Bradford-White Corp D)W275T*(BN User's Manual
Contents
1. BRADFORD WHITE WATER HEATERS Atmospheric Gas Water Heaters For Models Using White Rodgers Robertshaw and Honeywell Gas Control SERVICE MANUAL Troubleshooting Guide and Instructions for Service To be performed ONLY by qualified service providers Models Covered by This Manual GX225S BN GX155S BN 25X78B N 55X80B N M1XR65T BN CX SX MI75S BN CX SX M2XR75S BN CX SX MI100T BN CX SX 65T65 BN CX SX 75T80 BN CX SX C S D W275T BN CX SX Denotes Warranty Years GX155S6BN Model Shown Manual 238 46647 00B Save this manual for future reference BRADFORD WHITE WATER HEATERS Table of Contents Service Page Procedure Troubleshooting Chart White Rodgers and Robertshaw Gas Control 3 Troubleshooting Chart Honeywell Gas Control 4 Thermocouple Testing and Replacement White Rodgers and Robertshaw Gas Control 6 AG I Thermopile Testing and Replacement Honeywell Gas Control T AG I Pilot Assembly Inspection Cleaning and Replacement White Rodgers and Robertshaw Gas Control 9 AG II Pilot Assembly Inspection Cleaning and Replacement Honeywell Gas Control 10 AG II Gas Control Testing and Replacement White Rodgers and Robertshaw 12 AG III Gas Control Replacement Honeywell 12 AG III Honeywell Thermowell Testing and Replacement 16 AG III Honeywell Gas Control and Thermowell Replacement 18 AG III Burner Operation Inspection Adjustment Cleaning and Replacement 20 AG2. 2 See Installation amp operation manual 3 See Service Procedure AG IIl Page 12 4 See Service Procedure AG IIl Page 12 x 3 See Service Procedure AG III Page 12 2 Gas Control set too low for desired water Cold inlet water temperature is very cold High demand periods Integrated mixing device is set too low for temperature Incorrectly sized water heater for 3 application A Gas Control is out of calibration not 5 functioning Out of spec dip tube is diluting hot water with cold water 6 desired water temperature ES 3 1 2 Check dial on gas control Extremely cold water going into the water heater will decrease the amount of hot water produced It may be necessary to temper incoming water supply Adjust high demand usage Contact Plumbing professional Check gas control for proper operation replace if necessary Inspect dip tube and replace if necessary Reset device using the procedure in the instructions included with the device lt gt 5 See Service Procedure AG III Page 12 6 See Service Procedure AG V Page 23 BRADFORD WHITE E 3 WATER HEATERS Troubleshooting Chart For Models Using Honeywell Gas Control LED Indicat Observe LED indicator on gas control Error flash codes ee am are displayed with a three second pause before repeating Check and repair the system as noted in the troubleshooting
3. Bre Pilot valve stuck in the open position lt gt Replace gas control See Service Procedure AG III Page 18 a lt BRADFORD WHITE E WATER HEATERS a w SERVICE PROCEDURE AG I Thermocouple Testing and Replacement BRADFORD WHITE For Models Using White Rodgers or WATER HEATERS Robertshaw Gas Control OPEN CIRCUIT THERMOCOUPLE TESTING Step 1 Disconnect thermocouple from gas control Step2 Using a multimeter capable of measuring millivolts connect one alligator clip to the end ball or contact portion of the thermocouple and the other alligator clip to copper portion of the thermocouple Figure 1 Step 3 Following the lighting instruction label on the heater proceed to light the pilot and allow to operate for three minutes A reading of 20 to 30 millivolts indicates good thermocouple output NOTE It will be necessary to hold the gas control knob down in the PILOT position continuously throughout this test THERMOCOUPLE REPLACEMENT Step 1 Turn off gas supply to water heater Rotate knob of gas control to OFF position For White Rodgers gas control depress knob slightly and rotate For Robertshaw gas control rotate knob 2 clockwise to the OFF clockwise to the OFF position z Fi une 2 zA DINS a Step2 Remove outer jacket door Figure 3 Step 3 Slide open inner combustion chamber door Step 4 Disconnect therm
