Bradford White U-65T-55FR-3N User Manual

(To be performed ONLY by qualified service providers)

Save this manual for future reference

Manual 47132A

The Bradford White

R

U150L*FRN
U1504S*FRN
U430T*FRN
U440T*FRN
U4403S*FRN
U4503*FRN
U1XR403S*FRN

(*) Denotes Warranty Years.

U130T*FRN
U130S*FRN
U140T*FRN
U1403T*FRN
U1403S*FRN
U1404T*FRN
U1503*FRN

R

The Bradford White

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 Flame Arrestor Cleaning 23 ED-VIII

Dip Tube and Anode Inspection and Replacement 24 ED-IX

Generic Parts List 26 - - -

Page 2

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2

The Bradford White ECO-DEFENDER Safety System

The Bradford White ECO-DEFENDER Safety System was designed to
resist the ignition of flammable vapors that can occur outside of the water
heater. In addition, the ECO-DEFENDER Safety 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 White ECO-DEFENDER Safety
System.

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-resistant combustion 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

INTRODUCTION

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3

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-DEFENDER Series 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.

Page 4

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-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.

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.

How to Use This Manual

4

Page 5

LED Status Control Status Probable Cause Service Procedure

None (LED not on

or flashing)

Gas valve is operating

normally. Pilot flame

may not be present.

Check for pilot flame

through sight glass and

light if necessary.

1. Gas valve is
functi oni ng normally

2. Gas valve is not
powered. Light pilot

If the pilot will not stay lit
replace thermopile, see
page 10. If problem
persists replace gas
valve, see page 16.

One flash and

three second

pause.

If set point knob is in

"PILOT" position then

pilot flame is detected.

Turn set point knob to

desired setting

Gas valve is powered
and waiting for the set
point knob to be turned
to a water temperature
setting.

Normal operation. Adjust
thermostat to desired
temperature level.

LED on

continuously.

Set point knob has

been recently turned to

the "OFF" position.

Wait until LED goes out

before attempting to

relight

Set point knob was
turned to "OFF"
position.

LED will go out and the
control will function
normally when the pilot is
lit.

Two flashes and

three second

pause.

Weak pilot flame

detected. System will

reset when pilot flame

is sufficient.

1. Thermopile failure

2. Unstable pilot.

3. Pilot tube block or
restricted.

4. Resettable thermal
switch has opened.

1. See page 10.
2&3. See page 12.

4. See page 21.

Three flashes and

three second

pause.

Insufficient water

heating. System will

reset.

1. Thermowell sensor
and chamber
temperature sensor out
of calibration.

2. Possible short.

1&2. See pages 14 and

18.

Four flashes and

three second

pause.

Excessive tank

temperature. System

must be reset.

1. Thermowell sensor
out of calibration.

2. Faulty gas valve.

1. See page 14.

2. See page 16.

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.

Gas Control Troubleshooting

Red LED

Indicator

5

Page 6

LED Status Control Status Probable Cause Service Procedure

Five flashes

and three

second

pause.

Thermostat well fault.

1. Damage to the
thermowell wire.

2. Thermowell
sensor resistance
out of range.

See page 14.

Six flashes

and three

second

pause.

Chamber door

temperature sensor out

of specification.

Possible electrical

short.

1. Chamber door
temperature sensor
out of calibration.

2. Possible
electrical short.

See page 18.

Seven flashes

and three

second

pause.

Gas valve electronic

fault detected.

1. Control needs to
be reset

2. Control is wet or
physically damaged

1.Turn gas control knob
to "OFF" position and
then follow li ghting
instructions.

2. Replace gas control,
see page 16.

Eight flashes

and three

second pause

False pilot flame

present.

Pilot valve stuck in
open position.

Replace gas control, see
page 16.

Ten flashes

and three

second pause

Insufficient combustion

air detected. Reset

system.

Insufficient
combustion air.

See page 19 and 23.

Gas Control Troubleshooting

6

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.

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

Gas Control Knob Shown In

“OFF” Position

¼” Hex Drive Screws Right

and Left Side Inner Door

¼” Hex Drive Screws at

Flange Area of Inner Door

White Wire Lead

Red Wire Lead

Feed Line Nut

Pilot Nut

Chamber Door

Temperature Sensor

Wire Harness

SERVICE PROCEDURE ED-I

Burner and Inner Door/Gasket Removal,

Inspection, Replacement and

Reinstallation

White Thermopile

Wire

Red Thermopile

Wire

Chamber Door

Temperature

Sensor

7

Installation of Inner Door With Gasket.

