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Service Manual 44943-00D - Bradford White Replacement Parts

1. BRADFORD WHITE WATER HEATERS Flammable Vapor Ignition Resistant Water Heaters Gas Water Heaters DJE SAFETY SYSTEMI SERVICE MANUAL Troubleshooting Guide and Instructions for Service FEATURING BRADFORD WHIT ICON For the Bradford White Defender Safety System Models MI30T F BN CX SX MI30S F BN CX SX MI303T F BN CX SX MI40T F BN CX SX MI403S F BN CX SX MI404T F BN CX SX MI503 F BN CX SX MI50L F BN CX SX MI504S F BN CX SX MI60T F BN CX SX C S D W2504T F BN CX SX M430T F BN CX SX M440T F BN CX SX M4403S F BN CX SX M4503 F BN CX SX M460T F BN CX SX M1XR403S F BN CX SX M1XR504T F BN CX SX M2XR504T F BN CX SX M2XR65T F BN CX SX M2C504T F BN CX SX 50T65F B N C X S X 65T65F B N C X S X Denotes Warranty Years Manual 238 44943 00D Save this manual for future reference The Bradford White FEATURING Flammable Vapor Ignition Resistant Water Heaters Table of Contents Page Service Procedure Introduction 3 Trouble shooting Chart 4 Inner Door Gasket Removal Inspection Replacement and Installation 7 RG I Thermocouple Thermopile Testing and Replacement 10 RG II Pilot Assembly Inspection Cleaning and Replacement 13 RG III Piezo Igniter Electrode Testing and Replacement 14 RG IV White Rodgers Robertshaw Gas Valve Testing and Replacement 15 RG V Honeywell Gas Control Testing Disassembly and Replacement 20 RG VI Burner Operat
2. see photo on right with the temperature sensor still in the back plate use a multi meter set to the Ohms setting determine the resistance of Resume normal operation temperature sensor er caution and photos above E y a water temperature must also be known to determine if the resistance values are correct See next page to obtain water temperature Are temperature sensor resistance values correct NX Once the temperature sensor resistance values are known the Rea Gas cont N Replace temperature sensor WATER HEATERS a The Bradford White resruane SERVICE PROCEDURE RG VI a JINI 1 aF Gas Control INO CON DERE NORR I E Syster C Testing Disassembly amp Replacement Honeywell WARNING Stored water may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury DETERMINE WATER TEMPERATURE INSIDE TANK Note It is important to understand once the resistance for the temperature sensor is determined from the previous page water flow through the water heater should not occur Prior to drawing water from drain valve turn off the cold water supply to the water heater This will prevent cold water flow into the tank affecting the resistance value of the temperature sensor Step 1 Set the Gas Control knob to the OFF position Step 2 Turn off
3. Step 1 Closed circuit testing is the preferred method for testing thermocouple Following the lighting instruction label on the heater proceed to light the pilot and allow to operate for three minuets If the pilot will not stay lit hold the pilot button located on the combination thermostat gas valve down during this test Step 2 Using a multimeter capable of measuring millivolts connect one lead using an alligator clip to the copper sheath of the thermocouple use the second lead of the multi meter to probe the top terminal located at the back of the combination thermostat gas valve Step 3 Ifmeter reads 10 millivolts or higher the thermocouple is OK If reading is below 10 millivolts replace the thermocouple Probe top terminal on back of combination thermostat gas valve Alligator clip to copper sheath of thermocouple CLOSED CIRCUIT THERMOCOUPLE TESTING Robertshaw Control Step 1 Disconnect thermocouple from combination thermostat gas valve Step 2 Connect a thermocouple adaptor BWC P N 239 44642 00 Robertshaw P N 75036 at the thermocouple location in the combination thermostat gas valve Step 3 Reconnect thermocouple to adaptor Make certain all connections are tight finger tight plus 1 4 turn Step 4 Using a multimeter capable of measuring millivolts connect one alligator clip to the set screw of the adaptor and the other alligator clip to copper portion of the thermocouple Ste
4. OFF position Step 2 Remove pressure tap plug and install 1 8 NPT pipe coupling amp pressure tap Gas Control shown in the OFF position Step 3 Connect manometer to pressure tap Step 4 Follow instructions located on the lighting instructions label and proceed to light the main burner and observe manometer reading Step 5 Proper operating range for natural gas is 4 0 0 5 w c Proper operating range for LP gas is 10 0 0 5 w c Step 6 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 instruction label or the lighting instructions located in the installation and operation manual Step 7 If gas pressure is outside the specification noted above refer to Honeywell Gas Control Testing Disassembly and Replacement to replace Gas Control or valve body Pressure Tap Shown Installed THERMOPILE TESTING See SER VICE PROCEDURE RG II ECO Energy Cut Off TESTING The Honeywell Gas Control is designed with an ECO device that will reset To reset the Gas Control after an error code 4 turn the Gas Control knob to the OFF position and wait a minimum of 5 minutes before relighting following the instructions located on the lighting instru
5. Control Status Probable Cause Service Procedure 3 Gas Control is operating normally Pilot flame may not be present Check for pilot flame through sight glass and light if necessary None LED not on or flashing 1 Gas Control is functioning normally 2 Gas Control is not powered Light pilot If the pilot will not a lit replace pilot assembly If problem persists replace Gas gt If set point knob is in PILOT position then pilot flame is detected Turn set point knob to One flash and three second a Thermopile failure Gas Control is powered and waiting for the set point knob to be turned to a water temperature setting Control lt gt Normal operation Adjust thermostat to desired temperature P procedure RG VIII Z Three flashes and three second pause Insufficient water heating System will reset Temperature sensor out of calibration See service procedure RG VI r pause desired setting setting LED on Set point knob has been recently LED will go out and the turned to the OFF position Wait Set point knob was turned to OFF control will function continuously l until LED goes out before position normally when the pilot Solid attempting to relight is lit gt lt gt Vy See service 1 Thermopile failure 9 Ap a Two flashes and Weak pilo
6. Step 7 Clean any residual gasket residue or other debris from combustion chamber surface before installing the inner door gasket assembly Step 8 Place the left side inner door into position first Firmly position the radiused channel of the inner door around the feedline Using the 2 hex drive screws from step 3d secure left side inner door in place DO NOT OVER TIGHTEN SCREWS Step 9 Position thermocouple pilot tube and Piezo wire against left side inner door flange gasket DO NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE j i 5 N r Da ae T Radiused Channel for Feedline a SERVICE PROCEDURE RG I Inner Door Gasket Removal Inspection Replacement and Reinstallation BE AS SHOWN GASKET OVERLAP MUST 1 32 ENLARGED VIEW OF FLANGE AREA VIEW WITH GASKETS IN PLACE 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 Position thermocouple thermopile pilot tube and piezo wire BRADFORD WHITE WATER HEATERS The Bradford White reaume SERVICE PROCEDURE RG I D TETEE N JERR ICON Inner Door Gasket Removal Inspection GARETY SYSTEM System R