4. SES pik NAA on Ae Wi E table below i a Y bd SF LED Status Control Status Probable Cause Service a Procedure gt gt gt 1 Lite pilot per the instructions located on the lighting instructions label or the lighting instructions located in the installation and operation manual Not on and or not flashing Pilot flame may not be present Pilot flame is not present 2 See Service Procedure AG I Page 7 gt lt gt lt Gas control is powered and waiting for the set Normal operation Adjust gas point knob to be turned to a water control set point knob to temperature setting desired temperature level gt lt gt lt 1 Wait for LED to go out 2 Lite pilot per the instructions One flash and a three Gas control is in the PILOT position and second pause the pilot flame is detected Gas control has recently been turned to the located on the lighting LED is on continuously OFF position Wait until LED goes out Gas control was turned to the OFF position instructions label or the before attempting to relight lighting instructions located in the installation and operation manual gt gt gt lt 1 See Service Procedure AG I Two flashes and a three Weak pilot flame detected System will reset s PA a e Page 7 second pause when pilot flame is sufficient 3 Pilot Aba blocked eres J89 Saar
5. 7 n SERVICE PROCEDURE AG II Pilot Assembly Inspection Cleaning BRADFORD WHITE and Replacement For Models Using WATER HEATERS Honeywell Gas Control IGNITER ELECTRODE TESTING AND REPLACEMENT With the pilot not in operation no pilot flame the igniter and electrode circuit function can be observed by opening the combustion chamber door and viewing whether there is a sparking action Step 1 Make sure the gas control is in the OFF position Repeatedly Depress Igniter Step 4 Depress the igniter button repeatedly while viewing the spark through the open door of the combustion chamber If there is no spark proceed to Step 5 If there is a spark the igniter is OK Step 2 Remove outer jacket door Step 3 Slide open or remove the inner combustion chamber door Step 5 Remove the lead wire from the igniter at the connector Figure 14 provided for this Hold the igniter lead from the gas valve close to an unpainted metal surface such as the burner feedline and depress the igniter button see Figure 15 If there is a spark the igniter is OK If no spark is present the igniter is not functioning and the gas control must be replaced per Service Procedure AG III page 18 Look for spark in the gap Figure 15 BRADFORD WHITE nn WATER HEATERS 7 w SERVICE PROCEDURE AG IIl Gas Control Testing and Replacement BRADFORD WHITE For Models using White Rodgers or WATER HEATER
6. Defective magnet in gas control Check connection at gas control Proper tightness should be finger tight plus Ya turn Inspect thermocouple to ensure that it is fully engaged into pilot bracket Adjust tip of thermocouple to be fully engulfed by pilot flame Check thermocouple and replace if necessary Check ECO continuity and replace gas control if necessary Check magnet operation and replace gas control if necessary 2 3 Gas Control set too low for desired water temperature Gas Control temperature is satisfied Insufficient gas supply or low gas 3 pressure 4 Gas Control has wide differential or is out of calibration ar Adjust temperature dial on gas control Check temperature dial setting on gas control Check gas supply and line pressure Check gas control for proper operation replace if necessary 2 Insufficient combustion air supply Inconsistent gas supply or gas pressure Incorrect clogged vent system vent terminal or location 2 to the unit Check and clear Jacket slot openings of any dirt dust restrictions or other obstructions Check venting for proper sizing and proper operation Check gas supply and line pressure lt gt lt gt Verify adequate combustion air is available 4 See Service Procedure AG I Page 6 5 See Service Procedure AG III Page 12 6 See Service Procedure AG III Page 12
7. Figure 35 Step 3 Align slots located on the thermowell flange with tabs located on the back of the gas control see Figure 36 Gas control tabs Figure 36 Step 4 Carefully push the gas control back onto the thermowell flange Step 5 Install burner assembly and reconnect pilot tubing and main burner feed line to gas control Step 6 Reconnect wire harness and igniter wire to the gas control Step 7 Resume water supply to water heater and check for leaks Be sure tank is full of water Step 8 Reconnect the gas supply to gas control Check for gas leaks using a soapy water solution Step 9 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 nn nn O SERVICE PROCEDURE AG IV Burner Operation Inspection Adjustment BRADFORD WHITE Cleaning and Replacement WATER HEATERS C J 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 burner can have the gas and air mixture properly proportioned by adju
