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SERVICE MANUAL

1. 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 S ey BRADFORD WHITE Cc O R P O RATION 10 SERVICE PROCEDURE RG III Pilot Assembly Inspection Cleaning and Replacement PILOT ELECTRODE ASSEMBLY INSPECTION CLEANING AND REPLACEMENT 11 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 For White Rodgers Control depress knob slightly and rotate clockwise to the OFF position Turn off gas supply to water heater Rotate knob of combination thermostat gas valve to OFF position For Robertshaw Control rotate knob clockwise to the OFF Remove outer jacket door position Remove right side of inner door per SERVICE PROCEDURE RG I steps 3a through 3c Disconnect thermocouple 3 8 wrench pilot tube 7 16 wrench and feedline 4 wench from combination thermostat gas valve NOTE Feedline nut for natural gas control uses right hand threads LP control uses left hand thread ve l Feedline eat Disconnect piezo ignition wire from piezo igniter Remove burner assembly from combustion chamber Remove pilot electrode assembly from feedline 1 4 drive tool Inspect pilot for the following a Primary air openings for blockage Must be free from any debris
2. For Robertshaw Control rotate knob clockwise to the OFF Step 2 Remove outer jacket burner access door position Step 3 Inner Door Removal Vd tp Ap d p gt is MAS a NE ae a Disconnect resettable thermal switch wire leads leading from combination thermostat gas valve b Remove 2 1 4 hex drive screws from right side inner door c Remove 2 1 4 drive screws from flange section of mner door d Remove 2 1 4 drive screws from left side inner door e Remove inner door and inspect per step 4 Resettable Thermal Switch Wire Connection PO ee T S 3 14 Hex Drive Screws PS Er Right and Left Side Inner Door ER Ys Hex Drive Screws at Flange 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 Dirt or debris If the gasket is not effected by any of the above gasket replacement is not required If replacement 1s 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 remov
3. Combination thermostat gas valve is out 4 Contact Plumbing professional Shr gaa cous of calibration not functioning 5 Check combination thermostat gas valve Fag 6 Out of spec dip tube is diluting hot water for proper operation replace if with cold water necessary 6 Inspect dip tube and replace if necessary ca BRADFORD WHITE lt gt lt 2 lt gt SERVICE PROCEDURE 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 N 4 See Service Procedure RG II Page 8 See Service Procedure RG V Page 14 See Service Procedure RG V Page 13 See Installation amp operation manual See Service Procedure RG V Page 12 See Service Procedure RG V Page 12 Verify adequate combustion air is available See Service Procedure RG VIII Page 22 See Service Procedure RG V Page 12 C O R P O R AT ION SERVICE PROCEDURE RG I Inner Door Gasket Removal Inspection Replacement and Reinstallation ar LFF SLs rm P F z SAVY SYSTEM i oe li Melis Uo ie cel For White Rodgers Control depress knob slightly and rotate Inner Door Removal Procedure clockwise to the OFF position Step 1 Rotate knob of the combination thermostat gas valve to the OFF position
4. 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 Step 3 Disconnect inlet nipple from plumbing system Step 4 With an appropriate wrench remove inlet nipple dip tube from the water heater Use caution not to damage pipe threads Step 5 Visually Inspect inlet nipple dip tube Inlet nipple dip tube should be free of cracks and any blockage Hydro jets located near the bottom of the dip tube should be open and free of any blockage Anti siphon hole located approximately 6 from the bottom of nipple should be free of any blockage Any damage such as cracks restriction due to deformation or unintentional holes are not field repairable and the inlet nipple dip tube must be replaced Step 6 Upon completion of inspection or subsequent replacement reinstall inlet nipple dip tube into heater Connect nipple to plumbing system resume water supply and refill heater with water Step 7 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual S ey BRADFORD WHITE Cc O R P O RATION 24 SERVICE PROCEDURE RG IX Dip Tube and Anode Inspection and Replacement ANODE INSPECTION AND REPLACEMENT A WARNING Heater components and stored water