7. 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 knob of combination thermostat gas valve to OFF position For White Rodgers Control depress knob slightly and rotate clockwise to the OFF position For Honeywell Control rotate knob counter clockwise to the OFF position For Robertshaw Control rotate knob clockwise to the OFF position 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 inlet connection nipple Disconnect inlet nipple from plumbing system With an appropriate wrench remove inlet nipple dip tube from the water heater Use caution not to damage pipe threads 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 Upon completion of inspection or subsequent replacement
8. iron burner can have the gas and air mixture properly proportioned by adjusting the air shutter on the mixer face of the main burner see step 2 below Main burner must be free from any debris accumulation that may effect burner operation see burner cleaning procedure on page 17 CAST IRON BURNER ADJUSTMENT A 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 Upon completion of the cast iron burner adjustment procedure the inner door must be replaced per SERVICE PROCEDURE RG 1 steps 4 through 14 to reactivate Bradford White Defender Safety System A WARNING Inner door and burner components may be HOT when performing this operation Take necessary precaution to prevent personal injury Step 1 With main burner in operation remove right side inner door per SERVICE PROCEDURE I steps 3b amp 3c Be sure to maintain wire connection to resettable thermal switch for this adjustment procedure Step 2 To adjust for proper burning loosen the air shutter nut rotate the shutter to close the opening in the burner then slowly rotate the shutter until the yellow tips disappear and the flame becomes blue Tighten the air shutter nut Too much air will cause the flame to lift o
9. jacket burner access door when reinstalled WARNING A seal breach may result in a fire or explosion causing property damage personal injury or death DENY Position thermocouple pilot tube and Piezo wire d Firmly place right side inner door flange against the left side inner door flange and secure with 2 hex drive screws from step 6c DO NOT OVER TIGHTEN SCREWS e Align nght side inner door to combustion chamber and verify the fastener holes of the combustion chamber are aligned with the nght side inner door slotted openings Verify seal integrity around combustion opening Secure right side inner door using 2 hex drive screws from step 6b DO NOT OVER TIGHTEN SCREWS Verify both left and right sides of the inner door are properly positioned and sealed against the combustion chamber Secure flange with a drive screws N Verify threaded hole alignment with slotted openings in inner door o A Step 10 Reconnect wire leads from gas valve to resettable thermal switch See photo in step 6 Note wire terminations are interchangeable with either resettable thermal switch connection Step 11 Replace outer jacket burner access door Step 12 Reconnect gas supply to gas valve Step 13 Resume water supply to water heater Be sure tank is full of water Step 14 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located i
10. reinstall inlet nipple dip tube into heater Connect nipple to plumbing system resume water supply and refill heater 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 BRADFORD WHITE Se ee eee eee ee eee O WATER HEATERS The Bradford White FEATURING SERVICE PROCEDURE RG X x SINIT n Dip Tube and Anode DE EINIOIER I CON Inspection and Replacement SAFETY SYSTEM E System F ANODE INSPECTION AND REPLACEMENT A WARNING Heater components and stored water may be HOT when performing the following steps in Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 this procedure Take necessary precaution to prevent personal injury Turn off water supply to water heater Rotate knob of combination thermostat gas valve to OFF position For White Rodgers Control depress knob slightly and rotate clockwise to the OFF position For Honeywell Control rotate knob counter clockwise to the OFF position For Robertshaw Control rotate knob clockwise to the OFF position 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 nippl
11. 0 1150 1129 1110 1090 1071 1953 1035 1017 999 190 982 965 949 933 917 901 886 871 857 842 200 828 814 801 788 115 162 749 137 1295 713 amp BRADFORD WHITE EK WATER HEATERS The Bradford White reaturnc SERVICE PROCEDURE RG VI IED HR ICON Gas Control Testing Disassembly amp Replacement Honeywell SAASTY SYSTEMI System S i Z GAS CONTROL DISASSEMBLY REASSEMBLY 5 a yas TOUGH A ROT AALALA FRESS ONTA UTIN ATi LALOILONS SURUS i am RELE OO WEN SUTU UGAT Step 1 Rotate knob of the Gas Control to the OFF position Step 2 Turn off gas supply to water heater Step 3 Disconnect gas supply line from Gas Control Rotate knob counter clockwise to the OFF posistion Step 5 Remove inner door assembly following SERVICE PROCEDURE RG I steps 1 through 3c Step 6 Remove Gas Control cover screw Step 4 Disconnect piezo igniter wire Gas Control cover screw Step 7 Depress both tabs on the top of the Gas Control cover and pull to remove AcauTION Use caution not to bend or damage valve body pins when removing or installing Gas Control cover 7 ad v E v hlad IAIA Valve body pins 2 BRADFORD WHITE WATER HEATERS The Bradford White reaturnc SERVICE PROCEDURE RG VI IHR ICON Gas Control System Testing Disassembly amp Replacement Honeywell GAS CONTROL DISASSEMBLY REASSEMBLY Step 8 D
12. Step 7 Remove pilot assembly refer to SERVICE PROCEDURE RG 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 RG VIII Step 10 Reinstall burner assembly into combustion chamber reconnect feedline thermocouple and pilot tube to the combination thermostat gas valve Step 11 Reinstall inner door per SERVICE PROCEDURE RG I steps 4 through 13 Step 12 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual BRADFORD WHITE ES The Bradford White peaturne SERVICE PROCEDURE RG VIII JIN OEP ICON p Resettable Thermal Switch GAREY STEN ON Testing and Replacement 7 RESETTABLE THERMAL SWITCH CONTINUITY TESTING Step 1 Remove outer jacket door Step 2 Disconnect 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 op
13. URE RG VI DAN JER I CON Gas Control ELEY Te E Syster Testing Disassembly amp Replacement Honeywell GAS CONTROL REPLACEMENT Step 8 Install new Gas Control into water heater contintued b Reattach main burner feedline pilot tube piezo igniter wire inner door wire red and thermopile wire white to Gas Control Attach inner door wire red to the positive terminal and the thermopile wire white to the negative terminal Positive Terminal red wire white wire Negative taal c Gather piezo igniter wire thermopile wire vans inner door wire red and pilot tube and secure along side of feedline using new wire tie provided CAUTION d Reconnect gas supply piping to inlet of Gas Control Use back up wrench on wrench boss of Gas Control never use back up Step 9 Reinstallation of inner door assembly wrench on body of Gas Control a Prior to reinstallation of inner door fully inspect inner door gasket for the following gt Tears gt Gasket Adhesion to inner door gt Missing Material gt Other imperfections that will inhibit proper seal gt Cracks gt Material left on combustion chamber gt Dirt or debris If the gasket is not effected by any of the above gasket replacement will not be required If replacement is required replace using new gasket kit following the instructions provided with kit b Clean any gasket residue or other debris
