Bradford White URG230TN, URG240SN, URG240TN, URG250LN, URG250HN User Manual

Flammable Vapor Ignition Resistant

Water Heaters

Ultra Low NOx Gas Water Heaters

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Manual 238-51546-00B REV 10/18

Models Covered

by This Manual:

URG230T*N
URG240S*N
URG240T*N
URG250L*N
URG250H*N
URG250T*N
URG250S*N
URG130T*N
URG140T*N
URG150T*N
(*) Denotes Warranty Years

Save this manual for future reference

The Bradford White

ECO

DEFENDER

Safety System

®

Ultra Low NOx Gas Water Heaters

Page ED Service Procedure

Introduction.................................................................................................................................4 ---

How to Use This Manual ..........................................................................................................5 ---

Tools Required for Service........................................................................................................5 ---

Troubleshooting.........................................................................................................................6 ---

Burner Operation Inspection, Cleaning & Replacement....................................................... 10 ED-I

Pilot Inspection, Testing & Replacement.................................................................................12 ED-II

Gas Control Testing & Replacement........................................................................................13 ED-III

Chamber Sensor Testing ...........................................................................................................16 ED-IV

Thermopile Testing and Replacement......................................................................................17 ED-V

Igniter, Electrode Testingand Replacement ............................................................................18 ED-VI

Resettable Thermal Switch Testing and Replacement............................................................19 ED-VII

Diptube Inspection and Replacement.......................................................................................21 ED-VIII

Anode Inspection & Replacement............................................................................................22 ED-IX

Inner Door Removal, Inspection & Replacement................................................................... 23

Flue Baffle Inspection & Replacement ....................................................................................26 ED-XI

ScreenLok® ...............................................................................................................................27 ---

Glossary of Terms......................................................................................................................28 ---

Parts List.....................................................................................................................................29 ---

2

ED-X

2

ECO Defender Series

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!

x

Do not try to light any appliance.

Do not touch any electrical switch; do not use any

x

phone in your building.

Immediately call your gas supplier from a neighbor's phone.

x

Follow the gas supplier's instructions.

If you cannot reach your gas supplier, call the fire

x

department.

Installation and service must be performed by a qualified
installer, service agency or the gas supplier.

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:

x

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

x

Most people recognize this odor as a “sulfur” or “rotten egg”
smell.

x

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

x

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 ¾” X ¾”

TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE

THE MANUFACTURER FROM ANY CLAIM THAT MIGHT RESULT

FROM EXCESSIVE TEMPERATURE AND PRESSURES.

CAUTION

Turn off or disconnect the electrical power supply to the water heater
before servicing. Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous operation.
Verify proper operation after servicing.

3

3

ECO Defender Series

Introduction

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 the 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.

4

4

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 ECO-DEFENDER Series water heaters.

The Honeywell WV8860 Gas Control will display status codes in the event of abnormal operation. Status
codes are listed in the troubleshooting chart beginning on page 6 of this service manual. The troubleshooting
chart will also indicate the probable cause for the status 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 cannot be made using the
methods described in this service manual.

Tools Required for Service

ECO Defender Series

Manometer:

Multi-Meter:

Electronic Probes:

Thermometer:

Water Pressure Gage:

Various Hand Tools:

A liquid “U” tube type or a digital (magnahelic) type can be used. This
device is used to measure gas and/or air pressure and vacuum.

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.

In some cases, standard multi-meter probes will damage or simply not be
effective to obtain certain voltage and ohm readings. It will be necessary to
have special electronic “pin” type multi-meter probes. These probes are
available at most electronic wholesale outlets.

Used to measure water temperature. An accurate thermometer is
recommended.

Used to measure water supply pressure. Also used to determine tank
pressure by adapting to the drain valve of the heater.

Pipe wrench, channel locks, open end wrenches (3/8”, 7/16”, 1/2”), 12”
crescent wrench, allen wrench set, screw drivers (common & Phillip’s), 1/4”
nut driver, pliers (common & needle nose), socket set, side cutters, wire
cutters, wire strippers, wire crimpers, torpedo level, small shop vacuum,
step ladder, flashlight and 5-gallon pail.