8. Procedure AG Il Page 10 gt lt gt lt 1 See Service Thermowell sensor out of calibration Procedure AG III Page 16 gt gt gt gt lt 1 See Service Excessive tank temperature Thermowell sensor out of calibration Procedure AG III Page 16 No Dr A AN P Three flashes and a Tank temperature fault three second pause System will reset Four flashes and a three second pause 4 E BRADFORD WHITE Troubleshootin Chart cont For Models Using Honeywell Gas Control a gt Five flashes and a three second pause LED Status y Control Status Probable Cause EG Service Procedure s lt gt Thermowell fault Damage to thermowell wires Thermowell sensor resistance out of range lt gt See Service Procedure AG IIl Page 16 lt S Seven flashes and a three second pause gt Gas control fault detected I Gas control needs to be reset Gas control is wet or physically damaged lt gt Lite pilot per the instructions located on the lighting instructions label or the lighting instructions located in the installation and operation manual Z gt second pause dE Eight flashes and a three Pilot flame remains on while gas control is in the OFF position lt gt
9. Step 3 Remove or slide open the inner combustion chamber door Step 4 Disconnect red and white thermopile wires from the wire harness leading to the gas control Step 5 Disconnect the thermopile from the pilot bracket using a 7 16 open end wrench Step 6 Install the new thermopile into the pilot bracket and tighten the threads using care not to damage the thermopile lead wires Route new wires through the appropriate opening in the combustion chamber Step 7 Reconnect the lead wires being careful to match the colors red to red and white to white Step 8 Reinstall or slide closed inner combustion chamber door Step 9 Replace the outer door Step 10 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual 5 GREASE G RISK IN ATER SCALDIN TTER Wi Gas Control Knob oe Shown in OFF PRESS NT position Figure de 8 EEE BRADFORD WHITE 2 n SERVICE PROCEDURE AG II Pilot Assembly Inspection Cleaning BRADFORD WHITE and Replacement For Models Using White WATER HEATERS Rodgers or Robertshaw Gas Control For White Rodgers gas control depress knob PILOT ASSEMBLY INSPECTION slightly and rotate CLEANING AND REPLACEMENT clockwise to the OFF position Step 1 Turn off gas supply to water heater Rotate knob For Robertshaw gas of gas control to OFF position contr
10. gas control rotate knob Step 6 Slide open inner combustion chamber door clockwise to the OFF Step 5 Remove outer jacket burner access door position Figure 26 14 BRADFORD WHITE WATER HEATERS SERVICE PROCEDURE AG II Gas Control Testing and Replacement BRADFORD WHITE For Models using White Rodgers or WATER HEATERS Robertshaw Gas Control Step 7 Removal of gas control a Disconnect main burner feedline pilot tube and thermocouple from gas control 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 gas control from heater rotating counter clockwise using a control body wrench or a length of 2 NPT pipe threaded into inlet of control Wrench Boss To remove or install control insert only 2 NPT threaded pipe into inlet and e use to loosen or tighten control 2 Step 8 Installation of gas control Figure 27 a Install new gas control using a control body wrench or a length of 2 NPT pipe threaded into inlet of control DO NOT OVER TIGHTEN Use caution not to damage cast aluminum body of gas control Be certain not to damage the bundled wire leads NOTE gas control 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
11. noted in step 5 proceed to step 7 or 8 for proper service procedure Step 7 For White Rodgers control the manifold pressure is not adjustable If manifold pressure is outside the range in step 5 the control must be replaced Step 8 For Robertshaw control the manifold pressure is adjustable proceed to step 9 for adjustment procedure Step 9 While burner is in operation remove regulator access cap to expose the regulator adjusting screw With small screw driver rotate adjusting screw clockwise to increase pressure and counter clockwise to decrease pressure Figure 19 Step 10 Replace regulator access cap set gas control to OFF Remove manometer and pressure tap and replace pressure tap plug Check for gas leaks before placing water heater back in operation a 12 EEE BRADFORD WHITE WATER HEATERS Na SERVICE PROCEDURE AG III Gas Control Testing and Replacement BRADFORD WHITE For Models using White Rodgers or WATER HEATERS Robertshaw Gas Control THERMOCOUPLE TESTING See SERVICE PROCEDURE AG II MAGNET ASSEMBLY TESTING White Rodgers Control Stepl Following the lighting instruction label on the heater proceed to light the pilot and allow to operate for three minutes If the pilot will not stay lit hold the pilot button located on the combination thermostat gas valve down during this test Step 2 Using a multimeter capable of measuring millivolts connect one lead l using an alligator cl
