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

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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 ---

ED-X

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:

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

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

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

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.

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.

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.

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

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

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

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.

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

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.

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

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

Insufficient water heating. System will reset.

Thermopile failure.

Unstable pilot.

Pilot tube block or restricted.

Thermal sensor out of calibration.

Faulty gas control.

See service procedure IV

See service procedure II

Replace gas control.

ECO Defender Series V1

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.

Temperature sensor out of calibration.

Faulty gas control.

Damage to the

temperature sensor.

Temperature sensor resistance out of range.

1. Chamber temperature sensor out of calibration.

2. Possible short.

Control needs to be reset.

Control is wet or physically damaged.

Replace gas control

Verify control is not wet or physically damaged

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

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.

Pilot valve stuck in open position.

Insufficient combustion air.

Replace gas control

1. Reset gas control

2. Replace gas control.

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.

1. See service procedure IV.

2. See service procedure II.

3. See service procedure II.

Replace gas control

ECO Defender Series V2

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

+ 21 hidden pages

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

Specifications and Main Features

Frequently Asked Questions

User Manual