14. ase where trace amounts of flammable vapors are present in the air flowing into the combustion chamber the vapors are harmlessly ignited by the burner pilot flame If flammable vapors are in sufficient quantity to prevent normal combustion the burner pilot flame is shut down Should the flammable vapors continue to the burner the flame arrestor plate prevents the flames from traveling backwards and igniting vapors outside of the combustion chamber The calibrated multipurpose thermal switch recognizes this and shuts down the pilot and main burner This switch also deactivates the burner and pilot in the unlikely event of restricted airflow caused by severe lint dust or oil accumulation on the arrestor plate amp BRADFORD WHITE ee 3 White Rodgers Robertshaw Gas Valve Troubleshooting Chart Flammable Vapor Ignition Resistant Water Heaters Va SYMPTOM PROBABLE CAUSE Pilot Will Not Light No incoming gas or too low gas pressure Gas control knob set to wrong position 3 Pilot light button not being fully depressed when attempting to light pilot Pilot orifice or pilot tube is obstructed or kinked Pilot electrode not sparking to pilot Piezo igniter not functioning Pilot Will Not stay lit when button is released Poor thermocouple connection at combination thermostat gas valve Thermocouple not fully engaged in pilot assembly bracket Pilot
15. ction label or the lighting instructions located in the installation and operation manual BRADFORD WHITE ne es The Bradford aly FEATURING 1DE ICO BRADFORD SNI SAFETY SYSTEM ON TEMPERATURE SENSOR TESTING 7 If Control has gone into lockout due to excessive tank temperature four flash three second pause reset control by rotating gas control knob to OFF position and wait a minimum of 5 minutes Then follow lighting instructions and return gas control knob to desired setpoint C k Observe Green LED indicator N Does error code 4 four flash three second pause continue S y SERVICE PROCEDURE RG VI Gas Control J Testing Disassembly amp Replacement Honeywell 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 e Zz Y 7 Semperatiie Sensor iestna Using a multi meter set to the ohms setting insert one meter probe see caution Following Gas Control into center wire position of thermal well connector insert the second probe see Disassembly Reassembly caution into either of the outside wire positions see photo on left instructions disassemble Gas Control to access temperature C aE J Alternate the probe on the outside position to the opposite outside wire position
16. e Disconnect outlet nipple from plumbing system With an appropriate wrench remove outlet nipple anode from the water heater Use caution not to damage pipe threads Visually Inspect outlet nipple anode Outlet nipple anode should show signs of depletion this is normal If depletion is of the original anode diameter approximately 5 8 diameter replacement is recommended If any of the steel core of the anode is exposed replacement is recommended 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 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual WATER HEATERS The Bradford White FEATURING DAVAO ICON SAVAETY SYSTEMI System Generic Parts List Draft Hood Hot Water Outlet Anode Cold Water Inlet Tube Flue Baffle T amp P Relief Valve Gas Control Honeywell Gas Valve Robertshaw Gas Valve White Rodgers Piezo Igniter White Rodgers Robertshaw Brass Drain Valve Screw 8 18 x 3 4 Hex Washer Head Screw 10 12 x 3 4 Hex Washer Head Left Side Inner Door with Gasket Complete Right Side Inner Door Resettable Thermal Switch Outer Door Complete BN Burner Assembly Natural BN Burner Only Main Burner Orifice Pilot Assembl
17. e OFF position For White Rodgers Control depress knob slightly and rotate clockwise to the OFF position Step 2 Remove outer jacket door Step 3 Remove right side of inner door per SERVICE PROCEDURE RG I steps 3a through 3c Step 4 Disconnect thermocouple from combination thermostat gas valve Locate other end of thermocouple inside of combustion chamber and remove from pilot bracket Pull firmly pulling away from the pilot assembly Step 5 Install new thermocouple into pilot bracket making certain the thermocouple is fully engaged into the pilot bracket Position thermocouple against left side inner door flange at its original position Connect other end of thermocouple to combination thermostat gas valve finger tight 1 4 turn Step 6 Inspect inner door gasket per SER VICE PROCEDURE RG I Step 4 Thermocouple position Step 7 Install right side inner door per SER VICE PROCEDURE RG I Step 10 through Step 13 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 BRADFORD WHITE s The Bradford White surne SERVICE PROCEDURE RG II DD Fes Peules IN Gy ele ICON Thermocouple Thermopile Testing and SAFETY SYSTEM System Replacement p OPEN CIRCUIT THERMOPILE TESTING Honeywell Gas Control The following test should be performed w
18. e of inner door per For Robertshaw Control rotate SER VICE PROCEDURE RG L steps e tothe OPF 3a through 3c ia Step 4 Disconnect thermocouple thermopile pilot tube and feedline from gas control gas valve NOTE Feedline nut for natural gas control uses right hand threads LP control uses left hand thread Step 5 Disconnect piezo ignition wire from piezo igniter Step 6 Remove burner assembly from combustion chamber Step 7 Remove pilot electrode assembly from feedline Step 8 Inspect pilot for the following a Primary air openings for blockage Must be free from any debris dirt lint etc Primary Air b Kinks or cracks in the pilot tube If found Opening the pilot must be replaced Step 9 Inspect pilot orifice a Remove 2 nut from bottom of pilot assembly b Remove pilot tube and pilot orifice p Pilot Orifice c Inspect pilot orifice for blockage must be cleaned or replaced Honeywell pilot orifice not replaceable replace pilot assembly T E Step 10 Install pilot electrode assembly to feedline secure with screw from step 7 Honeywell pilot assembly is not recommended but can be Step 11 Re Install burner assembly into combustion chamber connect feedline achieved by viewing the pilot pilot tube and thermocouple thermopile to gas conrol gas valve assembly from the top and pressing the thermopile towards Step 12 Install inner door per SERVICE PROCEDURE RG I step 4 through 13 the right while pulling to remove S