12. 10502 10248 1000 9760 9526 80 9299 9078 8862 8653 8250 8057 7869 7685 7507 90 1333 7165 7000 6839 6683 6531 6383 6238 6098 5961 100 5827 5697 5570 5446 5326 5208 5094 4982 4873 4767 110 4663 4562 4464 4368 4274 4183 4094 4006 3922 3839 120 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 1953 1035 1017 999 190 982 965 949 933 917 901 886 871 857 842 200 828 814 801 788 775 762 749 737 125 113 BRADFORD WHITE nn a S a SERVICE PROCEDURE AG III Honeywell Gas Control and Thermowell BRADFORD WHITE Replacement WATER HEATERS C HONEYWELL GAS CONTROL amp THERMOWELL REMOVAL Step 1 Turn the gas control knob to the OFF position Step 2 Turn off water supply and drain water heater completely Step 3 Turn off and disconnect gas supply to control Step 4 Disconnect wire harness and burner assembly from the gas control Figure 31 Step 5 Remove gas control and thermowell by rotating flats of the thermowell counter clockwise HONEYWELL GAS CONTROL REMOVAL FROM THERMOWELL NOTE Following the instructions below allows the removal of the gas control from the thermowell without removing the thermowell
13. FORD WHITE WATER HEATERS 23 O Diptube and Anode BRADF ORD WHI TE Inspection and Replacement 7 S a SERVICE PROCEDURE AG V WATER HEATERS 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 Turn gas control knob to OFF position For White Rodgers Control position 5 depress knob slightly and ee ee rotate clockwise to the OFF A N ae ES on pe For Honeywell gas gt ras control rotate knob a Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 For Robertshaw Control rotate knob clockwise to the OFF position counter clockwise to the OFF position DE Figure 50 Figure 51 Turn off cold water supply to water heater Connect hose to drain spigot of water heater and route to a suitable drain Open a nearby hot water faucet to vent heater for draining Open drain spigot of water heater and allow to drain Disconnect plumbing system from outlet nipple anode With an appropriate wrench remove outlet nipple anode from the water heater Use caution not to damage the nipple threads Visually Inspect outlet nipple anode Outlet nipple anode may show signs of depletion this is normal If depletion is 1 2 of the original anode diameter approximately 4 diame
14. IV Dip Tube and Anode Inspection and Replacement 23 AG V 2 E BRADFORD WHITE Symptom Pilot will not light Pilot will not stay lit when button is released gt Pilot will light but the main burner will not come on Pilot goes out periodically after heating cycles once a day once a week etc gt Not enough hot water 1 2 3 4 lt gt Troubleshooting Chart For Models Using White Rodgers or Robertshaw Thermostat a gt Probable Cause Y Corrective Action No incoming gas or too low gas lt gt pressure Gas control knob set to wrong position 2 Pilot light button not being fully depressed when attempting to light pilot 3 Pilot orifice or pilot tube is obstructed or kinked 4 Turn on gas supply and or check line pressure Review lighting instruction Set gas control to correct position Review lighting instruction Fully depress pilot lighting button Clean repair or replace lt gt Service Procedure a 1 See Service Procedure AG III Page 12 4 See Service Procedure AG II Page 9 lt o au Poor thermocouple connection at gas control 2 Thermocouple not fully engaged in pilot lt gt assembly bracket 3 Pilot flame is not fully enveloping the thermocouple hot junction 4 Weak or defective thermocouple Open ECO on gas control 5