5

5

ECO Defender Series V1

g

Observe green LED indicator on
electronic gas control. Status flash
codes are displayed with a three second
pause before repeating. Check and
repair the system as noted in the
troubleshooting table below.

LED Status Control Status Probable Cause Service Procedure

If the pilot will not stay lit
None (LED not
on or flashing)

One flash and
three second
pause

LED strobe (two
quick flashes)
and three second
pause

LED on
continuously
(solid)

Pilot assembly is not lit

1.

If setpoint knob is in “PILOT”
position then pilot flame is
detected. Turn setpoint knob
to desired setting.

2.

If the setpoint knob is
already at the desired
setting, the water heater is
satisfied.

Thermostat calling for heat (no
faults).

Setpoint knob has been recently
turned to the “OFF” position. Wait
until LED goes out before
attemptin

to relight.

Gas control is not
powered. Light Pilot.

1.

Gas control is
powered and waiting
for setpoint knob to
be turned to a water
temperature setting.

2.

Water heater is
satisfied and
operating normally.

Tank temperature
below setpoint of
thermostat.

Setpoint knob was
turned to “OFF”
position.

replace pilot assembly. If

problem persists, replace

gas control.

Normal operation.

Normal operation.

LED will not go out and the
control will function
normally the is lit.

Two flashes
and three
second pause

Three flashes
and three
second pause

6

Weak pilot signal detected.
System will reset when pilot
flame is sufficient.

Insufficient water heating.
System will reset.

1.

Thermopile failure.

2.

Unstable pilot.

3.

Pilot tube block or
restricted.

1.

Thermal sensor out
of calibration.

2.

Faulty gas control.

1.

See service procedure IV

2.

See service procedure II

3.

See service procedure II

Replace gas control.

6

ECO Defender Series V1

Observe green LED indicator on
electronic gas control. Status flash
codes are displayed with a three second
pause before repeating. Check and
repair the system as noted in the
troubleshooting table below.

LED Status Control Status Probable Cause Service Procedure

Four flashes
three second
pause

Five flashes
and three
second pause

Six flashes
and three
second pause

Seven flashes
and three
second pause

Excessive tank temperature.
System must be reset.

Temperature sensor fault.

Chamber temperature sensor out
of specification. Possible short.

Gas valve electronic fault
detected.

1.

Temperature sensor
out of calibration.

2.

Faulty gas control.

1.

Damage to the

temperature sensor.

2.

Temperature sensor
resistance out of
range.

1. Chamber
temperature sensor
out of calibration.

2. Possible short.

1.

Control needs to be
reset.

2.

Control is wet or
physically damaged.

Replace gas control

1.

Verify control is not wet or
physically damaged

2.

Turn set point knob to
“OFF” position. Turn set
point knob to “PILOT”
position and light pilot.

3.

Replace gas valve if five
flash status persists.

1. Reset gas control

2. Replace gas control.

1. Reset gas control

2. Replace gas control.

Eight flashes
and three
second pause

Ten flashes
and three
second pause.

Standing pilot remains on while
setpoint knob is in “OFF”
position.

Insufficient combustion air
detected.

7

Pilot valve stuck in
open position.

Insufficient
combustion air.

Replace gas control

1. Reset gas control

2. Replace gas control.

7

ECO Defender Series V2

Observe colored LED indicator on
electronic gas control. Status flash
codes are displayed with a three second
pause before repeating. Check and
repair the system as noted in the
troubleshooting table below.

LED Status Control Status Probable Cause Service Procedure

If the pilot will not stay

None (LED not
on or flashing)

One flash every
four seconds
(LED green)

One flash every
second
(LED green)

Two flashes
(LED yellow)

Four flashes
(LED red)

Millivolt power is not
present. Light pilot.

Not an error. Indicates
pilot is lit and main
burner is off.

Not an error. Indicates
main valve is open and
main burner is lit.

Low thermopile voltage;
main valve not turned
ON.

Temperature cut-out
limit reached.

Gas valve is functioning
normally. Gas valve is not
powered. Light pilot.

You can now turn the know
to a desired setpoint
temperature
None. Control will
automatically shut main
burner off when water
temperature reaches the
setpoint temperature.