19. ement White Rodgers Robertshaw AAZITY SYSTIIMI Y C Step 7 Removal of gas valve a Disconnect main burner feedline pilot tube and thermocouple from gas valve amp remove burner from combustion chamber NOTE Feed line nut for natural gas control uses right hand threads LP control uses left hand thread b Remove piezo bracket with piezo igniter refer to SERVICE PROCEDURE RG IV from gas valve c Remove gas valve from water heater rotating counter clockwise using a control body wrench or a length of NPT pipe threaded into inlet of control Wrench Boss 4 N To remove or install control insert only NPT threaded pipe into inlet gt vane use to loosen or tighten Sonal Step 8 Installation of gas valve a Install new gas valve using a control body wrench or a length of 2 NPT pipe threaded into inlet of control DO NOT OVER TIGHTEN Use caution not to damage cast aluminum body of gas valve Be certain not to damage the bundled wire leads Note Gas valve must be installed in proper upright position to assure the feedline will align properly at the inner door flange DO NOT OVER TIGHTEN If control is turned past proper alignment do not reverse direction to align b Reattach Piezo bracket with Piezo igniter to gas valve c Reattach main burner feedline pilot tube and thermocouple to gas valve NOTE Feedline nut for natural gas control uses right hand thread
20. en at predetermined temperatures depending on model 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 heater back in service PROBABLE CAUSE FOR RESETTABLE THERMAL SWITCH ACTIVATION Resettable thermal switch PROBABLE CAUSE CORRECTIVE ACTION r e sane l Approximate switch 1 Verify adequate combustion air supply is Color Code activation temperature available open 2 Clear jacket slot openings of any dirt dust Blue 240 Insufficient combustion air restrictions or other obstructions Yellow 270 3 inspect flame arrestor plate and clean with stiff brush and or vacuum to remove scale Red 290 deposits and debris 1 Weak switch or switch 1 Replace resettable thermal switch out of calibration 2 Verify switch color code and approximate 2 Incorrect switch temperature Flammable vapor incident 1 Replace water heater cm The Bradford White exuane SERVICE PROCEDURE RG VIII ENIE ICON Resettable Thermal Switch Testing and Replacement RESETTABLE THERMAL SWITCH REPLACEMENT Step 1 Rotate knob of combination thermostat gas valve to the off position For White Rodgers Control depress knob slightly and rotate clockwise to the OFF position For Honeywell Control rotate knob counter clockwise to the OFF pos
21. eplacement and Reinstallation Step 10 Firmly place right side inner door flange against the left side inner door flange and secure with 2 hex drive screws from step 3c 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 2 hex drive screws from step 3b DO NOT OVER TIGHTEN SCREWS Verify both left and nght sides of the inner door are properly positioned and sealed against the combustion chamber Secure flange with hex drive screws S Verify threaded hole alignment with slotted openings in inner door ae Step 12 Reconnect lead wires from combination thermostat gas valve to resettable thermal switch See photo in step 3 Note wire terminations are interchangeable with either resettable thermal switch connections Step 13 Replace outer jacket burner access door Step 14 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual BRADFORD WHITE ee 9 The Bradford White creature SERVICE PROCEDURE RG II DIEE l JHR ICON Thermocouple Thermopile Testing and Replacement CLOSED CIRCUIT THERMOCOUPLE TESTING White Rodgers Control
22. er to pressure tap Step 4 Follow lighting instructions and proceed to light main burner and observe manometer reading Pressure Tap VS An F Shown Installed 2 a oS Step 5 Proper operating range for natural gas is 4 0 0 3 W C Proper operating range for L P gas is 10 0 0 5 W C Step 6 If pressure is OK set gas valve to OFF remove manometer and pressure tap and replace pressure tap plug Check for gas leaks before placing water heater back in operation If pressure 1s out of the specification noted in step 5 proceed to step 7 or 8 for proper service procedure Step 7 For White Rodgers control the manifold pressure is not adjustable If manifold pressure is outside the range in step 5 the control must be replaced Step 8 For Robertshaw control the manifold pressure is adjustable proceed to step 9 for adjustment procedure Step 9 While burner is in operation remove regulator access cap to expose the regulator adjusting screw With small screw driver rotate adjusting screw clockwise to increase pressure and counter clockwise to decrease pressure Step 10 Replace regulator access cap set gas valve to OFF Remove manometer and pressure tap and replace pressure tap plug Check for gas leaks before placing water heater back in operation amp BRADFORD WHITE ee ee ee ee ee ee ee eee WATER HEATERS The Bradford White FEATURING SERVICE PROCEDURE RG V a N J SINIT a
23. ermocouple location in the gas valve Reconnect thermocouple to adaptor Make certain all connections are tight finger tight plus 1 4 turn Using a multimeter capable of mo millivolts connect one alligator clip to the set screw of the adaptor and the other alligator clip to copper portion of the thermocouple Following the lighting instruction label on the heater proceed to light the pilot and allow to operate for three minuets With a meter reading of 13 millivolts or greater rotate knob of gas valve to the OFF position The magnet should remain closed for a drop of at least 6 millivolts You will here a snap or click sound when the magnet opens if you hear this sound prior to a drop of 6 millivolts the magnet is out of specification and the gas valve should be replaced 16 M BRADFORD WHITE WATER HEATERS N The Bradford White Featurne SERVICE PROCEDURE RG V IN 1 HK CoO N Gas Valve G ER I r ster Testing and Replacement White Rodgers Robertshaw AASTY SYSTEMI y C 7 ECO Energy Cut Off TESTING Step 1 Disconnect thermocouple from gas valve Step2 Using a multimeter capable of measuring Ohms or continuity attach one lead alligator clip to the pilot tube Insert the other lead probe fully into the magnet opening Be sure the probe makes contact only at the top center of the magnet opening Do not allow the probe to make contact with the th
24. ff the burner ports and create noisy burner operation Too little air yellow tips will result in soot formation Place right side inner door into proper position to confirm proper burner flame pattern and correct air shutter adjustment It may be necessary to allow the burner to operate for several minutes for burner flame to stabilize CO O Air Shutter Nut MISOT6FCX MI3O3T6FCX ALL 50S 40S 401T 5053 504 505 FCX MODELS BRADFORD WHITE WATER HEATERS 31 The Bradford White ceaturinc ODER ICON SERVICE PROCEDURE RG VII Burner Operation Inspection Adjustment SAFETY SYSTEM a Cleaning and Replacement MAIN BURNER Inspection Adjustment Cleaning and Replacement cont Step 3 Step 4 Step 5 Step 6 Fully inspect inner gasket per SER VICE PROCEDURE RG I step 4 Replace gasket if required following SER VICE PROCEDURE I steps 5 amp 6 Be certain that thermocouple pilot tube and piezo wire are routed by inner door flange as shown and Reinstall inner door per SERVICE PROCEDURE RG I step 10 and 11 Position thermocouple thermopile pilot tube and Piezo wire Observe burner operation through sight glass of inner door Burner should operate as adjusted in step 2 1f not repeat procedure compensating air shutter position for proper burner operation with inner door in place It may be necessary to clean main burner or mai