WARNING

Stripped fastener connections may allow

for seal breach of inner door. A seal

breach may result in a fire or explosion

causing property damage, personal injury

or death. Do not over tighten screws in

steps 8, 10 and 11.

If a fastener connection is stripped,

contact the manufacturer listed on the

water heater rating plate.

Step 7. Clean any residual gasket residue or other debris

from combustion chamber surface before
installing the inner door/gasket assembly.

SERVICE PROCEDURE ED-I

Burner and Inner Door/Gasket Removal,

Inspection, Replacement and

Reinstallation

Step 8. Place the burner door into position first. Tighten

the feed line nut to the gas valve. Use the ¼” hex
drive screw without the built-in washer to secure
the right side of the burner door to the chamber.
Use the ¼” hex drive screws with the built-in
washer to secure the left side of the burner door in
place. DO NOT OVER TIGHTEN SCREWS.

Step 9. Position thermopile wires, pilot tube and igniter wire

against burner door flange gasket.

Page 8

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.

8

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.

Verify threaded hole

alignment with slotted

openings in inner door.

SERVICE PROCEDURE ED-I

Burner and Inner Door/Gasket Removal,

Inspection, Replacement and

Reinstallation

Page 9

Position Thermopile Wire,

Pilot Tube and Igniter Wire

Secure flange with

¼" drive screws.

9

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).

CLOSED CIRCUIT THERMOPILE TESTING (Honeywell Control)

SERVICE PROCEDURE ED-II

Thermopile Testing and Replacement

Page 10

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.

OPEN CIRCUIT THERMOPILE TESTING

Left Side of Wire Harness

Right Side of Wire Harness

10

THERMOPILE REPLACEMENT

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

SERVICE PROCEDURE ED-II

Thermopile Testing and Replacement

Page 11

Gas Control Knob Shown In

“OFF” Position

Thermopile Position

11

PILOT/ELECTRODE ASSEMBLY INSPECTION,
CLEANING AND REPLACEMENT

Step 1. Turn off gas supply to water heater. Rotate gas

control knob to the “OFF” position.

Step 2. Remove outer jacket door.

Step 3. Remove burner and right side of inner door

per SERVICE PROCEDURE ED-I, steps
3a through 3g.

Step 4. Remove burner assembly from combustion chamber.

Step 5. Remove pilot/electrode assembly from burner (¼" drive tool)

Step 6. Inspect pilot for the following:

a) Primary air openings for blockage. Must be free from any
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.

SERVICE PROCEDURE ED-III

Pilot Assembly Inspection, Cleaning

and Replacement

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 instructions

located in the installation and operation manual.

Page 12

Primary Air

Opening

Pilot Orifice

Gas Control Knob Shown In

“OFF” Position

Feed Line Nut

Pilot Nut

Chamber Door

Temperature

Sensor

12

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.

SERVICE PROCEDURE ED-IV

Igniter and Electrode Testing

and Replacement

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.

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-III for pilot
replacement. If no spark is present the igniter is not functioning and the control must be replaced,
see SERVICE PROCEDURE ED-V

Page 13

View spark

Action through

Sight glass

Repeatedly

Depress

Igniter

Igniter Lead

13

Thermal Well Testing

Thermal well testing

Position gas control knob to the

“OFF” position and disconnect
thermal well harness from gas

control.

N

Y

Using a multi-meter set to the ohms setting, insert one meter probe (see caution)
into center wire position of thermal well connector, insert the second probe (see
caution) into either of the outside wire positions (see photo 1).

Alternate the probe on the outside position to the opposite outside wire position
(see photo 2).

Replace thermal well

(see page 16)

Using a multi-meter set to the

Ohms setting, determine the

resistance of thermal well sensor

(see caution photos 1 & 2)

Disconnect thermal

well wire harness

1

2

Replace gas control

(see page 16)

S

ERVICE PROCEDURE ED-V

G

as Control Replacement Thermal

Well and Chamber Door Sensor

T

esting and Replacement

Page 14

Once the thermal well resistance values are known, the water

temperature must also be known to determine if the resistance

values are correct. See page 15 to obtain water temperature.

Are thermal well resistance values correct?

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.

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,

proceed to thermal well testing to

determine cause.

14

°F012345678 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

In Degrees F

Sensor Resistance at Various Temperatures

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.

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

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.

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.

Page 15

S

ERVICE PROCEDURE ED-V

G

as Control Replacement Thermal

Well and Chamber Door Sensor

T

esting and Replacement

15

Gas Control & Thermal Well Removal From Water Heater

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

Thermal
Well

Page 16

Gas Control Removal From Thermal Well

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)

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

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.