Check thermopile and its
connections. Check pilot
flame.

Check the valves and the
water temperature sensor.
Reduce the water
temperature setpoint.
Thoroughly check
out main valve operation
and water temperature
control before walking
away.

lit replace pilot
assembly. If problem
persists, replace gas
control.

Normal operation.

Normal operation.

1. See service procedure
IV.

2. See service procedure
II.

3. See service procedure
II.

Replace gas control

8

8

ECO Defender Series V2

Observe colored LED indicator on
electronic gas control. Status flash
codes are displayed with a three second
pause before repeating. Check and
repair the system as noted in the
troubleshooting table below.

LED Status Control Status Probable Cause Service Procedure

Check water temperature

sensor and its connection
Five flashes
(LED red)

Six flashes
(LED red)

Solid ON
(LED red)

Nine flashes
(LED red)

Ten flashes
(LED red)

Water temperature
sensor failure.

Door temperature
sensor failure.

Not an error-indicates
that the control is in
OFF mode.

Tank leakage detected
by accessory module.

Abnormal combustion
chamber temperature
profile during heating
cycle.

for open circuits, shorts, or

differences in resistance

between the two sensor

elements.

Check door temperature

sensor and its connection

for open circuits or shorts.

None; wait until LED turns

off if you want to restart

system.

Control recovers after

receiving message from

accessory module.

Clean all combustion air

intakes to the appliance.

Clean the burner. Remove

all obstacles that may

restrict air flow to the

burner.

Replace gas control

See service procedure X.

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

1. Check T&P valve.

2. Check all water fittings.

3. Pressurize and leak test
tank.

Replace gas control

9

9

ECO Defender Series

Burner Inspection

At periodic intervals (every 6 months) a visual
inspection should be made of the pilot and main
burner for proper operation and to assure no
debris is accumulating.

Pilot flame should be stable, some causes for an unstable
pilot flame are:

a)

b)
c)

Main burner should light smoothly from
pilot and burn with a blue flame with a
minimum of yellow tips.

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

Water heater vent is less than the allowable
vent length.
Gas pressure is out of specification.
Pilot flame not fully
engulfing spark/flame
sensor.

Burner Cleaning

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

Step 7.

Position gas control knob to the
“OFF” position.
Turn off gas supply to water
heater.
Remove outer jacket door and inner door per
service procedure ED-X on page 21.
Disconnect pilot tube (7/16” wrench) and
feedline (3/4” wrench) from gas control.
Disconnect chamber door temperature sensor
from gas control.
Disconnect resettable thermal switch’s white
and red wire leads from gas control.
Remove burner assembly from combustion
chamber.

10

10

ECO Defender Series

Burner Cleaning (cont.)

Step 8.

Step 9.

Remove manifold mount from burner
inner door by removing (2) ¼” hex
drive screws.

Thoroughly inspect burner surface
area and burner port area. Remove
any loose debris using a stiff brush,
compressed air and/or a shop
vacuum.

Step 10.

Step 11.

Step 12.

Unscrew main burner orifice and feedline
from manifold mount. Remove main burner
orifice from feedline (1/2” wrench) inspect
orifice, clean or replace if necessary.

Reassemble burner and reinstall into
water heater. Restore gas supply and
check for gas leaks.
To resume operation, follow the
instructions located on the lighting
instruction label or the lighting instructions
located in the installation and operation
manual.

11

11

ECO Defender Series

Pilot Inspection, Testing and
Replacement

Step 1.
Step 2.
Step 3.

Step 4.

Step 5.
Step 6.
Step 7.
Step 8.
Step 9.
Step 10.

Step 11.

Step 12.

Step 13.

Step 14.

Step 15.

Step 16.
Step 17.
Step 18.
Step 19.