5. SERVICE PROCEDURE RG V 17 eo Noe eh Combination Thermostat Gas Valve Testing SAFETY SYSTEM and Replacement ECO Energy Cut Off TESTING Step 1 Disconnect thermocouple from combination thermostat 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 threaded 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 combination thermostat gas valve must be replaced COMBINATION THERMOSTAT GAS VALVE REPLACEMENT For White Rodgers Control Step 1 Rotate knob of the combination thermostat gas valve depress knob slightly and rotate 4 99 to the OFF position clockwise to the OFF position Step 2 Turn off gas supply to water heater Step 3 Disconnect gas supply line from combination thermostat gas valve For Robertshaw Control rotate knob clockwise to the OFF Step 4 Turn off water supply and drain water heater completely position Step 5 Remove outer jacket burner access door Step 6 Right side inner door removal a Disconnect resettable thermal switch wire leads leading from combination thermostat gas valve and remove wire tie from feedline
6. 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 S a BRADFORD WHITE cCc O R P O R A T IO N 22 SERVICE PROCEDURE RG VIII screenLok Flame Arrestor Cleaning 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 Robertshaw Control rotate knob clockwise to the OFF position Step2 Remove outer jacket door Step 3 Remove inner door per SERVICE PROCEDURE RG L step 3a through 3e Step 4 Disconnect main burner feed line 4 wrench pilot tube 7 16 wrench and thermocouple 3 8 wrench from combination thermostat gas valve and remove burner assembly from combustion chamber NOTE F
7. b Remove 2 1 4 hex drive screws from right side mner door c Remove 2 1 4 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 a Hex Drive Screws shown on Right Side Inner Door s Hex Drive Screws at Flange section of Inner Door 3 BRADFORD WHITE C O R P O R AT ION 15 SERVICE PROCEDURE RG V Combination Thermostat Gas Valve Testing and Replacement Step 7 Step 8 Step 9 ary BRADFORD WHITE C O R Removal of combination thermostat gas valve a Disconnect main burner feedline wrench pilot tube 7 16 wrench and thermocouple 3 8 wrench from combination thermostat 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 Combination Thermostat Gas Valve c Remove Combination Thermostat Gas Valve from heater rotating counter clockwise using a control body wrench or a length of 2 NPT pipe threaded into inlet of control Wrench Boss a k To remove or install control insert only NPT threaded pipe into inlet gt a use to loosen or tighten Ono Installa
8. 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 off the bu
9. copper sheath of thermocouple CLOSED CIRCUIT THERMOCOUPLE TESTING Robertshaw Control Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Disconnect thermocouple from combination thermostat gas valve Connect a thermocouple adaptor BWC P N 239 44642 00 Robertshaw P N 75036 at the thermocouple location in the combination thermostat gas valve Reconnect thermocouple to adaptor Make certain all connections are tight finger tight plus 1 4 turn 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 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 If meter reads 13 millivolts or higher the thermocouple is OK If reading is below 13 millivolts replace the thermocouple BRADFORD WHITE C O R P O R AT ION SERVICE PROCEDURE RG II Thermocouple Testing and Replacement OPEN CIRCUIT THERMOCOUPLE TESTING 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 thermocoupl
10. dirt lint etc b Kinks or cracks in the pilot tube If found Primary Air the pilot must be replaced Opening Inspect pilot orifice a Remove 2 nut from bottom of pilot assembly b Remove pilot tube and pilot orifice Pit Orifice Re Install burner assembly into combustion chamber connect feedline pilot tube and thermocouple to combination thermostat gas valve c mspect pilot orifice for blockage must be cleaned or replaced Install pilot electrode assembly to feedline secure with screw from step 7 Install inner door per SERVICE PROCEDURE RG I step 4 through 13 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual 3 BRADFORD WHITE C O R P O R AT ION SERVICE PROCEDURE RG IV Piezo Igniter Electrode Testing and Replacement 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 Step 2 Repeatedly depress the Piezo igniter while viewing the pilot thru the sight glass If a spark is present the circuit 1s OK If there is no spark proceed to step 3 View spark Action through Repeatedly Sight glass Depress Piezo Igniter Step 3 Remove orange wir