S

ERVICE PROCEDURE ED-V

G

as Control Replacement Thermal

Well and Chamber Door Sensor

T

esting and Replacement

Insert tool from
back of control

Service tool shown

inserted in to back

of control

View from back of

control for clarity

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.

16

Gas Control Assembly to Thermal Well

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.

Thermal well
flange slots

Page 17

3

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).

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.

Route wires
through relief
opening

S

ERVICE PROCEDURE ED-V

G

as Control Replacement Thermal

Well and Chamber Door Sensor

T

esting and Replacement

Gas control Tabs

Chamber Door

Temperature

Sensor

3 Pin Thermal Well

Connection

Thermopile

Wire Harness

Connection

Igniter Connection

4

17

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-meter set 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.

CHAMBER SENSOR TESTING

Page 18

Temperature Range (oF)

Re si sta nce Ra ng e (kOh m s)

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

Sensor Resistance at Various Temperatures

SERVICE PROCEDURE ED-V

Gas Control Replacement Thermal

Well and Chamber Door Sensor

Testing and Replacement

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.

5

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.

Gas Control Knob Shown In

“OFF” Position

Chamber Door

Temperature Sensor

Wire Harness

18

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).

MAIN BURNER: Inspection,
Cleaning and Replacement

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.

SERVICE PROCEDURE ED-VI

Burner Operation Inspection,

Cleaning and Replacement

WARNING

Inner door and burner components may be HOT when performing this operation. Take

necessary precaution to prevent personal injury.

Page 19

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

19

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-III for 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.

BURNER CLEANING (Cont.)

SERVICE PROCEDURE ED-VI

Burner Operation Inspection,

Cleaning and Replacement

Page 20

20

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.

RESETTABLE THERMAL SWITCH CONTINUITY TESTING

PROBABLE CAUSE FOR RESETTABLE THERMAL SWITCH ACTIVATION

PROBABLE CAUSE CORRECTIVE ACTION

Burner Failure

1. Inspect burner per SERVICE PROCEDURE
ED-VI

2. Replace burner per SERVICE PROCEDURE
ED-VI

Weak switch or switch

out of calibration.

1. Replace resettable thermal switch

Flammable vapor incident 1. Replace water heater.

S

ERVICE PROCEDURE ED-VII

Resettable Thermal Switch

Testing and Replacement

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.

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).

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

G

as Control Knob Shown In

“OFF” Position

Manifold Mount

22

SERVICE PROCEDURE ED-VIII

ScreenLok Flame Arrestor Cleaning

Step 1. Rotate gas control knob to the “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-VI and 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

ScreenLok Flame Arrestor Cleaning

Gas Control Knob Shown In

“OFF” Position

23

SERVICE PROCEDURE ED-IX

Dip Tube and Anode

Inspection and Replacement

Page 24

Step 1. Rotate gas control knob to the “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-jets located near the bottom of the dip tube should be open and free of any blockage.
Anti-siphon hole 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.

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.

Gas Control Knob Shown In

“OFF” Position

24

Step 1. Turn off water supply to water heater. Rotate gas control knob to the “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 the steel core of the anode is exposed, replacement is recommended.

Step 6. Upon completion of inspection or subsequent replacement, reinstall outlet nipple/anode into 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.

ANODE INSPECTION AND REPLACEMENT

SERVICE PROCEDURE ED-IX

Dip Tube and 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.

Page 25

Gas Control Knob Shown In

“OFF” Position

25

1 Flue Baffle
2 Hot Water Outlet/Anode
3 Cold Water Inlet Tube
4 T&P Relief Valve
5 Thermal Well
6 Brass Drain Valve
7 Gas Valve
8 Main Burner Orifice
9 Heat Trap Inlet
10 Heat Trap Outlet
11 Outer Door
12 Draft Diverter
13 Complete Burner Assembly
14 RN Burner and Door
15 Flexible Gas Feed Line
16 Pilot Assembly

17 Screw #8-18 x ½ Hex Washer Head
18 Resettable Thermal Switch
19 Screw #6-20 x 3/8 PHCR
20 Screw #8-18 x ¾ Hex Washer Head
21 Manifold Mount
22 Complete Right Side Inner Door
23 Resistance Temperate Detector (RTD)
24 Screw #10-12 x ¾ Hex Washer Head
25 ¾ NPT Tank Plug (XR Models)
26 Wire Tie
27 ASSE Approved Mixing Valve (Optional)
28 Thermopile
29 Inner Door Gasket Set
30 Pilot Orifice
31 Kit-Heat Trap Insert
32 Intermediate Gas Valve Harness

Page 26

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