Position gas control knob “OFF” position.
Turn off gas supply to water heater.
Remove outer jacket door and inner door per
service procedure ED-X on page 21.
Disconnect pilot tubing nut (7/16” wrench) and
feedline nut (3/4” wrench) from gas control.
Disconnect igniter/flame sense wire from gas control.
Disconnect wire connections to the resettable thermal switch.
Disconnect chamber door thermal sensor from gas control.
Remove burner assembly from combustion chamber.
Remove pilot assembly from burner (1/4” nut driver).
Visually inspect igniter/flame sense wire for damage.
Replace pilot if damage is found.
With a multi-meter set to ohms setting,
check continuity through igniter/flame
sense wire. Replace pilot if no continuity.
Visually inspect igniter/flame sense
electrode for deterioration. Replace
pilot as necessary. Electrode should
not be in contact with pilot hood.
Visually inspect igniter/flame sense
electrode for oxidation build up.
Carefully clean any oxidation using very
fine emery cloth.
Visually inspect pilot tubing for kinks or
cracks. If damage is found, replace
pilot.
Inspect pilot tubing and pilot orifice for
blockage:

a.

Remove ferrule nut from bottom of pilot
assembly (7/16” wrench).

b.

Remove pilot tube and pilot orifice.

c.

Inspect pilot tubing and pilot orifice for blockage.
replace as necessary.
Reassemble pilot and install onto burner.
Reinstall burner assembly to water heater.
Restore gas supply and check for gas leaks.
To resume operation, follow the instructions located on the lighting
instruction label or the lighting instructions located in the installation and
operation manual.

Clean or

12

12

ECO Defender Series

Line Pressure

The gas control is designed for a maximum
line pressure of 14.0” w.c. and a minimum
line pressure of 1.0” w.c. over the water
heater’s rated manifold pressure (check
rating plate). Line pressure must be
checked with the main burner on and off to
assure proper readings.

Manifold Pressure Testing

(this procedure presumes a maximum
line pressure of 14.0” w.c.)

Step 1.

Step 2.

Step 3.
Step 4.

Step 5.

Step 6.

Step 7.

Set the gas control knob to the “OFF”
position.
Remove pressure tap plug and install
1/8” NPT pipe, coupling & pressure
tap.
Connect manometer to pressure tap.
Follow instructions located on the
lighting instructions label and proceed
to light the main burner and observe
manometer reading.
Proper manifold pressure operating
range for Natural Gas is 5.0” ±0.5” w.c.
If pressure is within the range specified
in the previous step, set Gas
Control knob to the “OFF” position,
remove manometer and pressure tap,
and replace pressure tap plug. Check
for gas leaks prior to placing water
heater back into operation by following
the instructions located on the lighting
label, or the lighting instructions
located in the installation and operation
manual.
If gas pressure is outside the
specification noted above, refer to
page 16 to replace gas control.

13

13

ECO Defender Series

Determine Water Temperature Inside Tank

WARNING

Stored water may be HOT WHEN PERFORMING THE FOLLOWING STEPS IN

THIS PROCEDURE. Take necessary precaution to prevent personal injury.

Step 1.
Step 2.

Position gas control knob to the “OFF” position.
Draw approximately 4 gallons of water from the 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).
Compare the measured water temperature with the setting on the gasStep 3.
control.
10°F.

In most instances, they should not differ by more than approx.

14

14

ECO Defender Series

Gas Control Removal from Water Heater

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.
Step 7.
Step 8.

Step 9.

Step 10. Reattach main burner feedline, pilot tube and all wire harnesses.
Step 11. Reconnect gas supply piping to inlet of gas control.

Rotate the gas control knob to the
“OFF” position.
Drain the heater to a point below the
gas control level.
Turn off the gas supply to the water
heater and disconnect gas piping from
the gas control.
Disconnect wire harnesses from the
gas control.
Remove the outer jacket burner
access door.
Disconnect main burner feedline, swing counter-clockwise away from gas control.
Disconnect pilot tube from gas control and move away from gas control.
Removal gas control from water heater by rotating counter clockwise. DO NOT
use a wrench on the gas control body, damage to the gas control may occur. If
necessary, use a length of ½” NPT pipe threaded into gas inlet of gas control.
Install new gas control into water heater by rotating clockwise. DO NOT use a
wrench on the gas control body, damage to the gas control may occur. If
necessary, use a length of ½” NPT pipe threaded into gas inlet of gas control.

