right side 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.

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SERVICE PROCEDURE I

ECO-MAGNUM

Burner and Inner Door/Gasket Removal,

Inspection, Replacement and 75/100-Gallon Atmospheric

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 6. After inspection of inner door as noted in step 5, completely remove gasket and adhesive residue from burner door and right side inner door as needed.

Step 7. 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. Ensure that the chamfer of the gasket faces outward. Set the flange section first, this will help to achieve the proper overlap position.

	Re-installation of Inner Door With Gasket
	Step 8. Clean any residual gasket residue or other debris	WARNING
	from combustion chamber surface before
		Stripped fastener connections may allow
	re-installing the inner door/gasket assembly.
		for seal breach of inner door. A seal
	Step 9. Place the burner door into position first. Tighten	breach may result in a fire or explosion
	the feed line nut to the gas control. Use the ¼”	causing property damage, personal injury
	hex drive screw without the built-in washer to	or death. Do not over tighten screws in
	secure burner door to the chamber at position #1.	steps 9, 11 and 12.
	Use the ¼” hex drive screws with the built-in
	washer to secure the door at positions #2 & #3
	(see photos 4&5, on page 7).	If a fastener connection is stripped,
	DO NOT OVER TIGHTEN SCREWS.	contact the manufacturer listed on the
		water heater rating plate.
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ECO-MAGNUM

SERVICE PROCEDURE I

Burner and Inner Door/Gasket Removal,

75/100-Gallon Atmospheric Inspection, Replacement and

Reinstallation

Position Thermopile Wire,	6
Pilot Tube and Igniter Wire

Step 10. Position thermopile wires, pilot tube and igniter wire against burner door flange gasket

(see photo 6).

Step 11. Firmly place right side inner door flange against the burner door flange and secure with two ¼” drive screws from step 4d (see photo 7). DO NOT OVER TIGHTEN SCREWS.

Step 12. 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 (see photo 7). Verify seal integrity around combustion opening. Secure right side inner door using 1/4” hex drive screws from step 4c.

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.

7

Step 13. Reconnect red gas valve lead and red thermopile lead to resettable thermal switch. Reconnect white gas control lead to the gas valve (See photos 1&2 on page 7).

Step 14. Reconnect the pilot tube to the gas control and tighten. Reconnect the igniter wire to the gas control.

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.

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