25. flame is not fully enveloping the thermocouple hot junction Weak or defective thermocouple 5 Open ECO on combination thermostat gas valve Defective magnet in combination thermostat gas valve Resettable thermal switch has opened Pilot will light but the main burner will not come on Combination thermostat gas valve set too 1 Adjust temperature dial on combination low for desired water temperature Combination thermostat gas valve temperature is satisfied Insufficient gas supply or low gas pressure Combination thermostat gas valve has Pilot goes out periodically after heating cycles once a day once a week etc CORRECTIVE ACTION SERVICE PROCEDURE 1 Turn on gas supply and or check line 1 pressure 2 Review lighting instruction Set combination thermostat 4 gas valve to correct position 3 Review lighting instruction Fully depress pilot lighting button 5 4 Clean repair or replace 5 Verify correct electrode position Replace pilot assembly 6 6 Replace Piezo igniter See Service Procedure RG V Page 12 See Service Procedure RG III Page 10 See Service Procedure RG III Page 10 See Service Procedure RG IV Page 11 Check connection at combination thermostat gas valve Proper tightness should be finger tight plus turn 2 Inspect thermocouple to ensure that
26. flashes and EE E E A 1 Control need to be reset 1 Reset Gas Control three second A ed 2 Control is wet or physically 2 Replace Gas pause l damaged Control alg thease an Standing pilot remains on while set i whi n three second point knob is in OFF position Pilot valve stuck in open position Replace Gas Control pause a Ds A A Pi 6 Se BRADFORD WHITE The Bradford White ceaturne SERVICE PROCEDURE RG I OER ICO Inner Door Gasket Removal Inspection CIETY SVE ON Replacement and Reinstallation For Honeywell Control rotate knob counter clockwise to the OFF position Inner Door Removal Procedure Step 1 Rotate knob of the combination thermostat gas valve to the OFF position Step 2 Remove outer jacket burner access door san F For Robertshaw Control For White Rodgers Control rotate knob clockwise to depress knob slightly and rotate Step 3 Inner Door Removal o clockwise to the OFF position a Disconnect resettable thermal switch wire leads leading from Gas Control gas valve b Remove 2 hex drive screws from nght side inner door c Remove 2 hex drive screws from flange section of inner door d Remove 2 hex drive screws from left side inner door e Remove inner door and inspect per step 4 PIA Resettable Thermal Switch Wire Connection Hex Drive Screws Right and Left Side Inner Door Hex Drive Screws at j Fla
27. from combustion chamber surface before installing the inner door gasket assembly c Position thermopile wire pilot tube and Piezo wire against left side inner door flange gasket DO NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE Be sure that thermopile and pilot tube are not in position to interfere with outer jacket burner access door when reinstalled WARNING A seal breach may result in a fire or explosion causing property damage personal injury or death Position thermopile pilot tube and Piezo wire BRADFORD WHITE 29 WATER HEATERS The Bradford White ceawanc SERVICE PROCEDURE RG VI Dy ens ODER ICON Gas Control SAFETY SYSTEM meme System Testing Disassembly amp Replacement Honeywell GAS CONTROL REPLACEMENT Step 9 Reinstallation of inner door assembly continued d Firmly place right side inner door flange against the left side inner door flange and secure with 2 hex drive screws from step 6c DO NOT OVER TIGHTEN SCREWS e 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 openings Verify seal integrity around combustion opening Secure right side inner door using 2 hex drive screws from step 6b DO NOT OVER TIGHTEN SCREWS Verify both left and nght sides of the inner door are properly positioned and sealed against the combustion chamber Secure f
28. hile the pilot flame is on Step 1 Turn knob to pilot position and depress Step 2 Continue pressing knob and remove red wire from resettable thermal door switch Step 3 Using a multimeter capable of measuring millivolts connect the positive side of the multimeter to the terminal of the resettable thermal door switch Connect the negative side of the multimeter to any earth ground location jacket base screw etc Resettable Thermal Door Switch Terminal Normal thermopile operation will be between 350mV 850mV If reading is less than 350mV replacement of pilot assembly 1s recommended following SERVICE PROCEDURE RG III Step 4 Ifthermopile reading is between 350mV 850mV remove multimeter and reconnect red wire to positive terminal of Gas Control Step 5 Release Gas Control knob and turn to desired setting to resume normal operation 12 BRADFORD WHITE The Bradford White FEATURING SERVICE PROCEDURE RG III BRADFORD WHITE ICON Pilot Assembly Inspection Cleaning me Systern and Replacement PILOT ELECTRODE ASSEMBLY INSPECTION paid aus as CLEANING AND REPLACEMENT a Step 1 Turn off gas supply to water heater Rotate knob of gas control gas valve For White Rodgers Control cc 3 4 depress knob slightly and rotate to OFF position clockwise to the OFF position Step 2 Remove outer jacket door Step 3 Remove night sid
29. inlet water supply to water heater Step 3 Draw approximately 4 gallons of water from drain valve into a container or suitable drain 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 water heater to drain Step 4 Using the chart below determine correct resistance value for the water temperature from step 3 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 decreases Sensor Resistance at Various Temperatures In Degrees F F 0 1 2 3 40 26109 25400 24712 24045 50 19906 19383 18876 18383 60 15314 14925 14548 14180 5 6 T 8 9 22 1 22163 21573 21000 20445 17440 16990 16553 16128 15715 13477 13140 12812 12494 12185 70 11884 11592 11308 11032 10502 10248 10000 9760 9526 80 9299 9078 8862 8653 8250 8057 7869 7685 1507 90 1333 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 3 58 3679 3602 3527 3453 3382 3312 3244 3177 3112 130 3048 2986 2925 2866 2808 2152 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 180 117
30. ion Inspection Adjustment Cleaning and Replacement 31 RG VII Resettable Thermal Switch Testing and Replacement 34 RG VIII ScreenLok Flame Arrestor Cleaning 36 RG IV Dip Tube and Anode Inspection and Replacement 37 RG X Generic Parts List 39 INTRODUCTION The Bradford White DEFENDER Safety System The Bradford White DEFENDER Safety System was designed to resist the ignition of flammable vapors that can occur outside of the water heater 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 DEFENDER Safety System How the Safety System Works During normal operation air for combustion 1s drawn into the water heater through the opening in the jacket This air travels down and around the combustion chamber and enters through holes in the very 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 supplied gas and is efficiently combusted producing very low NOx emissions In the c
31. isconnect temperature sensor from control board and remove wire from the temperature sensor wire routing clip sat nang Check jis Temperature sensor wire routing clip Disconnect ae temperature sensor Release lock tab BRADFORD WHITE WATER HEATERS 25 Z The Bradford White eatanc SERVICE PROCEDURE RG VI ICON Gas Control GAFETY SYSTEMI System s Testing Disassembly amp Replacement Honeywell GAS CONTROL DISASSEMBLY REASSEMBLY Step 10 Remove the valve ae yy removing screw located at the lower left corner then unclipping the lower right side from the backplate first followed by the lower left side using a flat head screwdriver CAUTION Use caution not to bend or damage valve body pins Unclip lower right side first Unclip lower left lt gt side second Valve body screw Step 11 Remove temperature sensor and insertion stick from Sa ate by first removing wire from the temperature sensor wire routing clips located on the backplate Note the orientation of insertion stick insertion stick can only be installed in one way 3 Temperature sensor wire routing clips CAUTION When reinstalling temperature sensor and insertion stick make sure the assembly is inserted FULLY into the backplate and the wires are routed through the wire routing clips Failure to do so will not allow valve body t