15

15

ECO Defender Series

Chamber Sensor Testing

Step 1. Rotate the gas control knob to

the “OFF” position.

Step 2. Disconnect the chamber sensor wire

harness from the gas control.

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).

Step 5. Measure the ambient air temperature near the sensor. Compare the ambient

temperature range to the expected resistance range on the chart below.
that resistance increases as temperature decreases.

Note

16

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 (°F)

41-50
50-59
59-68
68-77
77-86

86-104
104-113
113-122
122-131

Resistance Range (kOhms)

279-175
219-139
173-112

137-90
110-72

89-59
73-48
60-39
49-32

16

ECO Defender Series

Closed Circuit Thermopile Testing

WARNING

115 volt potential exposure. Use

caution to avoid personal injury.

Step 1.

Step 2.

Step 3. If reading is

Closed circuit testing is the
preferred method for testing the
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.
Using a multimeter capable of measuring millivolts, place
on 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.
If meter reads 300 millivolts or higher, the thermopile is OK.
below 300 millivolts, replace the pilot assembly per service procedure ED-II
on page 10.

Open Circuit Thermopile Testing

17

Step 1.

Step 2.

Step 3.

Disconnect red thermopile wire from wire harness leading to the gas control.
Disconnect the white thermopile wire from the resettable thermal switch.
Using a multi meter capable of measuring millivolts, connect one lead to
the red thermopile wire and one lead to the white thermopile wire.
Following the lighting instruction label on the heater,
proceed to light the pilot
and allow the heater to
operate for three minutes.

It will be necessary to hold
the gas control knob down
in the “PILOT”
position continuously
throughout this test. A

reading over 400 millivolts
indicates a good thermopile
output. A reading under 400 millivolts indicates a bad thermopile,
replace the pilot assembly per service procedure ED-II on page 10.

17

ECO Defender Series

Igniter, Electrode Testing and Replacement

Step 1.
Step 2.

Step 3.

Remove outer jacket door.
Repeatedly depress the igniter button while
viewing the pilot through the sight glass. If a
spark is present, the circuit is OK. If there is
no spark, proceed to step 3.
Remove white wire from igniter. Hold the
igniter lead from the gas control to an
unpainted surface such as the feedline or gas
control 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-II on page 10.

18

18

ECO Defender Series

Resettable Thermal Switch Testing and Replacement

Step 1.
Step 2.

Step 3.

Step 4.

Step 5.

Remove outer jacket door.
Disconnect white wire leads from the
resettable thermal switch.
Using a multimeter capable of
measuring continuity (Ohms), place one
probe of the meter on one of the brass
connection tabs of the resettable
thermal switch, and the remaining probe
on the other connection tab.
If continuity is indicated, the switch is
closed, allowing millivolt current to pass.
If continuity is not indicated, the switch
is open, possibly due to an overheating
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 into service.

19

PROBABLE CAUSE FOR RESETTABLE THERMAL SWITCH

PROBABLE CAUSE CORRECTIVE ACTION

Inspect burner per service

-

Burner failure

Weak switch or switch out of

Flammable vapor incident Replace water heater

procedure ED

replace burner if

Replace resettable thermal switch

I on page 8 and

19

ECO Defender Series

Resettable Thermal Switch Testing and Replacement (cont.)

Step 1.

Step 2.
Step 3.

Step 4.

Step 5.

Step 6.

Step 7.

Step 8.
Step 9.

Rotate gas control knob to the
“OFF” position.
Remove outer jacket door.
Disconnect wire leads from
resettable thermal switch.
Remove (2) ¼” hex drive screws
from the manifold mount.
Remove resettable thermal switch from
manifold mount (Phillips screw driver).
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.
Reconnect wire leads from gas valve and thermopile to resettable
thermal switch.

Note: Wire terminations are interchangeable with either resettable
thermal switch connection.

Replace outer jacket door.
To resume operation, follow the instructions located on the lighting
instruction label or the lighting instruction located in the installation and
operation manual.

20

20

ECO Defender Series

Diptube Inspection & 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.
Step 2.

Step 3.
Step 4.

Step 5.

Step 6.

Step 7.