11. 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 1s out of specification and the combination thermostat gas valve should be replaced Disconnect thermocouple from combination thermostat gas valve Connect a thermocouple adaptor BWC P N 239 44642 00 Robertshaw P N RN at the thermocouple location in the combination thermostat gas valve Reconnect thermocouple to adaptor Make certain all connections are tight finger tight plus 1 4 turn 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 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 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 aai of 6 millivolts the magnet 1s out o specification and the combination thermostat gas valve should be replaced S ey BRADFORD WHITE 14 Cc O R P O RATION
12. this procedure BURNER CLEANING Steel amp Cast Iron Step 1 Remove inner door assembly per SERVICE PROCEDURE RG LI steps 1 through 3c Step2 Disconnect main burner feed line 4 wrench pilot tube 7 16 wrench and thermocouple 3 8 wrench 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 Step 3 Thoroughly inspect burner surface area and burner ports and remove any loose debris accumulation Burner Surface Area Burner Port Area Step 4 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 BRADFORD WHITE C O R P O R AT ION 19 SERVICE PROCEDURE RG VI Burner Operation Inspection Adjustment Cleaning and Replacement BURNER CLEANING Cont Step 5 Disconnect unscrew Main burner stamped steel B burner from main cg Bos burner orifice or on cast iron burners C burner loosen air shutter amp Ta disconnect unscrew feedline from burner Step 6 Remove main burner orifice from feed line 2 wrench on steel 7 burner 3 8 wrench on cast iron Inspect and clean if necessary NS Q Step 7 Remove pilot assembly refer to SERVICE PROCEDURE RG III for cleaning and insp
13. II Dip Tube and Anode Inspection and Replacement 23 RG IX Generic Parts List 25 S S BRADFORD WHITE C O R P O R AT ION 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 1s efficiently combusted producing very low NOx emissions In the case where trace amounts of flammable vapors are present in the air flowing into the combustion chamber the vapors
14. NOT OVER TIGHTEN SCREWS Verify both left and right sides of the mner door are properly positioned and sealed against the combustion chamber secure flange with Ys drive screws a j N Verify threaded hole alignment with slotted openings in inner door k P Step 10 Reconnect wire leads from combination thermostat 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 Combination Thermostat 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 in the installation and operation manual BRADFORD WHITE C O R P O R AT ION 17 SERVICE PROCEDURE RG VI Burner Operation Inspection Adjustment 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 iron
15. 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 C BRADFORD WHITE cCc O R P O R A T IO N CS ia Es re i Ww tan ASI ar fo Meu LS L La E HASE TROUBLESHOOTING CHART Flammable Vapor Ignition Resistant Water Heaters gt 1 SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION Pilot Will Not Light 1 No incoming gas or too low gas pressure 2 Gas control knob set to wrong position 3 Pilot light button not being fully depressed when attempting to light pilot 4 Pilot orifice or pilot tube is obstructed or kinked 5 Pilot electrode not sparking to pilot 6 Piezo igniter not functioning 1 Turn on gas supply and or check line pressure 2 Review lighting instruction Set combination thermostat gas valve to correct position 3 Review lighting instruction Fully depress pilot lighting button 4 Clea
16. e 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 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 the 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 3 8 wrench 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 SERVICE PROCEDURE RG I Step 4 Thermocouple position Step 7 Install right side inner door per SERVICE PROCEDURE RG I Step 10 through Step 13
17. e 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 1s OK the pilot is not functioning and must be replaced see SERVICE PROCEDURE RG III for pilot replacement If no spark is present the igniter is not functioning and must be replaced Step 4 With orange 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 combination thermostat gas valve and unhook bracket from rear of combination thermostat gas valve Common Screw Driver S ey BRADFORD WHITE Cc O R P O RATION 12 SERVICE PROCEDURE RG V Combination Thermostat Gas Valve Testing and Replacement oe 4 fSssav SVS A A ts Mee l SrA As uy ps j f L j VA Combination Thermostat Gas Valve Testing and Replacement The combination thermostat gas valve is a non repairable device If trouble shooting has determined a problem with the combination thermostat 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 combination thermostat gas valve may be faulty LINE PRESSURE The combination thermo