15. S Robertshaw Gas Control Gas Control Testing and Replacement The gas control is a non repairable device If trouble shooting has determined a problem with the gas control it must be replaced If the burner and or pilot do not function service checks for gas pressure thermocouple output magnet assembly and ECO are to be performed If these check OK the gas control may be faulty LINE PRESSURE The gas control is designed for a maximum line pressure of 14 0 w c and a minimum line pressure of 1 0 w c over the water heater 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 a Na T N Step 1 Set gas control to OFF position Step 2 Remove pressure tap plug and install pressure tap Step 3 Connect manometer to pressure tap Fi TE 16 aan Pressure Tap ZI NE Step4 Follow lighting instructions and proceed to light Shown FEN main burner and observe manometer reading Installed u ls Step 5 Proper operating range for natural gas is 4 0 0 3 W C Proper operating range for L P gas is 10 0 0 5 W C Step 6 If pressure is OK set gas control to OFF Figure 17 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
16. continuously throughout this test In an OPEN CIRCUIT test Any reading over 400 millivolts indicates good thermopile output For readings under 400 millivolts 2 4 replacement of thermopile is recommended Figure 5 CLOSED CIRCUIT THERMOPILE TESTING Step 1 Closed circuit testing is the preferred method for testing the thermopile Following the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual proceed to light the pilot and allow the control to operate for three minutes Step 2 Using a multimeter capable of measuring millivolts measure across thermopile connections at the gas control see Figure 6 Ina CLOSED CIRCUIT test Any reading over 300 millivolts indicates good thermopile output For readings under 300 millivolts replacement of thermopile is recommended Gas Control Knob NOTE It may be necessary to hold the gas control knob down in the PILOT position continuously throughout this test Thermopile Connections at gas control Figure 6 BRADFORD WHITE E SI T SERVICE PROCEDURE AG I Thermopile Testing and Replacement BRADFORD WHITE For Models Using Honeywell Gas Control WATER HEATERS C J THERMOPILE REPLACEMENT Step 1 Turn off the gas supply to the water heater by rotating the gas control knob to the OFF position see Figure 7 Step 2 Remove outer jacket door
17. from the tank Step 1 Turn the gas control knob to the OFF position Step 2 Turn off and disconnect gas supply piping to the gas control Step 3 Disconnect wire harnesses and burner assembly from the gas control Step 4 Using the gas control service tool part number 239 45991 00 available from your Bradford White parts supplier insert tool into the back of the gas control see Figure 32 amp 33 View from back of gas control for clarity Insert tool into back of gas control Figure 32 Figure 33 Step 5 Pivot service tool towards water heater as far as possible see Figure 34 Lift up straight on gas control The gas control should move about 1 8 Hold gas control in position and remove tool Lift straight up on the gas control to remove completely from the thermowell Figure 34 BRADFORD WHITE WATER HEATERS 18 3 N SERVICE PROCEDURE AG III Honeywell Gas Control and Thermowell BRADFORD WHI TE Replacement WATER HEATERS J HONEYWELL GAS CONTROL ASSEMBLY TO THERMALWELL Step 1 Install threaded end of thermowell into water heater When tight be sure thermowell flange is positioned so that thermowell relief opening is in the 6 o clock position for proper control alignment see Figure 35 Thermowell flange slots Route wire through relief opening 6 o clock position Step 2 Route lead wires through the relief opening see Figure 35
18. ip to the copper sheath of the thermocouple use the second lead of the multi meter to probe the top terminal located at the back of the gas control EAZ Alligator clip to copper sheath of thermocouple Probe top terminal on back of gas control Figure 20 Step 6 With a meter reading of 13 millivolts or greater rotate knob of gas control to the OFF position Step 7 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 gas control should be replaced MAGNET ASSEMBLY TESTING Robertshaw Control Step 1 Disconnect thermocouple from gas control Step 2 Connect a thermocouple adaptor BWC P N 239 44642 00 Robertshaw P N 75036 at the thermocouple location in the gas control Figure 21 Step 3 Reconnect thermocouple to adaptor Make certain all connections are tight finger tight plus 1 4 turn Step 4 Using a multimeter capable of measuring millivolts connect one er Ya alligator clip to the set screw of the adaptor and the other alligator clip to copper portion of the thermocouple Figure 22 Step 5 Following the lighting instruction label on the heater proceed to light the pilot and allow to operate for three minuets Step 6 With a meter reading of 13 millivolts or greater rotate knob of gas c
