SERVICE MANUAL - Rogers Supply
Contents
1. TW Series TTW SERVICE PROCEDURE IV Blower Testing and Replacement WARNING Blower Testin 115 volt potential exposure Use caution when making voltage checks to avoid personal injury Step 1 Position gas control power switch to ON position and adjust control to call for heat Step2 Remove the three screws Phillips Screw driver from control access cover on blower assembly and remove cover see photo 7 Remove exhaust adapter Disconnect vent system from top of blower and remove vent adapter see photo 10 Connect manometer to pressure tap of blower see photo 8 Disconnect pressure switch tubing from blower see photo 8 Does blower energize Y Within 2 minutes Pressure tap With blower running and exhaust Y adapter removed from top of Blower OK blower is there a negative pressure of 2 15 to 2 30 W C N Is there 115vac across Determine voltage N i Y blue and green wires Replace blower problem and correct see photo 13 Pressure switch tubing Does blower energize after 2 minutes run for 30 seconds and shut down See pressure switch testing Page 18 N Disconnect cord set shown in photo 9 Is yY Is there 115VAC there 115VAC across across terminals v terminals shown in shown in photo 12 Reconnect cord set 7 photo 11 shown in photo 92. position and adjust thermostat dial to call for heat Is there 10 to 13 VAC between red wire leading to blower temperature N switch and green ground wire Blower must be running during this the heartbeat code alternating bright dim Is LED on gas valve flashing y voltage check see photo 27 Y Verify 115VAC to gas control see page 30 Is there 10 to 13 VAC between yellow wire leading from pressure switch and N No voltage from gas control call for technical support Check for loose or broken wire Is there continuity through blower green ground wire see photo 27 Y Correct igniter sensor problem Check igniter sensor see page 17 is igniter sensor OK J Do you hear or can you N see the igniter sparking Y Safety circuit voltage is OK y If burner does not light observe LED flash code on gas valve and refer to troubleshooting section on page 13 connection at switch terminals temperature switch see page 22 Determine cause of blower temperature switch activation and correct Faulty cord set or gas control Green ground wire Red wire leading to blower temp switch Yellow wire leading from pressure switch Page 29 TTW SERVICE PROCEDURE IX 115 VAC Circuit Trace WARNING 115 volt potential exposure Use c
3. 10 13 15 17 18 20 22 24 28 29 30 31 32 33 34 37 38 39 TTW Service Procedure Vi VII TTIW Series WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or A CAUTION Incorrect operation of this appliance may create a hazard to life and death property and will nullify the warranty FOR YOUR SAFETY vicinity of this or any other appliance Do not store or use gasoline or other flammable combustible or corrosive vapors and liquids in the A DANGER Do not store or use gasoline or other flammable combustible or corrosive vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier IMPORTANT Before proceeding please inspect the water heater and its components for possible damage DO NOT install any water heater with damaged components If damage is evident then please contact the supplier where the water heater was purchased or the manufact
4. Damage to thermal well wire sensor damaged Page 24 second pause 2 Thermal well sensor resistance out of range or unplugged Eight four flash three second pause Gas valve fault detected 1 Control needs to be reset 2 Control is wet or physically damaged 1 Interrupt power supply 2 Replace gas control page 26 Page 14 la TTIW Series TTW SERVICE PROCEDURE Burner Operation Inspection Adjustment Cleaning and Replacement S Burner Inspection and Air Shutter Adjustment At periodic intervals every 6 months a visual inspection should be made of the pilot and main burner for proper operation and to assure no debris is accumulating Pilot flame should be stable some causes for an unstable pilot flame are a Water heater vent is less than the allowable vent length b Gas pressure is out of specification c Pilot flame not fully engulfing spark flame sensor Main burner should light smoothly from pilot and burn with a blue flame with a minimum of yellow tips Steel burner models self adjust air to gas ratio mixture and do not have an adjustable air shutter Cast 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 cast iron burner adjustment below Main burner must be free from any debris accumulation that may effect burner operation see burner cleaning procedure on page 16 Cast Iron Burner A
5. operation 5 Blower not spinning up to speed System auto 6 Blower temp or exhaust temp too high 5 Page 20 resets 7 Faulty blower temperature switch 6 amp 7 Page 22 1 Unstable pilot 2 Pilot tube blocked or restricted 1 Page 15 Pior name 3 Oxidation build up on pilot electrode Six three flash three extinguished 4 PONE i 2 4 Page 17 second pause System auto resets Wire damage to pilot assembly or bad connection at gas valve Insufficient combustion air 6 Gas pressure is out of specification a 5 Refer to installation manual Undesired false Six four flash three pilot flame second pause sanged System auto resets Flammable Seven flash three Vapor Sensor Pilot valve stuck in open position WARNING EXPLOSION HAZARD Indicates gasoline vapors were detected at potentially Replace gas control page 26 i Page 28 second pause explosive levels p fault detected e Verify no gasoline vapors are still present e Reset the control by cycling power to the appliance or by cycling the ON OFF switch e Replace the Flammable Vapor Sensor element if a gasoline spill event occurred Flammable e Very Flammable Vapor Sensor FVS resistance is not below Vapor Sensor 25 KO Eight one flash three out of e Check wiring to FVS and insure it is not shorted Page 28 second paus specification e Replace control if everything above checks out OK Thermal well Eight three flash three 1
6. 37 TW Series BTU GPM Hz KW h LED NPT Ohms PSI RPM TCO VAC W C F NOTES British Thermal Units Gallons per Minute Hertz Killo watts per hour Light Emitting Diode National Pipe Thread Ohms of resistance Pounds per Square Inch Revolutions per Minute Temperature Cut Off Volts Alternating Current Inches of Water Column Degrees Centigrade Degrees Fahrenheit Glossary of Terms Page 38 TTIW Series Blower Complete Air Mixing Inlet cover Pressure Switch Blower Temp Switch Blower Gasket Blower Power Cord Vent Adapter w vent term Condensate Hose Kit Flue Reducer M2 only 10 Heat Trap Outlet 11 Hot Water Outlet Anode 12 Flue Baffle 90 NO On PONS Heat Trap Inlet Inlet Dip Tube Wire Harness T amp P Valve NPT Plug Burner Assy Nat Burner Head Main Burner Orifice Pilot Assy Nat Pilot Orifice Feedline Burner Assy L P Parts List 29 30 31 Cast lron Burner Pilot Assy L P Pilot Orifice L P Feedline Jam Nut Air Shutter Main Burner Orifice L P Outer Door Right Side Inner Door Screw 8 15 x 3 4 Left Side Inner Door Screw 10 12 x 3 4 Brass Drain Valve Flammable Vapor Sensor Clip Flammable Vapor Sensor Sensor Harness Thermal Wel