18. e 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 S ey BRADFORD WHITE Cc O R P O RATION an aril Ve Cele SAFETY SYSTEM aD RECOMMENDED PATTERN FOR RTV SEALANT S D L 7 pe BGH be SY f el PLACE FLANGE SECTIONS FIRST EXPANDED VIEW Installation of Inner Door With Gasket 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 1 4 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 Radiused Channel for Feedline 3l GASKET OVERLAP MUST BE AS SHOW 1 32 SERVICE PROCEDURE RG I Inner Do
19. ead 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 Cc O R P O RATION SERVICE PROCEDURE RG II Thermocouple Testing and Replacement STAT je S ARETY SYSI TEV CLOSED CIRCUIT THERMOCOUPLE TESTING White Rodgers Control Step 1 Step 2 Step 3 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 Ifthe pilot will not stay lit hold the pilot button located on the combination thermostat gas valve down during this test 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 If meter 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 i thermostat gas valve Alligator clip to
20. ebris 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 S amp S 16 P O R A T I O N SERVICE PROCEDURE RG V ot pe Cyt Nee be Combination Thermostat Gas Valve Testing SAFETY SYSTEM and Replacement 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 jacket burner access door when reinstalled WARNING A seal breach may result in a fire or explosion causing property damage personal injury or death 3 N Position eee pilot tube and Piezo wire d Firmly place right side inner door flange against the left side inner door flange and secure with two 1 2 hex drive screws from step 6 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 1 4 hex drive screws from step 6b DO
21. ection 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 1n the installation and operation manual S ey BRADFORD WHITE Cc O R P O RATION 20 SERVICE PROCEDURE RG VII LETAN PO Ca Resetting Thermal Switch SAFETY SYSTEM Testing and Replacement 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 open at predetermined temperatures depending on model An open switch can be reset by depressing the red colo
22. eedline nut for natural gas control uses right hand threads LP control uses left hand thread 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 Step 6 Remove any debris from burner assembly per SERVICE 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 SERVICE 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 3 BRADFORD WHITE C O R P O R AT ION 23 SERVICE PROCEDURE RG IX Dip Tube and Anode Inspection and Replacement DIP TUBE INSPECTION AND REPLACEMENT A WARNING 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 Rotate knob of combination thermostat gas valve to OFF position For White Rodgers Control depress knob slightly and rotate clockwise to the OFF position ss For Robertshaw Control rotate knob clockwise to the OFF position Step 2 Turn off cold water supply to heater
23. elefax 215 641 9750 wa BRADFORD WHITE CANADA INC Mississauga ON Sales Technical Support 866 690 0961 905 238 0100 Fax 905 238 0105 Email parts bradfordwhite com techserv bradfordwhite com www bradfordwhite com www bradfordwhitecanada com
24. gulator 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 combination thermostat 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 3 BRADFORD WHITE C O R P O R AT ION 13 SERVICE PROCEDURE RG V Combination Thermostat Gas Valve Testing and Replacement 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 hehting 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 Using a multimeter a ath 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 combination thermostat gas valve Probe top terminal on back of combination j thermostat gas valve Alligator clip to copper sheath of thermocouple With a meter reading of 13 millivolts or