19. mbly Inspection Cleaning BRADFORD WHITE and Replacement For Models Using WATER HEATERS Honeywell Gas Control PILOT ASSEMBLY INSPECTION CLEANING AND REPLACEMENT Step 1 Turn off the gas supply to the water Heater Rotate gas control knob to the OFF position Step 2 Remove outer jacket door Step 3 Remove burner assembly per Service Procedure AG IV page 20 E cd A Step 4 Remove the pilot assembly from the burner assembly Figure 12 Step 5 Inspect the pilot assembly for the following Pilot Orifice a Primary air opening for any blockage Must be free from any debris dirt lint dust etc b Kinks or cracks in the pilot tube If found the pilot must be replaced Step 6 Inspect pilot orifice o E 13 a Remove 7 16 nut from the bottom of the pilot assembly b Remove pilot tube and pilot orifice c Inspect pilot orifice for blockage must be free from any debris dirt lint dust etc d Reassemble pilot orifice and pilot tube to pilot assembly Step 7 Install pilot assembly to burner assembly using the screw from Step 4 Step 8 Reinstall burner assembly per Service Procedure AG IV page 22 Steps 10 through 12 Step 9 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual Step 10 Check all gas connections for gas leaks using a soapy water solution de
20. not reverse direction to align b Reattach main burner feedline pilot tube and thermocouple to gas control NOTE Feedline nut for natural gas control uses right hand threads LP control uses left hand thread c Connect gas supply piping to inlet of control Use back up wrench on wrench boss of control never use back up wrench on body of control Step 9 Reconnect gas supply to gas control Step 10 Resume water supply to water heater Be sure tank is full of water Step 11 Slide inner combustion chamber door closed Step 12 Re attach outer jacket door Step 13 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual BRADFORD WHITE qe 15 a O N SERVICE PROCEDURE AG Ill Honeywell Thermowell Testing and BRADFORD WHI TE Replacemet WATER HEATERS ee HONEYWELL THERMOWELL TESTING Step 1 If gas control has gone into lockout due to excessive tank temperature four flashes and a three second pause reset the gas control to the OFF position Then follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual Step 2 Observe the water heater operation If the gas control continues to lockout due to excessive tank temperature proceed to Step 3 thermowell testing to determine the cause Step 3 To perform thermowell
21. ocouple from gas control 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 Connect other end of thermocouple to gas control finger tight 1 4 turn Step6 Route carefully through the relief opening in the combustion chamber skirt Step7 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual Step 8 Slide inner door closed when finished Thermocouple position Figure 4 de 6 BE BRADFORD WHITE g L n SERVICE PROCEDURE AG Thermocouple Testing and Replacement BRADFORD WHITE For Models Using Honeywell Gas Control WATER HEATERS s J OPEN CIRCUIT THERMOPILE TESTING Step 1 Disconnect red and white thermopile wires from the wire harness leading to the gas control Step 2 Using a multimeter capable of reading millivolts check across thermopile leads Step 3 Following the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual proceed to light the pilot and allow the gas control to operate for three minutes NOTE It may be necessary to hold the gas control knob down in the PILOT position
22. ol rotate knob l clockwise to the OFF Step2 Remove outer jacket door position Step 3 Slide open inner combustion chamber door Step 4 Disconnect thermocouple pilot tube and feedline from gas control NOTE Feedline nut for natural gas control uses right hand threads LP control uses left hand thread Step 5 Remove burner assembly from combustion chamber Step 6 Remove pilot assembly from feedline Step 7 Inspect pilot for the following a Primary air openings for blockage Must be free from any debris dirt lint etc b Kinks or cracks in the pilot tube If found the pilot must be replaced Step 8 Inspect pilot orifice Pilot Orifice el l Opening Figure 11 a Remove 1 2 nut from bottom of pilot assembly b Remove pilot tube and pilot orifice c inspect pilot orifice for blockage must be cleaned or replaced Step9 Install pilot assembly to feedline secure with screw from step 6 Step 10 Re Install burner assembly into combustion chamber connect feedline pilot tube and thermocouple to gas control Step 11 Slide inner combustion chamber door closed and re attach outer jacket door Step 12 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual BRADFORD WHITE WATER HEATERS a N w SERVICE PROCEDURE AG II Pilot Asse