7. Position gas valve power switch to the OFF Pa Thermal position and Unplug Heater from power supply Drain heater to a point below the gas ra control level Hl Turn off gas supply to water heater and disconnect gas piping from gas control Disconnect wire harnesses and burner assembly from gas control Remove gas control amp thermal well by rotating flats of Thermal Well counter clockwise 1 5 16 wrench Gas Control Removal From Thermal Well Step 1 Step 2 Step 3 Step 4 Insert tool from back of control Step 5 Page 26 Follow the steps below allows removal gas control from thermal well without removing thermal well from tank Position gas control power switch to the OFF position and unplug water heater from power supply Turn off gas supply to water heater and disconnect gas piping from gas control Disconnect wire harnesses amp burner assembly from gas control Using gas control service tool 239 45991 00 available from your BWC parts supplier Insert tool into back of gas control see photos below WM View from back of control for clarity Service tool shown inserted in to back of control Pivot tool towards heater as far as possible see photo below Lift straight up on gas control The control should move about 1 8 At this point remove tool not allowing the control to fall back With tool removed lift straight up on control to remove compl
8. from a neighbor s telephone Gas detectors are available Contact your gas supplier or plumbing professional for more information A WARNING Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time generally two weeks or more Hydrogen gas is extremely flammable To prevent the possibility of injury under these conditions we recommend the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system If hydrogen is present there will be an unusual sound such as air escaping through the pipes as hot water begins to flow Do not smoke or have open flame near the faucet at the time it is open A WARNING FAILURE TO INSTALL AND MAINTAIN A NEW LISTED 3 4 X 3 4 TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE MANUFACTURER FROM ANY CLAIM THAT MIGHT RESULT FROM EXCESSIVE TEMPERATURE AND PRESSURES CAUTION Turn off or disconnect the electrical power supply to the water heater before servicing Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Page 3 TTIW Series Page 4 Introduction The new Bradford White TTW1 TTW2 amp TW4 water heaters are designed to provide reliable performance with enhanced standar
9. is there 115VAC between Y Replace blower blue wire and green ground wire see photo 13 reen ground Replace N Does cord set have electrical cord set te continuity Determine power source problem and correct Check power cord Y Repair or replace Replace for damage j power cord gas control N Is there 115 VAC at wall outlet Blue wire Shown with pressure Replace blower switch removed Page 20 TW Series TTW SERVICE PROCEDURE IV Blower Testing and Replacement Blower removal Step 1 Position gas control power switch to the OFF position Step2 Unplug blower power cord from wall outlet Remove exhaust adapter and retain for use on new blower Step3 Disconnect vent system from exhaust adapter on top of blower lt 2 Step 4 Remove exhaust adapter from blower blade screw driver and retain for use on new blower Step5 Unplug cord sets from blower Step 6 Remove the three blower mounting screws 4 nut driver Step 7 Remove blower with gasket from water heater Blower Installation Step 8 Clean any debris from jacket head of water heater Step9 Set new blower with gasket in place using locating pins on blower flange to line up with location holes in jacket head Be sure not to damage gasket Step 10 Secure blower in place using mounting screws from step 6 Step 11 Re install exhaust
10. seconds Control LED flashes a short flash once every 4 seconds idle status code Pressure switch Blower temperature switch If either switch opens pilot valve and main valve is shut down The blower continues to runs for 30 seconds attempting to close the circuit The control LED Flashes 3 times with 3 second pause Flame Sensor If flame is lost pilot amp main valve are shut down blower runs for 15 seconds Control attempts to re light pilot 4 times If unsuccessful Blower is shut down and control proceeds to 5 minute lockout Control re attempts to light pilot starting at normal heating sequence 2 e Thermostat satisfies Control LED flashing once every 4 seconds C Burner off Blower post purge 15 seconds Abnormal Operation 1 Flammable Vapor Sensor Fault a If the resistance is greater than 70 000 Ohms the gas control immediately turns off all outputs Control waits and monitors resistance for 30 seconds If the resistance is greater than 65 000 ohms after 30 seconds the gas control proceeds to verify resistive delay for 2 minutes and flashes 7 times then once with a three second pause This process is repeated 5 times until the control either returns to normal operation or proceeds to flammable vapor lockout If the resistance is below 3000 ohms The gas control immediately turns off all outputs and proceeds to flash 8 times then once with three second pause The error self clears if the resistanc
11. 0 18 3 7 2 1 Through the Roof 1 55 16 8 7 2 1 Through the Roof 2 50 15 2 7 2 1 Through the Roof 3 45 13 7 7 2 1 4 Diameter 10 2 cm PVC Vent Connector Lengths Terminating of Maximum Straight Minimum Straight Elbows Length ft m Length ft m Through the Wall 1 175 53 3 10 3 1 Through the Wall 2 170 51 8 10 3 1 Through the Wall 3 165 50 3 10 3 1 Through the Wall 4 160 48 8 10 3 1 Through the Wall 5 155 47 2 12 3 6 Through the Roof 0 180 54 9 15 4 6 Through the Roof 1 175 53 3 15 4 6 Through the Roof 2 170 51 8 15 4 6 Through the Roof 3 165 50 3 15 4 6 Through the Roof 4 160 48 8 15 4 6 TTIW Series Control Timings Specifications Ignition State Timin Pre purge 2 Seconds Trial for Ignition 90 Seconds Flame Stabilization Period 3 Seconds Inter purge 15 Seconds Flame Failure Response Time 1 5 Seconds 2 second Maximum 1 second minimum Post purge 15 Seconds PS Fault Delay failed open close Retry after 2 Minutes Soft Lockout Retry after 5 Minutes TCO Limit Lockout Indefinite See Page 24 to reset Verify Resistive Delay Retry after 2 Minutes repeats 5 times Simulated Resistive Load Lockout Indefinite cycle power to reset Hardware Error Lockout Indefinite self clears if fault clears for at least 15 sec
12. The Bradford White TIW Series DaFENOER SAFETY SYSTEM Through The Wall Gas Water Heaters SERVICE MANUAL Troubleshooting Guide and Instructions for Service To be performed ONLY by qualified service providers For the Bradford White Through The Wall Models M1TW40S F BN CX M1TW50S F BN CX M1TW60T F BN CX M2TWSOT F BN CX M2TW65T F BN CX a aP TW450S65 F B N X tT TW465S65 F B N X Denotes Warranty Years WHITE Manual 46238A Save this manual for future reference BRADFORD T IITE Page 2 The Bradford White TTIW Series Through The Wall Gas Water Heaters Table of Contents Introduction How to use this manual Tool required for service Specifications Control Timings Sequence of Operation Troubleshooting Burner Inspection Cleaning and Replacement Pilot Testing Cleaning and Replacement Pressure Switch Testing and Replacement Blower Testing and Replacement Blower Temperature Switch Testing and Replacement Gas Control amp Thermal well Testing amp Replacement Flammable Vapor Sensor Testing and Replacement Safety Circuit Voltage Trace 115VAC Circuit Trace Dip Tube inspection and Replacement Anode Inspection and Replacement Flue Baffle Inspection and Replacement Inner Door Removal Inspection amp Replacement ScreenLok Flame Arrestor Cleaning Glossary of Terms Parts List Page 4 5 5 6 9