Rotate gas control knob to the “OFF”.
Turn off the cold-water supply to the water heater. Connect the hose to the
drain valve of the water heater and route it to an open drain. Open a nearby hot
water faucet to vent the water heater for draining. Open the drain valve of the
water heater and allow the water heater to drain to a point below the inlet
connection nipple.
Disconnect the inlet nipple from the plumbing system.
With an appropriate tool such as a pipe wrench, remove the inlet nipple/diptube
from the water heater. Use caution not to damage the pipe threads.
Visually inspect the inlet nipple/diptube. The Inlet nipple/diptube should be free
of cracks and any blockages. The Hydrojet slots should be open and free of any
blockages. Any damage such as cracks, restriction due to deformation or
unintentional holes, are not field repairable and the inlet nipple/diptube must be
replaced.
Upon completion of an inspection or subsequent replacement, reinstall the inlet
nipple/diptube into the water heater. Ensure pipe dope is used on the nipple’s
threads. Connect the nipple to the plumbing system, resume the water supply
and refill with water.
To resume operation, follow the instructions located on the lighting instruction
label or the lighting instructions located in the installation and operation manual.

21

21

ECO Defender Series

Anode Inspection & 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.
Step 2.

Step 3.
Step 4.

Step 5.

Step6.

Step 7.

Rotate the gas control knob to the “OFF” position.
Turn off the cold-water supply to the water heater. Connect a hose to the drain
valve of the water heater and route it to an open drain. Open a nearby hot
water faucet to vent the water heater for draining. Open the drain valve of the
water heater and allow the water heater to drain to a point below the outlet
connection nipple.
Disconnect outlet nipple from the plumbing system.
With an appropriate tool such as a pipe wrench, remove the outlet
nipple/anode from the water heater. Use caution not to damage the pipe
threads.
Visually inspect the outlet nipple/anode. The 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.
Upon completion of an inspection or subsequent replacement, reinstall the
outlet nipple/anode into the water heater. Ensure pipe dope is used on the
nipple’s threads. Connect the nipple to the plumbing system, resume the
water supply and refill with water.
To resume operation, follow the instructions located on the lighting instruction
label or the lighting instructions located in the installation and operation
manual.

22

22

ECO Defender Series

Inner Door Removal Procedure

Step 1.
Step 2.
Step 3.
Step 4.
Step 5.
Step 6.
Step 7.

Rotate the gas control knob to the “OFF” position.
Remove outer jacket burner access door.
Disconnect chamber door temperature sensor wire harness from gas control.
Remove (2) ¼” hex drive screws from right side inner door.
Remove (2) ¼” drive screws from flange section of inner door.
Remove (2) ¼” drive screws from left side inner door.
Remove inner door and inspect per step 8.

23

Step 8.

If the gasket is not affected by any of the above, gasket replacement is not required.
replacement is required, proceed to Inner Door Gasket Replacement Procedure.

Fully inspect inner door gaskets for the following:

-Tears

-Missing Material

-Cracks

-Dirt or debris

-Other imperfections that will inhibit proper seal

-Gasket adhesion to inner door

-Material left on combustion chamber (around opening)

If

23

ECO Defender Series

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 9. After inspection of inner door as noted in step 8, completely remove gasket

and adhesive residue from right and left side inner doors as needed.

Step 10. Use RTV sealant (recommended bead size 1/8”) to secure the inner door

gasket to the inner door sections (right & left). Refer to illustration on next
page for proper 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 overlap position.

Installation of Inner Door with Gasket

Step 11.

Step 12.

Step 13.

Clean any residual gasket residue or other debris
from the combustion chamber surface before
installing the inner door/gasket assembly.
Place the left side inner door into position first.
Using the ¼” hex drive screws from step 6,
secure left side inner door in place. DO NOT

OVER TIGHTEN SCREWS

Position pilot tube and igniter/sensor wire against
left side inner door flange 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 12, 14 and 15.

24

24

ECO Defender Series

Installation of Inner Door with Gasket (cont.)

Step 14.

Step 15.

Firmly place right side inner door flange against the left side inner door flange
and secure with (2) ¼” hex drive screws from step 5. DO NOT OVER
TIGHTEN SCREWS.