23. onnect unscrew main burner feedline from burner Step 6 Remove main burner orifice from feedline Inspect and clean if necessary Step 7 Inspect pilot assembly per service procedure AG II Figure 45 Step 8 Reassemble burner assembly Step 9 Inspect combustion chamber area of water heater and clean if needed prior to reinstallation of burner assembly Step 10 Reinstall burner assembly into combustion chamber reconnect feedline thermocouple or thermopile pilot tube and igniter wire for applicable models to the gas control Step 11 Slide close or attach inner combustion chamber door and reattach outer jacket door Step 12 To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual de 22 nana BRADFORD WHITE O N n SERVICE PROCEDURE AG V Diptube and Anode BRADF ORD WHI TE Inspection and Replacement WATER HEATERS DIPTUBE 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 Turn the gas control knob to the OFF position For White Rodgers Control depress knob slightly and rotate clockwise to the OFF i For Honeywell gas PRESS IHO Es position control rotate knob ar counter clockwise to the OFF posi
24. ontrol to the OFF position Step 7 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 gas control should be replaced BRADFORD WHITE nS SERVICE PROCEDURE AG III Gas Control Testing and Replacement BRADFORD WHITE For Models using White Rodgers or WATER HEATERS Robertshaw Gas Control ECO Eneray Cut Off TESTING Step 1 Disconnect thermocouple from gas control 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 Figure 23 Step 3 Ifcontinuity is indicated the ECO is OK If continuity is not indicated the ECO has opened and the gas control must be replaced GAS CONTROL REPLACEMENT For White Rodgers gas control depress knob slightly and rotate Step 2 Turn off gas supply to water heater clockwise to the OFF position Step 1 Rotate knob of the gas control to the OFF position Step 3 Disconnect gas supply line from gas control Step 4 Turn off water supply and drain water heater completely For Robertshaw
25. pilot tube Burner should operate as adjusted in step 2 on page 20 if not repeat procedure compensating air shutter position for proper burner operation with inner door closed Figure 38 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 procedure below BURNER CLEANING Steel amp Cast Iron Step 1 Step 2 Step 3 Step 4 Slide open or remove inner combustion chamber door Disconnect main burner feed line pilot tube and thermocouple or thermopile from gas control and remove burner assembly from combustion chamber NOTE Feedline nut for natural gas control uses right hand threads LP control uses left hand threads Thoroughly inspect burner surface area and burner ports and remove any debris build up Burner Surface Area Fa Figure 39 SS _ Figure 41 Figure 42 On cast iron burners inspect mo for any debris build up inside burner venturi If found disconnect main burner feedline from burner and remove debris build up Burner Venturi Opening Figure 43 Feedline BRADFORD WHITE nn a SERVICE PROCEDURE AG IV Burner Operation Inspection Adjustment BRADFORD WHITE Cleaning and Replacement WATER HEATERS C BURNER CLEANING Cont Step 5 Steel Burner Disconnect unscrew burner from main burner orifice Cast Iron Burner Disc
26. rming the steps below turn off cold water supply to the water heater This will prevent cold water flow into the tank affecting the resistance value of the thermowell connector Use special pin type Step 1 Turn the gas control to the OFF position and electronic probes or small diameter disconnect the thermowell harness from the gas control wire pins inserted into connector Step 2 Using a multimeter set to measure Ohms determine the resistance of the thermowell sensor See caution on this page Step 3 Hold one probe in the center pin and measure the outside positions pins see figure 29 amp 30 page 16 Step 4 Draw approximately 1 quart of water from the drain valve and immediately measure the water temperature using an accurate thermometer It may be necessary to open a hot water faucet to allow the heater to drain Step 5 Refer to Table 1 below to determine the correct resistance value for the water heater tank temperature Example If the temperature of the 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 Table 1 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 E 8 9 22771 22163 21573 21000 20445 17440 16990 16553 16128 15715 13477 13140 12812 12494 12185 70 11884 11592 11308 11032