13. adapter from step 4 Locating Pins on blower flange Pin location holes in jacket head Step 15 Position gas control power switch to the ON position Step 12 Reconnect vent system to exhaust adapter Step 13 Reconnect cord sets from step 5 Step 14 Plug blower power cord into wall outlet Step 16 Verify proper blower operation Page 21 TTW SERVICE PROCEDURE V eries Blower Temperature Switch Testing and Replacement Blower Temperature Switch WARNING Testing 115 volt potential exposure Use caution to avoid personal injury Step 1 Position power switch on gas control to the OFF position Step2 Remove the three screws Phillips screw driver from control access cover on blower and remove cover see photo 14 Step 3 Locate blower temperature switch see photo 15 Switch Setting Opens on rise approximately 165 F Auto resets on fall approximately 130 F Blower temperature switch location Cool switch to below 130 F Air mixing inlet Disconnect wire leads to switch Using a multi meter set to the ohms setting is there continuity between the switch terminals I Reconnect wire leads and Replace switch see page 23 Common causes for high exhaust temperature observe heater operation Exhaust 1 Vent length is below minimum allowable Do switch aaa Do exhaust gas temperature is 2 Vent
14. aution making voltage checks to avoid personal injury Step 1 Verify 115VAC and proper polarity at wall outlet Step 2 With unit plugged in and control power switch in the ON position verify LED status LED status LED status LED status LED status None Control LED not Short flash once every Heartbeat alternates Various flashing error i bright dim on or flashing four seconds E3 Waiting for Thermostat calling call for heat for heat listed on page 13 T Verify error 3 Disconnect cord set as shown in photo 28 Using a volt meter set to volts AC is there N Check for damage to Y AC supply power cord Replace Blower Is there r 15VAC J across terminals Reconnect cord set shown in 28 shown in su 30 115VAC across Repair damage terminals shown in Ty 29 voltage polarity see photo 31 Locate black amp white wires at connector It may be necessary to pull back wire sheath to identify wire colors see photo 32 Is there 115VAC across black amp white wires as shown in photo 32 Call for technical support Page 30 me wire harness Incorrect supply m gas control J Wire harness Wire sheath pulled back to N identify wire colors Check for 115VAC between black amp white wires NOTE Electronic meter probes required Use care not to da
15. ct vent z system and cord sets to blower Plug water heater 3 into wall outlet 4 To resume operation follow the lighting instruction located on the lighting instruction label or the lighting instruction located in the installation and operation manual Flue tube notch Baffle shown installed in flue tube notch Page 33 TTW SERVICE PROCEDURE XIII eries Inner Door Gasket Removal Inspection Replacement and Reinstallation Inner Door Removal Procedure Step 1 Position gas control power switch to the OFF position Step 2 Remove outer jacket burner access door Step 3 Inner Door Removal a Remove 2 1 4 hex drive screws from right side inner door b Remove 2 1 4 drive screws from flange section of inner door c Remove 2 1 4 drive screws from left side inner door d Remove inner door and inspect per step 4 14 Hex Drive Screws Right and Left Side Inner Door a a AVY 4 Hex Drive Screws at _ Flange Area of Inner Doo 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 is required proceed to Inner Door Gasket Replacement Procedure Inne
16. d features New design features include reliable spark to pilot ignition system enhanced diagnostics simplified servicing significantly quiet operation additional vent lengths and Bradford White Defender Safety System Spark to Pilot Ignition System employing the spark to pilot ignition system promotes reliable and consistent pilot and main burner ignitions to provide hot water on demand Integrated Immersion Thermostat Gas Control Valve with LED was developed for ease of troubleshooting by providing simple diagnostic codes to pinpoint an installation or component performance issue New Powerful Blower will eliminate problems with difficult venting situations Quieter and Cooler Blower Operation blower noise is significantly reduced for both interior and exterior environments Cooler operation increases blower life by reducing bearing wear and noise Rugged Wiring Connections receptacle type connections promote error free wiring Increased Vent Lengths increased venting performance is achieved while maintaining Energy Factor amp FHSR performance The TTW1 TTW2 amp TW4 water heaters use a combustion system were flue gases are combined with dilution air to reduce the flue gas temperature in the blower The diluted flue gases are evacuated to the exterior through low temperature vent materials The gas control maintains water temperature ignition sequence and regulates gas flow A safety circuit consisting of a pressure sw
17. diameter not to specification contacts open en ee temperatures rise to or too hot 3 Restricted dilution air inlet above 170 F 4 Missing or deteriorated flue baffle with vent connected 5 Gas pressure is out of specification Do switch contacts open Replace switch see page 23 Switch OK Page 22 TTIW Series TTW SERVICE PROCEDURE V Blower Temperature Switch Testing and Replacement Blower Temperature Switch WARNING Replacement 115 volt potential exposure Use caution Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Position gas control power switch to the OFF position and unplug heater from wall outlet Remove the three screws Phillips screw driver from the control access cover on blower and remove cover see photo 16 Locate blower temperature switch see photo 17 Disconnect red and yellow wire leads from switch With an appropriate tool such as side cutters snip the retaining lug from the blower housing to allow removal of temperature switch see photo 18 Remove switch from blower housing Install new switch Be sure switch is properly seated in mounting area Reconnect red and yellows wires to new switch Wires are interchangeable with either terminal Position gas control power switch to the ON position and verify proper heater operation Replace control access cover from