32. it is fully engaged into pilot bracket 3 Adjust tip of thermocouple to be fully 4 engulfed by pilot flame 4 Check thermocouple and replace if necessary 5 5 Check ECO continuity and replace combination thermostat gas valve if necessary 6 6 Check magnet operation and replace combination thermostat gas valve if necessary 7 Determine cause of switch activation To reset depress button on resettable thermal switch located on inner door See Service Procedure RG II Page 8 See Service Procedure RG V Page 14 See Service Procedure RG V Page 13 thermostat gas valve 2 Check temperature dial setting on combination thermostat gas valve 3 3 Check gas supply and line pressure 4 Check combination thermostat gas valve for proper operation replace if 4 Vi See Installation amp Operation manual See Service Procedure RG V Page 12 See Service Procedure RG V Page 12 wide differential or is out of calibration necessary 1 Insufficient combustion air supply Incorrect clogged vent system vent terminal or location Inconsistent gas supply or gas pressure Not enough hot water Combination thermostat gas valve set too low for desired water temperature Cold inlet water temperature is very cold High demand periods Incorrectly sized water heater for application Combination thermostat gas valve is out of calibration n
33. ition Step2 Remove outer jacket door Step 3 Remove inner door per SER VICE PROCEDURE RG L step 3a through 3e Step 4 Disconnect main burner feed line pilot tube and thermocouple thermopile from combination thermostat gas valve and remove burner assembly from combustion chamber a Feedline Nut Step 5 Clean ScreenLok Flame Arrestor using stiff brush compressed air and or shop vacuum to remove any scale or other debris accumulation Using a soft brush clear jacket openings of any dirt dust restrictions or other obstructions NOTE Feedline nut for natural gas control uses right hand threads LP control uses left hand thread Step 6 Remove any debris from burner assembly per SER VICE PROCEDURE RG V and reinstall burner assembly into combustion chamber Step 7 Reconnect feedline thermocouple and pilot tube to the combination thermostat gas valve Step 8 Reinstall inner door per SER VICE PROCEDURE RG I steps 4 through 13 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 WATER HEATERS The Bradford White FEATURING SERVICE PROCEDURE RG X EDI NVI EHR ICON Dip Tube and Anode SAVAETY SYSTEMI System DE Inspection and Replacement DIP TUBE INSPECTION AND REPLACEMENT A WARNING Heater components and stored water may be HOT when performing the
34. ition For Robertshaw Control rotate knob clockwise to the OFF position Step 2 Remove outer jacket door Step 3 Disconnect wire leads from resettable thermal switch Step 4 Remove resettable thermal switch from inner door Phillips screw driver Step 5 Place new resettable thermal switch in place Be sure contact surface of resettable thermal switch and inner door are free of any debris Secure resettable thermal switch into place using screws from step 4 DO NOT OVER TIGHTEN SCREWS Step 6 Reconnect wire leads from combination thermostat gas valve to resettable thermal switch Note Wire termination are interchangeable with either resettable thermal switch connection Step 7 Replace outer jacket door Step 8 To resume operation follow the instructions located on the lighting instruction label or the lighting instruction located in the installation and operation manual BRADFORD WHITE nn O Th B af d Whit FEATURING ed SAL LAL A ja SERVICE PROCEDURE RG IX 1DE ICON ScreenLok Flame Arrestor Cleaning SAFETY SYSTEM System J ScreenLok Flame Arrestor Cleanin Step 1 Rotate knob of combination thermostat gas valve to the off position For White Rodgers Control depress knob slightly and rotate clockwise to the OFF position For Honeywell Control rotate knob counter clockwise to the OFF position For Robertshaw Control rotate knob clockwise to the OFF pos
35. lange with hex drive screws N Verify threaded hole alignment with slotted openings in inner door na i Step 10 Reconnect 2 red wire leads from pilot assembly and Gas Control to resettable thermal switch Note wire terminations are interchangeable with either resettable thermal switch connection Step 11 Replace outer jacket burner access door Ac AUTION Use back up wrench on wrench boss Step 12 Reconnect gas supply to Gas Control of Gas Control never use back up wrench on body of Gas Control Step 13 Resume water supply to water heater Be sure tank is full of water before resuming operation Step 14 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual The Bradford White eatuanc SERVICE PROCEDURE RG VII IDE ESTING elke ICON Burner Operation Inspection Adjustment GAFETY SYSTEM System Cleaning and Replacement MAIN BURNER Inspection Adjustment Cleaning and Replacement At periodic intervals not more then 6 months a visual inspection should be made of the main burner for proper operation and to insure no debris accumulating Main burner should light smoothly from pilot and burn with a blue flame with a minimum of yellow tips Steel burner models have a self adjusting air mixture and do not have an adjustable air shutter Cast
36. n burner orifice to achieve proper burner operation If cleaning is required proceed to burner cleaning section in this procedure BURNER CLEANING Steel amp Cast Iron Step 1 Step 2 Step 3 Step 4 Remove inner door assembly per SER VICE PROCEDURE RG I steps 1 through 3c Disconnect main burner feed line pilot tube and thermocouple thermopile from combination thermostat gas valve and remove burner assembly from combustion chamber NOTE Feedline nut for natural gas control uses right hand threads LP control uses left hand thread Thoroughly inspect burner surface area and burner ports and remove any loose debris accumulation Burner Surface Area Burner Port Area On cast iron burners inspect for any debris build up inside burner venturi If found disconnect feedline from burner and remove debris build up Burner Venturi Opening Feedline i WATER HEATERS The Bradford White FEATURING SERVICE PROCEDURE RG VII W Fes easy Fes ICON Burner Operation Inspection Adjustment SGARary SYSTEM System Cleaning and Replacement BURNER CLEANING Cont ar _ Step 5 Disconnect unscrew Main burner steel from main burner orifice or on cast iron burners C burner loosen air shutter amp disconnect unscrew feedline from burner i Step 6 Remove main burner orifice from feed line Inspect and clean if necessary O WE yy