27. sting 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 21 CAST IRON BURNER 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 slide the inner combustion chamber door open Step2 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 are minimized and the flame becomes blue 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 yellow tips will result in soot formation Air a L Nut Figure 37 de 20 nn BRADFORD WHITE Burner Operation Inspection Adjustment BRADFORD WHITE Cleaning and Replacement la Ss a SERVICE PROCEDURE AG IV WATER HEATERS a J MAIN BURNER Inspection Adjustment Cleaning and Replacement cont Step 3 Step 4 Step 5 Step 6 Fully inspect combustion chamber for debris or carbon build up Be certain that thermocouple or thermopile and pilot tube are routed correctly through the relief opening in the combustion chamber Position thermocouple or thermopile and
28. ter replacement is recommended If any of the steel core of the anode is exposed replacement 1s recommended Upon completion of inspection or subsequent replacement reinstall outlet nipple anode into water heater Reconnect plumbing system to outlet nipple anode resume water supply and check for leaks To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual a WATER HEATERS NOTES NOTES NOTES BRADFORD WHITE WATER HEATERS 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 Parts Fax 215 641 2180 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 ts BRADFORD WHITE CANADA INC Mississauga ON Sales 866 690 0961 905 238 0100 Fax 905 238 0105 Technical Support 800 334 3393 Email parts bradfordwhite com techserv bradfordwhite com www bradfordwhite com
29. testing turn the gas control to the OFF position and disconnect the thermowell harness from the gas control Disconnect thermowell wire harness Figure 28 Figure 29 ACAUTION DO NOT Use standard multimeter probes to test Doing so will damage connector Use special pin type electronic probes or small diameter wire pins inserted into connector Figure 30 Step 4 Using a multimeter set to measure Ohms determine the resistance of the thermowell sensor See caution on this page Step 5 Hold one probe in the center pin and measure the outside positions pins see figure 29 amp 30 Step 6 Refer to Table 1 on page 17 to determine the correct resistance value for the water heater tank temperature Step 7 If the resistance values are correct the gas control needs to be replaced If they are incorrect the thermowell needs to be replaced 16 EEE BRADFORD WHITE SERVICE PROCEDURE AG III Honeywell Thermowell Testing and BRADFORD WHI TE Replacement WATER HEATERS DETERMINE WATER HEATER TANK TEMPERATURE A WARNING Stored water may be HOT when NOTE It is important to understand once the resistance for the thermowell is determined water flow through the water heater should not occur Prior performing the following steps in this procedure Take necessary precaution to prevent personal injury A CAUTION DO NOT use standard multimeter probes to test Doing so will damage to perfo
30. tion For Robertshaw Control rotate knob clockwise to the OFF position SOR e A 1 _ _ i RIECHT u Y am yy gt Figure 47 Figure 48 Step 2 Turn off cold water supply to water heater Connect hose to drain spigot of water heater and route to a suitable drain Open a nearby hot water faucet to vent water heater for draining Open drain spigot of water heater and allow to drain Step 3 Disconnect plumbing system from inlet nipple diptube Step 4 With an appropriate wrench remove inlet nipple diptube from the water heater Use caution not to damage the nipple threads Step 5 Visually inspect inlet nipple diptube Inlet nipple diptube should be free of cracks and any blockage The small curved openings 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 diptube into water heater Reconnect plumbing system to inlet nipple diptube resume cold water supply and check for leaks 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 BRAD
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