18. ds the gas control will continue with trial for ignition starting at blower pre purge b Flame Not Sensed The gas control energizes the spark igniter attempting to light the pilot and prove flame If flame is not sensed within 90 seconds the igniter turns off the pilot valve is closed and the gas control runs the blower through post purge and flashes 6 times then once with 3 second pause The control waits 5 minutes before repeating the ignition sequence 5 Flame Sensing Fault b Flame lost during run The gas control turns off pilot and main valves runs blower for 15 seconds inter purge The gas control increments the recycle count if the recycle count has not reached its limit 4 another trial for ignition begins If the recycle count has been reached the gas control turns off the blower and flashes 6 times then 3 times with 3 second pause The gas control waits 5 minutes before repeating the ignition sequence c Flame sensed out of sequence the gas control only looks for pilot flame when the blower is running If flame is present when the pilot valve is not open the gas control proceeds to wait for flame loss and flashes 5 times with 3 second pause This continues until flame is lost once the flame signal is lost the control flashes 6 times then 4 times with 3 second pause The control waits 5 minutes before repeating the ignition sequence Page 12 TTIW Series Troubleshooting Observe green LED indicator on El
19. e returns to normal range for at least 15 seconds 2 Temperature Sensor Fault a b Temperature sensor detected open circuit The gas control Immediately turns off all outputs and proceeds to flash 8 times then three times with three second pause The error self clears if the fault clears for at least 15 seconds Thermal well sensors not reading the same temperature within 5 5 F The gas control Immediately turns off all outputs and proceeds to flash 8 times then three times with three second pause The error self clears if the fault clears for at least 15 seconds Water temperature in excess of TCO Temperature Cut Off limit The gas control immediately turns off pilot main valve and proceeds to flash 4 times with 3 second pause Blower continues to run until gas control is reset To reset control rotate knob of temperature control to the minimum setting for at least 6 seconds before returning to desired temperature setting Page 11 TW Series Sequence of Operation Abnormal Operation cont 3 Pressure Switch Blower Temperature Fault a Pressure switch closed at start of call for heat The gas control waits four seconds then proceeds to flash 2 times with 3 second pause The control waits 2 minutes and then turns on blower for 30 seconds The blower turns off after 30 seconds and the control waits for pressure switch to open Any time the Pressure switch opens the blower turns on or stays on and the contr
20. ectronic 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 Control Service LED Status Probable Cause Status Procedure None control LED not No electrical Control power switch in OFF position Turn power on on or flashing power Supply voltage interrupted Short flash once every four seconds Stand by mode Waiting for call for heat no fault Temperature demand is satisfied Normal operation Adjust thermostat to temp level Heartbeat alternates bright dim Thermostat calling for heat no fault Tank temperature below set point of thermostat Normal operation Adjust thermostat to Four flash three second pause temperature System must be reset See Pg 24 Faulty gas control Pluming leak Tank not filled with water temp level 1 Unstable pilot 1 Page 15 Weak pilot signal 2 Pilot tube block or restricted nee Short flash once per E i Second on last call for 3 Oxidation build up on pilot electrode 2 4 Page 17 heat 4 Wire damage to pilot assembly or bad i connection at gas valve Pressure switch 1 Pressure switch tubing kinked or blocked Two flash three A 7 not working 2 Blocked pressure tap on switch or blower Page 18 second pause oe closed position 3 Faulty pressure switch 1 Vent blockage
21. etely from Thermal Well With service tool inserted pivot tool back towards heater as far as possible Lift straight up on control control will move 1 8 Remove tool and continue to lift straight up on control to remove from Thermal Well o TTW SERVICE PROCEDURE VI eries Gas Control amp Thermal Well Testing and Replacement Gas Control Assembly to Thermal Well Step 1 Step 2 Step 3 Step 4 Step 5 Igniter sensor connection Ground Wire connection blower harness connection Install threaded end of thermal well into tank Be sure thermal well flange is positioned as shown in photo 24 for proper control alignment Route wire leads back into relief opening see photo 24 Align slots located on thermal well flange with tabs located on back of gas control see photos 24 amp 25 Route wires N through relief opening Thermal well flange slots Carefully push control back onto thermal well flange as far as possible towards water heater Slide control down to lock into position Install burner and connect pilot and feedline to gas control Step 6 Reconnect wire harnesses to gas control per the illustration Step 7 Reconnect gas piping to gas control Restore gas supply and check for gas leaks Step 8 To resume operation follow the instruction located on the lighting instruction label or the lighting instruction located in the installation and opera
22. eter A digital type is strongly recommended This device is used to measure electrical values The meter you select must have the capability to measure volts AC volts DC Amps micro amps and ohms Electronic Probes In some cases standard multi meter probes will damage or simply not be effective to obtain certain voltage and ohm reading It will be necessary to have special electronic pin type multi meter probes These probes are available at most electronic wholesale outlets Thermometer Used to measure water temperature An accurate thermometer is recommended Water Pressure Gage Used to measure water supply pressure Also used to determine tank pressure by adapting to the drain valve of the heater Gas Control Service Tool BWC part number 239 45991 00 A specialized tool designed to remove the gas control from gas control thermal well Available from your Bradford White parts supplier Various Hand Tools Pipe wrench channel locks open end wrenchs 3 8 7 16 72 12 crescent wrench Allen wrench set screw drivers common amp Phillips 4 nut driver pliers common amp needle nose socket set side cutters wire cutters wire strippers wire crimpers torpedo level small shop vac step ladder and flashlight 5 gallon pail Page 5 TOW Series Specifications Power supply Dedicated 115VAC 60 Hz 15A Gas Supply Pipe Minimum 1 2 NPT schedule 40 black iron pipe recommended Approved Ga
23. explosion Firmly position the radiused channel of the inner causing property damage personal injury door around the feedline Using the 1 4 hex drive or death Do not over tighten screws in screws from step 3c secure left side inner door in steps 8 10 and 11 place DO NOT OVER TIGHTEN SCREWS oo o If a fastener connection is stripped Step 9 sete ei ee contact the manufacturer listed on the DO NOT ROUTE THROUGH RADIUSED water heater rating plate CHANNEL WITH FEEDLINE Position pilot tubing and igniter sensor wire Raclused Channe F for Feedline D Page 35 TTIW S 7 TTW SERVICE PROCEDURE XIII eries Inner Door Gasket Removal Inspection Replacement and Reinstallation Step 10 Step 11 Step 12 Step 13 Page 36 Firmly place right side inner door flange against the left side inner door flange and secure with two 1 4 drive screws from step 3b DO NOT OVER TIGHTEN SCREWS Align right side inner door to combustion chamber and verify the fastener holes of the combustion chamber are aligned with 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 3a 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 z Y drive screws j Verify threaded h