25. hermostat gas valve set too 1 Adjust temperature dial on combination thermostat gas valve 2 Check temperature dial setting on combination thermostat gas valve 3 Check gas supply and line pressure 4 Check combination thermostat gas valve for proper operation replace if necessary lt gt Pilot goes out periodically after heating cycles once a day once a week etc 1 Insufficient combustion air supply 2 Incorrect clogged vent system vent terminal or location 3 Inconsistent gas supply or gas pressure wide differential or is out of calibration 1 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 operation 1 Combination thermostat gas valve set too low for desired water temperature 2 Cold inlet water temperature is very cold 3 Check gas supply and line pressure 1 Check dial on combination thermostat gas valve 2 Extremely cold water going into the heater will decrease the amount of hot water 5 See Service Procedure 3 High demand periods produced It may be necessary to temper RG V Page 12 Not enough hot 4 Incorrectly sized water heater for incoming water supply rag water application 3 Adjust high demand usage 5
26. http waterheatertimer org How to install gas water heater html troubleshoot The tbh ch a SAFETY Si vS TIRI Flammable Vapor Ignition Resistant Water Heater SERVICE MANUAL Troubleshooting Guide and Instruction for Service To be performed ONLY by qualified service providers For the Bradford White Defender Safety System Models MI30T F BN CX M430T F BN CX MI30S F BN CX M440T F BN CX MI303T F BN CX M4403S F BN CX MI40T F BN CX M4403T F BN CX MI403S F BN CX M450S F BN CX MI404T F BN CX M4503 F BN CX MI503 F BN CX M460T F BN CX MI50L F BN CX M1XR403S F BN CX MI504S F BN CX M1XR504T F BN CX MI60T F BN CX M2XR504T F BN CX M2C504T F BN CX 50T65F BN CX Denotes Warranty Years Save this manual for future reference Manual 44943C S BRADFORD WHITE O R P O R AT ION FLAMMABLE VAPOR IGNITION RESISTANT WATER HEATERS Table of Contents Page Service Procedure Introduction 3 ee Trouble shooting Chart 4 Inner Door Gasket Removal Inspection Replacement and Installation 5 RG I Thermocouple Testing and Replacement 8 RG II Pilot Assembly Inspection Cleaning and Replacement 10 RG III Piezo Igniter and Electrode Testing 11 RG IV Combination Thermostat Gas Valve Testing and Replacement 12 RG V Burner Operation Inspection Adjustment Cleaning and Replacement 17 RG VI Resettable Thermal Switch Testing and Replacement 20 RG VII ScreenLok Flame Arrestor Cleaning 22 RG VI
27. may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Step 1 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 Robertshaw Control rotate knob clockwise to the OFF position Step 2 Turn off cold water supply to heater Connect hose to drain spigot of water heater and route to an open drain Open a nearby hot water faucet to vent heater for draining Open drain spigot of hot water heater and allow heater to drain to a point below the outlet connection nipple Step 3 Disconnect outlet nipple from plumbing system Step 4 With an appropriate wrench remove outlet nipple anode from the water heater Use caution not to damage pipe threads Step 5 Visually Inspect outlet nipple anode Outlet nipple anode should show signs of depletion this is normal If depletion is 1 2 of the original anode diameter approximately 3 4 diameter replacement is recommended If any of the steel core of the anode 1s exposed replacement 1s recommended Step 6 Upon completion of inspection or subsequent replacement reinstall outlet nipple anode into heater Connect nipple to plumbing system resume water supply and refill heater with water Step 7 To resume operation follow the instructions located on the lighting in
28. n repair or replace 5 Verify correct electrode position Replace pilot assembly 6 Replace Piezo igniter Pilot Will Not stay lit when button is released 1 Poor thermocouple connection at combination thermostat gas valve 2 Thermocouple not fully engaged in pilot assembly bracket 3 Pilot flame is not fully enveloping the thermocouple hot junction 4 Weak or defective thermocouple 5 Open ECO on combination thermostat gas valve 6 Defective magnet in combination thermostat gas valve 7 Resettable thermal switch has opened Check connection at combination thermostat gas valve Proper tightness should be finger tight plus turn 2 Inspect thermocouple to ensure that it is fully engaged into pilot bracket 3 Adjust tip of thermocouple to be fully engulfed by pilot flame 4 Check thermocouple and replace if necessary 5 Check ECO continuity and replace combination thermostat gas valve if necessary 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 Pilot will light but the main burner will not come on Vi low for desired water temperature 2 Combination thermostat gas valve temperature is satisfied 3 Insufficient gas supply or low gas pressure 4 Combination thermostat gas valve has Combination t