Align right side inner door to combustion chamber and verify the fastener
holes of the combustion chamber are aligned with right side inner door slotted
opening. Verify seal integrity around combustion opening. Secure right side
inner door using ¼” hex drive screws from step 4. DO NOT OVER TIGHTEN
SCREWS. Verify both left and right sides of inner door are properly
positioned and sealed against the combustion chamber.

Step 16. Replace outer jacket burner access door.
Step 17. To resume operation, follow the instructions located on the lighting instruction label

or the lighting instructions located in the installation and operation manual.

25

25

ECO Defender Series

Flue Baffle Inspection and Replacement

ED SERVICE PROCEDURE

XI

Flue Baffle Inspection &

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

Rotate the gas control knob to the “OFF”
position.
Disconnect vent system from the exhaust
adapter on top of the water heater.
Remove the draft diverter on top of the water
heater.
Remove the flue baffle from the heater (see
photo A below).
Inspect baffle for deterioration, missing
restrictors. Clean any scale or debris build
up. Replace with a new baffle as necessary.
Reinstall baffle into the flue tube. Be sure
hanger tabs are inserted into the notch
locations at the top of the flue tube (see
photos B & C).

Step 7.

Step 8.

Step 9.

26

Check burner to ensure no scale has accumulated during this operation.
See burner cleaning procedure on page 8.
Reinstall the draft diverter on top of the water heater. Re-connect the
vent system.
To resume operation, follow the lighting instructions located on
the lighting instruction label or the lighting instructions located in
the installation operation manual.

26

ECO Defender Series

ScreenLok®Flame Arrestor Cleaning

NOTICE

Some models are not equipped with the

ScreenLok

®

Flame Arrestor.

Step 1.
Step 2.
Step 3.

Step 4.

Step 5.

Step 6.

Step 7.
Step 8.

Step 9.

Rotate the gas control knob to the “OFF” position.
Remove outer door.
Remove outer jacket door and inner door per service procedure ED-X on page

24.
Disconnect main burner feedline (3/4” wrench), pilot tube (7/16” wrench) and
igniter/flame sensor wire from gas control and remove burner assembly from
combustion chamber.
Clean ScreenLok®Flame Arrestor using a stiff brush, compressed air and/or
shop vacuum to remove any scale or other debris accumulation. Using a soft
brush, clear jacket openings from any dirt, dust, restrictions or other obstructions.
Remove any debris from burner assembly per procedure ED-I and reinstall
burner assembly into combustion chamber.
Reconnect feedline, pilot tube and igniter/flame sensor wire to the gas control
Reinstall outer jacket door and inner door per service procedure ED-X on page

24.
To resume operation, follow the instructions located on the lighting instruction
label or the lighting instructions located in the installation and operation manual.

27

27

ECO Defender Series

Glossary of Terms

BTU
GPM
Hz
kWh
LED
NPT
Homs
PSI
RPM
ECO
VAC
“w.c.
ºC
ºF

British Thermal Units
Gallons per Minute
Hertz
Kilowatt hour Light
Emitting Diode National
Pipe Thread Ohm
s of resistance Pounds
per Square Inch
Revolutions per minute
Energy Cut Out

Volts Alternating Current
Inches of Water Column
Degrees Centigrade
Degrees Fahrenheit

28

28

ECO Defender Series

Heat Trap Outlet

1.
Hot Water Outlet Anode

2.
T&P Valve

3.

4.

Draft Diverter

5.

Heat Trap Inlet

6.

Flue Baffle

7.

Inlet Diptube

8.

¾ NPT Plug (“H” Models
only)

9.

Burner Ass’y complete

29

10.

Main Burner Feedline

11.

Resettable Thermal
Switch

12.

Main Burner

13.

Pilot Assembly

14.

Pilot Orifice

15.

Right Side Inner Door
Ass’y

16.

Thermal Switch Harness

17.

Manifold Mount

18.

Main Burner Orifice

19.

Drain Valve

20.

Polymer Gas Control

21.

Outer Jacket Door

22.

Inner Door Gasket Kit

23.

Kit-Heat Trap Insert

24.

ASSE Approved Mixing
Valve

29