24. her of the outside wire positions see photo 19 Alternate the probe on the outside position to the opposite outside wire position see photo 20 Once the thermal well resistance values are known the water temperature must also be known to determine if the resistance values are correct See page 25 to obtain water temperature Replace thermal well see page 26 Are thermal well resistance values correct Replace gas control see page 26 Page 24 TTW SERVICE PROCEDURE VI eries Gas Control Thermal Well Testing and Replacement 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 thermal well is determined from page 24 water flow through the heater should not occur Prior to performing the steps below turn off the cold water supply to the water heater This will prevent cold water flow into the tank affecting the resistance value of thermal well Step 1 Position gas control power switch to OFF position Step 2 Draw approximately 1 quart of water from drain valve into container and immediately measure water temperature using an accurate thermometer It may be necessary to open a hot water faucet to allow heater to drain Step3 Using the chart below determine correct resistance
25. ir Shutter Adjustment 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 outer jacket door and inner door per service procedure XIII on page 34 Step 2 To adjust for proper burning loosen the air shutter nut rotate the air shutter to close the opening in the burner then slowly rotate the air shutter open until flame becomes as blue as possible with a minimum of yellow tips Tighten the air shutter nut Too much air will cause the flame to lift off the burner ports and create noisy burner operation Too little air will result in soot formation Step 3 Reinstall inner door and observe burner operation Burner should operate as adjusted in step 2 If not repeat air shutter adjustment compensating for proper burner operation with inner door closed Air Shutter Nut Air Shutter Page 15 TTW SERVICE PROCEDURE I eries Burner Operation Inspection Adjustment Cleaning and Replacement Burner Cleaning Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 9 Step 10 Step 11 Step 12 Page 16 Position gas control power switch to the OFF position and unplug heater from wall outlet Turn off gas supply to water heater Remove outer jacket door and inner door per service procedure XIII on Page 34 i Igniter f Disconnect pilot tube 7 16
26. itch and blower temperature switch verifies proper conditions exist for safe and reliable operation If a situation outside of normal operating parameters exists the gas control diagnostic LED will flash a code to positively identify an operational issue This service manual is designed to facilitate problem diagnosis and enhance service efficiency To further promote quicker service times the new gas valve can be removed and replaced without draining the water heater A special tool is required and will be provided with each gas valve kit shipped from our Service Parts department Please read the service manual completely before attempting service on this new series of power vent models How the Safety System Works During normal operation air for combustion is 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 supplied gas and is efficiently combusted producing very low NOx emissions In the unlikely event trace amounts of flammable vapors are present in the air flowing into the combustion chamber the vapors are harmlessly ignited by the burner If flammable vapors are in sufficient quantity to prevent n
27. l Gas Control Gas Control Service Tool Kit Gas Control Inner Door Gasket Kit ASSE App vd Mixing Valve Kit Heat Trap Insert Page 39 amp BRADFORD WHITE C O R P O RATION 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 Technical Support 800 334 3393 Fax 269 795 1089 Warranty 800 531 2111 Fax 269 795 1089 International Telephone 215 641 9400 Telefax 215 641 9750 Fax on Demand 888 538 7833 www bradfordwhite com te BRADFORD WHITE CANADA INC Mississauga ON Sales Technical Support 866 690 0961 905 238 0100 Fax 905 238 0105 www bradfordwhitecanada com Email parts bradfordwhite com techserv bradfordwhite com www bradfordwhite com www bradfordwhitecanada com
28. lly closed If the safety circuit is closed the control waits 4 seconds gas control LED flashes 2 times with 3 second pause Gas control waits 2 minutes then blower runs for 30 seconds This cycle repeats until safety circuit opens G Blower energizes G Pressure switch proves blower vent system operation If the pressure switch does not close within 30 seconds the control LED Flashes 3 times with 3 second pause The blower runs for 30 seconds every 2 minutes trying to get the pressure switch or blower temperature switch to close This cycle repeats as long as there is a call for heat Blower pre purge period 2 seconds s Trial for pilot ignition 90 seconds a The gas control lights the pilot by activating spark igniter and gas flow to pilot burner b If flame is not sensed within 90 seconds igniter and gas flow are deactivated blower will post purge and control LED flashes 6 times with 3 second pause Main burner Ignition After pilot flame is sensed gas control activates main valve for main burner ignition The gas control will ignore flame and pressure switch signals for 3 seconds allowing for main burner to stabilize Page 10 TW Series Sequence of Operation Normal Heating Sequence cont Steady state operation During Steady State Operation the Control Monitors Thermostat temperature sensor When set point temperature is satisfied gas valve is shut down and blower will post purge for 15
29. m Straight Minimum Straight Elbows Length ft m Length ft m Through the Wall 1 45 13 7 2 6 Through the Wall 2 40 12 2 2 6 Through the Wall 3 35 10 7 2 6 Through the Wall 4 30 9 2 2 6 Through the Roof 0 50 15 2 7 2 1 Through the Roof 1 45 13 7 7 2 1 Through the Roof 2 40 12 2 7 2 1 Through the Roof 3 35 10 7 7 2 1 Through the Roof 4 30 9 2 7 2 1 3 Diameter 7 6 cm PVC Vent Connector Lengths Terminating of Maximum Straight Minimum Straight Elbows Length ft m Length ft m Through the Wall 1 115 35 0 10 3 1 Through the Wall 2 110 33 5 10 3 1 Through the Wall 3 105 32 0 10 3 1 Through the Wall 4 100 30 5 10 3 1 Through the Wall 5 95 29 0 10 3 1 Through the Roof 0 120 36 6 15 4 6 Through the Roof 1 115 35 0 15 4 6 Through the Roof 2 110 33 5 15 4 6 Through the Roof 3 105 32 0 15 4 6 Through the Roof 4 100 30 5 18 5 5 Page 7 TW Series Venting Specifications for 48 Gallon 65 Gallon Page 8 Vent Tables Specifications 3 Diameter 7 6 cm PVC Vent Connector Lengths Terminating of Maximum Straight Minimum Straight Elbows Length ft m Length ft m Through the Wall 1 55 16 8 2 6 Through the Wall 2 50 15 2 2 6 Through the Wall 3 45 13 7 2 6 Through the Wall 4 40 12 2 2 6 Through the Roof 0 6