37. n the installation and operation manual BRADFORD WHITE ee ee eee eee ee eee eee O i a The Bradford White ceatuanc SERVICE PROCEDURE RG VI DD Fes eaves ING Pelee ICON Gas Control GAFETY SYSTEMI System Testing Disassembly amp Replacement Honeywell Honeywell Gas Control Testing Disassembly and Replacement The Gas Control is made up of 5 major components the control cover the piezo igniter the valve body the temperature sensor and the back plate The Gas Control 1s designed so that any of these components may be replaced without replacing the entire Gas Control f Valve Body papate Gas Control Cover AN Gas Control Cover Screw ae Temperature Sensor Piezo Igniter Valve Body y Insertion Stick Screw s 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 WATER HEATERS The Bradford White eatanc SERVICE PROCEDURE RG VI 7 PR ICON Gas Control C Testing Disassembly amp Replacement Honeywell E MANIFOLD PRESSURE TESTING this procedure presumes a maximum line pressure of 14 0 w c Step 1 Set the Gas Control to the
38. nge Area of Inner Door Step 4 Fully inspect inner door gaskets for the following gt Tears gt Other imperfections that will inhibit proper seal gt Missing Material gt Gasket adhesion to inner door gt Cracks gt Material left on combustion chamber around opening gt Di rt 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 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 right 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 amp 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 over lap position 7 The Bradford White cearainc DE EIN TOE TR SAVAETY SYSTEMI A a RECOMMENDED PATTERN FOR RTV SEALANT BRADFORD WHITE ICON System WRARD PLACE FLANGE SECTIONS FIRST EXPANDED VIEW Installation of Inner Door With Gasket
39. nge wire disconnected from piezo igniter Using a common screw driver place blade of screw driver under piezo bracket and gently pry bracket from front of gas valve and unhook bracket from rear of gas valve Common Screw Driver Step 4b For Honeywell gas controls To replace igniter see Gas Control Disassembly Reassembly in SERVICE PROCEDURE RG VI 14 BRADFORD WHITE The Bradford White reaturinc 7 SERVICE PROCEDURE RG V Nil ll JHR ICON Gas Valve GAREY SYSTEM ON Tetine and Replacement White poder ROD Gas Valve Testing and Replacement White Rodgers Robertshaw The gas valve is a non repairable device If trouble shooting has determined a problem with the gas valve it must be replaced If the burner and or pilot do not function service checks for gas pressure thermocouple output magnet assembly and ECO are to be performed If these check OK the gas valve may be faulty LINE PRESSURE The gas valve 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 rated manifold pressure check rating plate Line pressure must be checked with burner on and burner off to assure proper readings MANIFOLD PRESSURE TESTING this procedure assumes a maximum line pressure of 14 0 w c Step 1 Set gas valve to OFF position Step2 Remove pressure tap plug and install pressure tap Step 3 Connect manomet
40. o i be reinstalled properly and may damage temperature e Insertion stick fully l sensor wires inserted into backplat 20 M BRADFORD WHITE WATER HEATERS b The Bradford White caturne SERVICE PROCEDURE RG VI PR Ico SAN Gas Control E Syste C Testing Disassembly amp Replacement Honeywell p GAS CONTROL DISASSEMBLY REASSEMBLY Step 12 Remove temperature sensor from insertion stick by pulling apart as illustrated below Pull in this direction Temperature sensar Insertion stick Step 13 To reassemble Gas Control follow the previous steps in reverse order Once Gas Control is reassembled burner ae is reinstalled and the gas supply line is reconnected resume water supply to water heater Be sure tank is full of water before relighting Step 14 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual Pull in this direction a BRADFORD WHITE WATER HEATERS BRADFORD WHITE ICON Gas Control f J The Bradford White eatanc SERVICE PROCEDURE RG VI Testing Disassembly amp Replacement Honeywell GAS CONTROL REPLACEMENT Rotate knob counter clockwise to the OFF position Step 1 Rotate knob of the Gas Control to the OFF position Step 2 Turn off gas supply to water heater Ste
41. ot functioning Out of spec dip tube is diluting hot water with cold water 3 Check gas supply and line pressure N Verify adequate combustion air is E to the unit Check and clear Jacket slot openings of any dirt dust restrictions or other obstructions Inspect flame arrestor plate and clean with stiff bristled brush and or vacuum to remove any debris accumulation 2 Check venting for proper sizing and proper See Service Procedure RG VIII Page 22 See Service Procedure RG V Page 12 operation 1 Check dial on combination thermostat gas valve 2 Extremely cold water going into the heater will decrease the amount of hot water produced It may be necessary to temper incoming water supply 3 Adjust high demand usage 4 Contact Plumbing professional 5 Check combination thermostat gas valve for proper operation replace if necessary Inspect dip tube and replace if necessary A 5 6 See Service Procedure RG V Page 12 See Service Procedure RG IX Page 23 4 ee BRADFORD WHITE WATER Honeywell Gas Control Troubleshooting Chart Flammable Vapor Ignition Resistant Water Heaters Observe green LED indicator on Gas Control Error flash codes are displayed with a three second pause before repeating Check and repair the system as noted in the troubleshooting table below Green LED Indicator j A gt LED Status
42. p 3 Disconnect gas supply line from Gas Control Step 4 Turn off water supply and drain water heater completely Step 5 Remove outer jacket burner access door Step 6 Right side inner door removal a Disconnect red wire leads from resettable thermal switch b Remove 2 hex drive screws from RIGHT side inner door c Remove 2 hex drive screws from FLANGE SECTION of inner door d Remove right side inner door and set aside Be careful not to damage gasket material on inner door Remove t Wire Tie Hex Drive Screws at Flange Area of Inner Door Resettable Thermal Switch Wire Connection Hex Drive Screws Right and Left Side Inner Door Step 7 Removal of Gas Control a Disconnect main burner feedline pilot tube piezo igniter wire inner door wire red and thermopile wire white from Gas Control b Remove 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 1 2 NPT pipe threaded into gas inlet of Gas Control Step 8 Install new Gas Control into water heater a 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 1 2 NPT pipe threaded into gas inlet of Gas Control 28 M BRADFORD WHITE The Bradford White FEATURING SERVICE PROCED
43. p 5 Following the lighting instruction label on the heater proceed to light the pilot and allow to operate for three minuets Ifthe pilot will not stay lit hold the red reset button located on the combination thermostat gas valve down during this test Step 6 If meter reads 13 millivolts or higher the thermocouple is OK If reading is below 13 millivolts replace the thermocouple 10 BRADFORD WHITE The Bradford White creature SERVICE PROCEDURE RG II IDEAE OER ICON Thermocouple Thermopile Testing and SAFETY SYSTEM System Replacement OPEN CIRCUIT THERMOCOUPLE TESTING White Rodgers Robertshaw Gas Valve Step 1 Disconnect thermocouple from combination thermostat gas valve Step 2 Using a multimeter capable of measuring millivolts connect one alligator clip to the end ball or contact portion of the thermocouple and the other alligator clip to copper portion of the thermocouple 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 the pilot button down continuously throughout this test A reading of 20 to 30 millivolts indicates good thermocouple output THERMOCOUPLE REPLACEMENT White Rodgers Robertshaw Gas Valve Step 1 Turn off gas supply to water heater Rotate knob of combination thermostat gas valve to OFF position For Robertshaw Control rotate knob clockwise to th