29. or Gasket Removal Inspection Replacement and Reinstallation 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 BRADFORD WHITE C O R P O R AT ION SERVICE PROCEDURE RG I Inner Door Gasket Removal Inspection Replacement and Reinstallation Step 10 Firmly place right side inner door flange against the left side inner door flange and secure with two 1 2 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 1 4 hex drive screws from step 3b 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 yy 14 drive screws 3 Verify threaded hole alignment with slotted openings in inner door Step 12 Reconnect l
30. red 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 ir padane erence l 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 5 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 Eo BRADFORD WHITE C O R P O R AT ION 21 SERVICE PROCEDURE RG VII Resetting 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 Robertshaw Control rotate knob clockwise to the OFF position Step2 Remove outer jacket door Step 3 Disconnect wire leads from resettable thermal switch
31. rner 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 Air Shutter Nut MISOT6FCX MISOSTEFCX ALL 30S 40S 407T 503 504 50S FCX MODELS S exam BRADFORD WHITE Cc O R P O RATION 18 SERVICE PROCEDURE RG VI izi ats LNS Burner Operation Inspection Adjustment SAFETY SYSTEM Cleaning and Replacement MAIN BURNER Inspection Adjustment Cleaning and Replacement cont Step 3 Fully inspect inner gasket per SERVICE PROCEDURE RG I step 4 Replace gasket if required following SERVICE PROCEDURE I steps 5 amp 6 Step 4 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 pilot tube and Piezo wire Step 5 Observe burner operation through sight glass of inner door Burner should operate as adjusted in step 2 if not repeat procedure compensating air shutter position for proper burner operation with inner door in place Step 6 It may be necessary to clean main burner or main burner orifice to achieve proper burner operation If cleaning is required proceed to burner cleaning section in
32. stat 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 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 combination thermostat gas valve to OFF position Step 2 Remove pressure tap plug 3 16 Allen wrench and install pressure tap 7 16 wrench Step 3 Connect manometer to pressure tap Step 4 Follow lighting instructions and proceed to light Pressure Tap X main burner and observe manometer reading Shown Installed 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 combination thermostat 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 is 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 1s adjustable proceed to step 9 for adjustment procedure Step 9 While burner is in operation remove regulator access cap to expose the re
33. struction label or the lighting instructions located in the installation and operation manual S ay BRADFORD WHITE C O R P O R AT ION 29 A oS ala Cy y SAFETY SYSTEM w es e a OCONDTBWN S amp S ary BRADFORD WHITE Cc O R P O RATION Draft Hood Hot Water Outlet Anode Cold Water Inlet Tube Flue Baffle T amp P Relief Valve Thermostat Piezo Igniter 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 Screw 6 20 x 3 8 PHCR Outer Door Complete BN Burner Assembly BN Burner Only Main Burner Orifice PARTS LIST Pilot Assembly Pilot Orifice Thermocouple Feed Line Complete Cast Iron Burner Assembly Cast Iron Burner Only Main Burner Orifice Pilot Assembly Pilot Orifice Air Shutter Air Shutter Nut Thermocouple Feed Line ASSE Approved Mixing Valve Optional Y NPT Tank Plug XR models Inner Door Gasket Kit Wire Tie 26 NOTES NOTES BRADFORD WHITE C O R POR AT I Ambler PA For U S and Canada field service contact your professional installer or local Bradford White sales representative Sales 800 523 2931 Fax 215 641 1670 Application amp Sizing 800 523 2931 Fax 215 641 1612 Technical Support 800 334 3393 Fax 269 795 1089 Warranty 800 531 2111 Fax 269 795 1089 International Telephone 215 641 9400 T
34. tion of Combination Thermostat Gas Valve a Install new combination thermostat 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 combination thermostat gas valve Be certain not to damage the bundled wire leads Note Combination thermostat 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 combination thermostat gas valve c Reattach main burner feedline pilot tube and thermocouple to combination thermostat gas valve NOTE Feedline nut for natural gas control uses right hand threads LP control uses left hand thread d Gather wire leads of combination thermostat 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 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 d

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