30. mage connector during this check TW Series TTW ames oe x Inspection and replacement Dip Tube Inspection and Replacement A WARNING Water Heater components and stored water may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Step 1 Position on off switch of gas control valve to OFF position and unplug water heater from wall outlet Step 2 Turn off cold water supply to water heater Connect hose to drain valve of water heater and route to an open drain Open a nearby hot water faucet to vent heater for draining Open drain valve of 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 tool such as a pipe 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 jet slots should be open and 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 water heater Connect nipple to plumbing system resume water supply and refill with water Step 7 T
31. nstruction located in the installation and operating manual Page 17 4 TTW SERVICE PROCEDURE III eries Pressure Switch Testing and Replacement Pressure Switch Testing WARNING 115 volt potential exposure Use caution Step 1 Position power switch on gas control f making voltage checks to avoid personal injury to the OFF position Step2 Remove the three screws Phillips screw driver from control access cover on blower assembly and remove cover see photo 1 Step 3 Carefully remove pressure switch from blower housing see photo 2 With steps 1 2 amp 3 complete disconnect wire leads from pressure switch Pressure Switch Pressure switch Slide pressure switch in direction wire leads of arrow while tilting slightly away from blower housing y Use a multi meter set to the ohms setting With blower off Check tubing and pressure check across pressure N tap on switch for blockage switch terminals Is there blockage Are switch contacts open ge no electrical continuity Replace switch see page 19 Y Clear blockage Position gas valve power switch to the ON position y and adjust thermostat Check tubing and Is vent system length Is vent a See blower testing to call for heat N pressure tap on within vent table rae system ec page 20 this will start the blower switch for blockage specification
32. o resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual Page 31 4 TTW SERVICE PROCEDURE XI TIW Series a Inspection and replacement Anode Inspection and Replacement A WARNING Water Heater components and stored water may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Step 1 Position on off switch of gas control valve to the OFF position and unplug water heater from wall outlet Step 2 Turn off cold water supply to water heater Connect hose to drain valve of water heater and route to an open drain Open a nearby hot water faucet to vent water heater for draining Open drain valve of water heater and allow water heater to drain to a point below the outlet connection nipple Step 3 Disconnect outlet nipple from plumbing system Step 4 With an appropriate tool such as a pipe 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 2 of the original anode diameter approximately 34 diameter replacement is recommended If any of the steel core of the anode is exposed replacement is recommended Step 6 Upon completion of inspection or subsequent replacement reinstall
33. ol proceeds to waiting for pressure switch to close b Pressure switch or blower temperature switch failed to close The gas control runs the blower for 30 seconds waiting for the pressure switch and or blower temperature switch to close If either switch does not close in 30 seconds the blower turns off and the control flashes 3 times with 3 second pause The gas control waits two minutes before turning on the blower for another 30 seconds to see the circuit close This cycle repeats as long as there is a call for heat or until the circuit closes c Pressure switch or blower temperature switch opens during burner operation The gas control turns off the pilot and main valve runs blower for 15 seconds inter purge waiting for pressure switch and or blower temperature switch to close If either switch fails to close the control proceeds as described in 3b above If the circuit closes again by the end of the inter purge the recycle counter is incremented if the recycle count has not reached its limit 4 another trial for ignition begins If the recycle count has been reached the gas control turns off the blower and flashes 6 times then 2 times with 3 second pause The gas control waits 5 minutes before repeating ignition sequence 4 Trial For Ignition Fault a Pressure switch opens during trial The gas control turns off igniter and pilot valve The gas control proceeds as described in 3b above If the pressure switch closes within 30 secon
34. ole alignment with slotted openings in inner door Replace outer jacket burner access door To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual TTIW Series ScreenLok Flame Arrestor Cleaning ScreenLok Flame Arrestor Cleaning Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Position Gas Control Power Switch to the OFF position Remove outer jacket Remove inner door per TTW SERVICE PROCEDURE XIII step 3a through step 3d Disconnect main burner feed line 3 4 wrench pilot tube 7 16 wrench and igniter flame sensor wire from gas control and remove burner assembly from combustion chamber Clean ScreenLok Flame Arrestor using stiff brush compressed air and or shop vacuum to remove any scale or other debris accumulation Using a soft brush clear jacket openings from any dirt dust restrictions or other obstructions Remove any debris from burner assembly per TTW SERVICE PROCEDURE I and reinstall burner assembly into combustion chamber Reconnect feedline pilot tube and igniter flame sensor wire to the gas control Reinstalll inner door per TTW SERVICE PROCEDURE XIII step 7 through step 12 To resume operation follow the instructions located on the lighting instruction label or the lighting instruction located in the installation and operation manual Page
35. onds T o f N Pilot Wiring Diagram wo J Blower BI ae o ower Motor ee Temperature a Switch Pressure Switch Blower W Housing ae Ht i N SoH Y pz Honeywell O z R w PLU O Flammable Vapor Sensor Thermal Well Bis BK BK ay Page 9 TW M Sequence of Operation Series J Power up Sequence C Start Up Upon power up the control runs a safe start check with a typical start up delay of 5 seconds Flammable Vapor To assure no outputs are energized if the Flammable Vapor Sensor is out of range the control will test the Flammable Vapor Sensor for proper operating range If the Flammable Vapor Sensor is within range the control resumes normal operation with no perceptible delay If the Flammable Vapor Sensor is out of range the control LED immediately flashes 7 times with 3 second pause Normal Heating Sequence Thermostat calls for heat Prior to energizing blower gas control checks safety circuit to insure the circuit is open Normal switch positions in the safety circuit are as follows a Pressure switch normally open b Blower temperature switch norma