44. rap Gas Valve DENENOER I CON Testing and Replacement White ogee RODET Naw THERMOCOUPLE TESTING See SERVICE PROCEDURE RG II MAGNET ASSEMBLY TESTING White Rodgers Control Step 1 Step 2 Step 6 Step 7 MAGNET ASSEMBLY TESTING Robertshaw Control Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Following the lighting instruction label on the heater proceed to light the pilot and allow to operate for __ three minuets If the pilot will not stay lit hold the pilot button located on the gas valve down during this test Using a multimeter capable of measuring millivolts connect one lead l using an alligator clip to the copper sheath of the thermocouple use the second lead of the multi meter to probe the top terminal located at the back of the gas valve Probe top terminal on back of combination thermostat gas valve Alligator clip to copper sheath of thermocouple With a meter reading of 13 millivolts or greater rotate knob of combination thermostat gas valve to the OFF position The magnet should remain closed for a drop of at least 6 millivolts You will here a snap or click sound when the magnet opens if you hear this sound prior to a drop of 6 millivolts the magnet is out of specification and the gas valve should be replaced Disconnect thermocouple from gas valve Connect a thermocouple adaptor WC P N 239 44642 00 Robertshaw P N 75036 at the th
45. readed sides of the opening Step 3 If continuity is indicated the ECO is OK If continuity is not indicated the ECO has opened and the gas valve must be replaced COMBINATION THERMOSTAT GAS VALVE REPLACEMENT Step 1 Rotate Step 2 Turn off gas supply to water heater Step 3 Disconnect gas supply line from gas valve Step 4 Turn off water supply and drain water heater completely knob clockwise to the OFF Step 5 Remove outer jacket burner access door For White Rodgers Control E depress knob slightly and rotate knob of the gas valve to the OFF position clockwise to the OFF position For Robertshaw Control rotate position Step 6 Right side inner door removal amp BRADFORD WHITE WATER HEAT a Disconnect resettable thermal switch wire leads leading from gas valve and remove wire tie from feedline b Remove 2 hex drive screws from night side inner door c Remove 2 hex drive screws from flange section of inner door d Remove right side inner door and set aside Be careful not to damage gasket material on inner door Remove Wire Tie Resettable Thermal Switch Wire Connection Hex Drive Screws shown on p Right Side Inner Door Hex Drive Screws at Flange section of Inner Door 17 ERS a N The Bradford White catuanc SERVICE PROCEDURE RG V DENIER ICON Bu vane IN ite 7 E I Co i om Testing and Replac
46. s LP control uses left hand thread d Gather wire leads of gas valve and Piezo igniter and secure along side of feedline using new wire tie provided e Connect gas supply piping to inlet of control Use back up wrench on wrench boss of control never use back up wrench on body of control Step 9 Reinstallation of inner door assembly a Prior to reinstallation of inner door fully inspect inner door gasket for the following gt Tears gt Gasket Adhesion to inner door gt Missing Material gt Other imperfections that will inhibit proper seal gt Cracks gt Material left on combustion chamber gt Dirt or debris If the gasket is not effected by any of the above gasket replacement will not be required If replacement is required replace using new gasket kit following the instructions provided with kit Ia xzx EEE BRADFORD WHITE The Bradford White carne 7 SERVICE PROCEDURE RG V ID rer OER ICON Gas Valve GARETY SYSTEM System Tetine and Replacement White poder ROD Step 9 Reinstallation of inner door assembly cont b Clean any gasket residue or other debris from combustion chamber surface before installing the inner door gasket assembly c Position thermocouple pilot tube and Piezo wire against left side inner door flange gasket DO NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE Be sure that thermocouple and pilot tube are not in position to interfere with outer
47. t signal detected System 2 Unstable pilot ocedire PEJII three second will reset when pilot flame is 3 Pilot tube block or restricted 3 a Ne ause sufficient 4 Resettable thermal switch has p procedure RG II opened l 4 See service 1 Four flashes and three second pause Excessive tank temperature System must be reset Temperature sensor out of calibration 2 Faulty Gas Control See service procedure RG VI 2 See service procedure RG VI E BRADFORD WHITE ee HEATERS 5 Honeywell Gas Control Troubleshooting Chart Flammable Vapor Ignition Resistant Water Heaters Observe green LED indicator on Gas Control Error flash codes are displayed with a three second pause before repeating Check and repair the system as noted in the troubleshooting table below Green LED Indicator a y y y Service gt LED Status Control Status Probable Cause aan S A A A Procedure J Five flashes and 1 Damage to the temperature mp sensor See service three second Themnostatwek sensor tauk 2 Temperature sensor resistance procedure RG VI pause out of range 1 Check T amp P valve Six flashes and _ 2 Check all water Iree csecond Water leak detected by accessory Excessive amount of water in drain fittings module pan water dam m pause 3 Pressurize and leak test tank Seven
48. tep 13 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual BRADFORD WHITE nS The Bradford White taure SERVICE PROCEDURE RG IV i N DHR ICON Piezo Igniter Electrode Testing GAPETY SYSTEM System and Replacement p PIEZO IGNITER ELECTRODE TESTING AND REPLACEMENT With the pilot not in operation no pilot flame you can check the Piezo and electrode circuit by viewing pilot thru the sight glass located on the inner door and observing the spark action Step 1 Remove outer jacket door Step2 Repeatedly depress the Piezo igniter 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 E View spark Action through Repeatedly Sight glass Depress Piezo Igniter Step 3 Remove orange or white wire from Piezo igniter and install a jumper wire in its place Hold the other end of the jumper by the wire insulation or using an insulated tool next to an unpainted surface such as the feedline or gas valve and depress the Piezo igniter If there is a spark the igniter is OK the pilot is not functioning and must be replaced see SER VICE PROCEDURE RG III for pilot replacement If no spark is present the igniter is not functioning and must be replaced Step 4a For White Rodgers Robertshaw gas valves With ora
49. y Pilot Orifice Thermocouple Thermopile Complete SX Burner Assembly LP SX Burner Only Main Burner Orifice Pilot Assembly Pilot Orifice Thermocouple Thermopile ASSE Approved Mixing Valve Optional 34 NPT Tank Plug XR Models Inner Door Gasket Kit Wire Tie Heat Trap Outlet Heat Trap Inlet Heat Trap Kit BRADFORD WHITE eee errr eee eee reer O

Service Manual 44943-00D - Bradford White Replacement Parts

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