36. ontrol Feedline nut G B Pict tubing nut Disconnect igniter flame sense wire from gas control Remove bumer assembly from combustion chamber Remove pilot assembly from feedline 4 nut driver Visually inspect igniter flame sense wire for damage Replace pilot if damage is found With a multi meter set to the ohms setting check continuity poe E e a through igniter flame sense wire Replace pilot if no continuity i i Visually inspect igniter flame sense electrode for deterioration tae Replace pilot as necessary Electrode should not be in contact 4 with pilot hood If so carefully adjust electrode to a gap j E distance of 3 32 09 from pilot hood me Igniter flame Igniter flame sense wire sense electrode Visually inspect igniter flame sense electrode for oxidation build up Carefully clean any oxidation using very fine emery cloth Visually inspect pilot tubing for kinks or cracks If damage is found replace pilot Inspect pilot tubing and pilot orifice for blockage a Remove ferrule nut from bottom of pilot assembly 7 16 wrench b Remove pilot tube and pilot orifice c Inspect pilot tubing and pilot orifice for blockage Clean or replace as necessary Reassemble pilot and install to feedline Reinstall burner assembly to water heater Restore gas supply and check for gas leaks To resume operation follow the instruction located on the lighting instruction label or the lighting i
37. or improper vent configuration 1 Check vent or vent tables Pressure switch 2 Pressure switch tubing kinked or blocked Three flash three or blower temp 3 Faulty pressure switch om 3 Paga We second pause switch not working 4 Blower not spinning up to speed 4 Page 20 open position 5 Blower temp or exhaust temp too high 6 Faulty blower temperature switch 5 amp 6 Page 22 Excessive tank 1 Thermal well sensor out of calibration 1 Page 24 2 3 4 2 Replace gas control page 24 Five flash three second pause Undesired false pilot flame present Pilot valve stuck in open position Replace gas control page 24 Page 13 TTIW Series Troubleshooting Control Service LED Status Probable Cause Status Procedure 1 Unstable pilot Faleg to hight 2 Pilot tube blocked or restricted 1 Page 15 Six one flash three pilot pees 3 Oxidation build up on pilot electrode second pause System auto 2 4 Page 17 r sels 4 Wire damage to pilot assembly or bad connection at gas valve 1 Check vent or vent tables Pressure switch 1 Vent blockage or improper vent configuration or blower temp 2 Pressure switch tubing kinked or blocked 2 amp 3 Page 18 switch opened 3 Faulty pressure switch f f Six two flash three f 4 Refer to venting section of during burner 4 Vent termination being affected by wind second pause sae installation manual
38. ormal combustion the flammable vapor sensor recognizes this and shuts down the pilot and main burner Should the flammable vapors continue to burn the flame arrestor plate prevents the flames from traveling backwards and igniting vapors outside of the combustion chamber TTIW Series How to Use This Manual It is intended for this manual to be used by qualified service personal for the primary purpose of troubleshooting and repair of the Bradford White TTW Series water heaters Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting the water heater The Honeywell WV4460E Electronic Gas Control will display error codes in the event of abnormal operation Error codes are listed in the troubleshooting chart beginning on page 13 of this service manual The troubleshooting chart will also indicate the probable cause for the error code and direct the service professional to a service procedure to properly diagnose the abnormal operation In some difficult to diagnose conditions it may be necessary to isolate the heater from the vent system to determine the problem Contact the Bradford White technical support group immediately if diagnosis can not be made using the methods described in this service manual Tools Required for Service Manometer A liquid U tube type or a digital magna helic type can be used This device is used to measure gas and or air pressure and vacuum Multi M
39. outlet nipple anode into water heater Connect nipple to plumbing system resume water supply and refill 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 Page 32 5 TTW SERVICE PROCEDURE XII TTIW Series Flue Baffle Inspection and replacement Remove blower to gain access to flue baffle Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Disconnect vent system from exhaust adapter Blower Mounting Position gas control power switch to the OFF position crews and unplug blower from wall outlet Disconnect vent system from exhaust adapter on top of blower Unplug cord sets from blower see photo 33 Remove the three blower mounting screws A nut driver see photo 33 Remove blower with gasket from water heater Remove flue baffle from Heater see photo 34 Inspect baffle for deterioration missing restrictors are Clean any scale or debris build up Replace with new baffle as necessary Reinstall baffle into flue tube Be sure baffle hanger tab are inserted into notch location at the top of the flue tube see photos 35 amp 36 Check Burner to insure no scale has accumulated during this operation See burner cleaning procedure on page 15 Reinstall blower on water heater Conne
40. r 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 Page 34 o TW Series TTW SERVICE PROCEDURE XIII Inner Door Gasket Removal Inspection E Replacement and Reinstallation J RECOMMENDED PATTERN FOR RTV SEALANT GASKET OVERLAP MUST BE AS SHOWN 1 32 ENLARGED VIEW OF FLANGE AREA 5NI Z SECTIONS FIRST VIEW WITH GASKETS EXPANDED VIEW IN PLACE Installation of Inner Door With Gasket Step 7 Clean any residual gasket residue or other debris WARNING from combustion chamber surface before Stripped fastener connections may allow installing the inner door gasket assembly for seal breach of inner door A seal Step 8 Place the left side inner door into position first breach may reSoltima nie OF
41. s blocked Is blower OK Check with multi meter do Is there blockage listed on pages 7 amp 8 pressure switch contacts close with blower running ls Switch contacts are OK Reconfigure vent system to be compliant with vent tables Correct blower problem See safety circuit trace page 29 Page 18 o TTW SERVICE PROCEDURE III eries Pressure Switch Testing and Replacement Pressure Switch Replacement WARNING Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 115 volt potential exposure Use caution to avoid personal injury Position gas control power switch to OFF position Remove the three screws Phillips screw driver from control access cover on blower assembly and remove cover see photo 3 Pressure Switch Carefully remove pressure switch from blower housing see photo 4 lide pressure switch in direction of arrow while tilting slightly away from blower housing Disconnect tubing from pressure switch see photo 5 Disconnect yellow wires from pressure switch see photo 6 Reconnect wires from step 5 to new pressure switch Reconnect tubing to new pressure switch Carefully position pressure switch into blower housing Position gas control power switch to ON position and verify proper heater operation Replace control access cover from step 2 Page 19
42. s Type Natural or Propane Unit must match gas type supplied Gas Pressure 5 0 W C min for Nat gas 11 0 W C min for L P gas 14 0 W C maximum Nat amp L P Venting System Power vent through the wall or vertical through the roof Approved Vent Materials PVC CPVC or ABS Minimum Clearance ad 18 from top 24 from front 4 sides and rear for Servicing Water Supply Pressure 150 PSI maximum allowable working pressure Check local codes for supply pressure TCO Limit Residential 188 F 87 C Commercial 199 F 93 C Residential Temperature Set Point Range 60 F 16 C to 160 F 71 C Approximate temperatures Commercial Temperature Set Point Range 80 F 27 C to 180 F 82 C Approximate temperatures Blower Temperature Switch Normally closed opens 165 F 74 C auto reset 130 F 54 C TTW1 Models Normally open closes on vacuum increase 68 opens on vacuum decrease 65 Pressure switch TTW2 Models Normally open closes on vacuum increase 1 28 opens on vacuum decrease 1 25 TTW1 115VAC 60Hz 3 1 amps 3000 RPM 42CFM 1 5 W C Blower TTW2 115VAC 60Hz 3 1 amps 3000 RPM 68CFM 0 4 W C Page 6 TTIW Series Venting Specifications for 40 Gallon 50 Gallon 60 Gallon Vent Tables Specifications 2 Diameter 5 1 cm PVC Vent Connector Lengths Terminating of Maximu
43. step 2 to avoid personal injury Blower temperature switch location Snip retaining lug from blower housing Page 23 e TTW SERVICE PROCEDURE VI eries Gas Control Thermal Well Testing and Replacement Gas Control Testing See pages 29 amp 30 for gas control voltage testing Thermal Well Testin Sener eat well wire harness If Control has gone into TCO lockout due to excessive tank temperature four flash 3 second pause reset control by rotating knob of temperature control to the minimum setting for at least 6 seconds before returning to desired temperature setting Observe heater operation If control continues to lockout due to excessive tank temperature proceed to thermal well testing to determine cause Thermal well testing Position gas control power switch to the OFF position and disconnect thermal well harness from gas sono CAUTION DO NOT use standard multimeter probes for this test l Doing so will damage connector Use special pin type electronic probes or small diameter wire pins inserted into connector Using a multi meter set to the Ohms setting determine the Using a multi meter set to the ohms setting insert one meter probe see caution resistance of thermal well sensor in see caution photos 19 amp 20 into center wire position of thermal well connector insert the second probe see caution into eit
44. tion manual 3 pin thermal well connection Page 27 TTIW Series TTW SERVICE PROCEDURE VII Flammable Vapor Device Testing Flammable Vapor Device Testing Step 1 Position power switch on gas control to the O OFF position Step 2 Disconnect flammable vapor sensor from gas control Step 3 Using a multi meter set to the ohms setting check resistance of flammable vapor sensor a see caution below O Resistance must be within 3 000 ohms and g l 48 000 ohms If outside of this range replace flammable vapor sensor Flammable Vapor Sensor Multi meter set to ohms setting ACAUTION DO NOT use standard multimeter probes for this test Doing so will damage connector Use special electronic pin type probes or small diameter wire pins inserted into connector Electronic pin type Meter Probes Flammable Vapor Sensor Page 28 TTIW Series TTW SERVICE PROCEDURE VIII Safety Circuit Voltage Trace Safety Circuit Voltage Trace WARNING 115 volt potential exposure Use caution making voltage checks to avoid personal injury NOTE This procedure assumes a cool tank Remove three screws Phillips Screw driver from control access cover on blower and remove cover see photo 26 Position gas control switch to the ON
45. urer listed on the rating plate for replacement parts A WARNING Water heaters are heat producing appliances To avoid damage or injury do not store materials against the water heater or vent air intake system Use proper care to avoid unnecessary contact especially by children with the water heater and vent air intake components UNDER NO CIRCUMSTANCES MUST FLAMMABLE MATERIALS SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER VENT AIR INTAKE SYSTEM OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER OR VENT AIR INTAKE SYSTEM A CAUTION If sweat fittings are to be used DO NOT apply heat to the nipples on top of the water heater Sweat the tubing to the adapter before fitting the adapter to the water connections It is imperative that heat is not applied to the nipples containing a plastic liner A WARNING DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE FOLLOWING Liquefied petroleum gases propane gas and natural gas have an odorant added by the gas supplier that aids in the detection of the gas Most people recognize this odor as a sulfur or rotten egg smell Other conditions such as odorant fade can cause the odorant to diminish in intensity or fade and not be as readily detectable If you have a diminished sense of smell or are in any way unsure of the presence of gas immediately contact your gas supplier
46. value for the water temperature from step 2 Example If temperature of water is 84 F then the resistance through the sensor would be 8449 see shaded area NOTE Sensor resistance increases as the temperature falls 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 7 8 9 22771 22163 21573 21000 20445 17440 16990 16553 16128 15715 13477 13140 12812 12494 12185 70 11884 11592 11308 11032 10502 10248 1000 9760 9526 80 9299 9078 8862 8653 8250 8057 7869 7685 7507 90 7333 7165 7000 6839 6683 6531 6383 6238 6098 5961 100 5827 5697 5570 5446 5326 5208 5094 4982 4873 4767 110 4663 4562 4464 4368 4274 4183 4094 4006 3922 3839 120 3758 3679 3602 3527 3453 3382 3312 3244 3177 3112 130 3048 2986 2925 2866 2808 2752 2697 2643 2590 2538 140 2488 2439 2391 2344 2298 2253 2209 2166 2124 2083 150 2043 2004 1966 1928 1891 1856 1820 1786 1753 1720 160 1688 1656 1625 1595 1566 1537 1509 1481 1454 1427 170 1402 1376 1351 1327 1303 1280 1257 1235 1213 1191 180 1170 1150 1129 1110 1090 1071 1053 1035 1017 999 190 982 965 949 933 917 901 886 871 857 842 200 828 814 801 788 775 762 749 737 725 713 Page 25 TTIW Series TTW SERVICE PROCEDURE VI Gas Control amp Thermal Well Testing and Replacement Gas Control amp Thermal Well Removal From Water Heater Step 1 Step 2 Step 3 Step 4 Step 5 Gas Control
47. wrench and feedline 4 wrench from gas control Disconnect igniter flame sensor wire from gas control Remove burner assembly from combustion chamber Thoroughly inspect burner surface area and burner port area and remove any loose debris Unscrew burner from main burner orifice On cast iron burners loosen air shutter nut and unscrew feedline from burner Remove main burner orifice from feedline 2 wrench on steel burners 3 8 wrench on cast iron inspect orifice clean or replace if necessary L P Main burner orifice Left hand thread Reassemble burner and reinstall into water heater Restore gas supply and check for gas leaks To resume operation follow the instruction located on the lighting instruction label or the lighting instruction located in the installation and operating manual TW Series TTW SERVICE PROCEDURE II Pilot testing Cleaning and Replacement Pilot Inspection Testing and Replacement Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Step 12 Step 13 Step 14 Step 15 Position gas control power switch to the OFF position and unplug heater from wall outlet Turn off gas supply to water heater Remove outer jacket door and inner door per service procedure XIII on page 34 Igniter flame sense wire Disconnect pilot tube nut 7 16 wrench and feedline nut 4 wrench from gas c
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