Bradford White ECO-DEFENDER U130T*FRN User manual

(To be performed ONLY by qualified service providers)
Save this manual for future reference
Manual 47132A
The Bradford White
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U150L*FRN
U1504S*FRN
U430T*FRN
U440T*FRN
U4403S*FRN
U4503*FRN
U1XR403S*FRN
(*) Denotes Warranty Years.
U130T*FRN
U130S*FRN
U140T*FRN
U1403T*FRN
U1403S*FRN
U1404T*FRN
U1503*FRN
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The Bradford White
Ultra Low NOx Gas Water Heaters
Page Service Procedure
Introduction 3 - - -
Gas Control Troubleshooting Chart 5 - - -
Tools Required for Service 4 - - -
Burner and Inner Door Gasket Removal, Inspection, Replacement
and Installation 7 ED-I
Thermopile Testing and Replacement 10 ED-II
Pilot Assembly Inspection, Cleaning and Replacement 12 ED-III
Igniter and Electrode Testing and Replacement 13 ED-IV
Gas Control Replacement Thermal Well and Chamber Door Sensor
Testing and Replacement 14 ED-V
Burner Operation Inspection, Cleaning and Replacement 19 ED-VI
Resettable Thermal Switch Testing and Replacement 21 ED-VII
ScreenLok Flame Arrestor Cleaning 23 ED-VIII
Dip Tube and Anode Inspection and Replacement 24 ED-IX
Generic Parts List 26 - - -
Page 2
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The Bradford White ECO-DEFENDER Safety System
The Bradford White ECO-DEFENDER Safety System was designed to
resist the ignition of flammable vapors that can occur outside of the water
heater. In addition, the ECO-DEFENDER Safety System is designed to
meet the stringent NOx emissions standards required in the South Coast
Air Quality Management District (SCAQMD) Rule 1121. Use and
installation are nearly identical to previous versions of atmospherically
fired and vented water heaters. A number of exclusive design features are
incorporated in the system that will require additional knowledge on the
part of the qualified service provider. The following information will
instruct service professionals on the function, proper diagnosis and repair
of water heaters employing the Bradford White ECO-DEFENDER Safety
System.
How the Safety System Works
During normal operation, most air for combustion is drawn into the water
heater through the openings in the jacket door. This air travels into the
burner venturi, mixing with the gas jet. This air is then mixed with gas
inside the burner and drawn to the burner screen and is efficiently
combusted producing Ultra Low NOx emissions. Additional air is drawn
through the openings in the jacket. This air travels down and around the
combustion chamber and enters through holes in the bottom of the
corrosion-resistant combustion chamber. The air then travels up through
the oriented flame arrestor plate louvers, where the velocity of the air is
increased and its direction altered. The air then mixes in a normal manner
with the combustion products from the burner.
In the case where trace amounts of flammable vapors are present in the air
flowing into the combustion chamber and burner venturi, the vapors are
harmlessly ignited by the burner / pilot flame. If flammable vapors are in
sufficient quantity to prevent normal combustion, the burner and pilot
flames are designed to shut down.
Should the flammable vapors continue to the burner, the flame arrestor
plate and burner screen prevent the flames from traveling backwards and
igniting vapors outside of the combustion chamber. This causes the
thermopile to overheat and shuts down the main pilot and burner. The
thermopile powers the intelligent diagnostic control which is capable of
recognizing restricted airflow conditions caused by severe lint, dust and
oil accumulation on the burner screen and arrestor plate. The intelligent
diagnostic control will deactivate the burner and pilot in the unlikely event
of restricted airflow.
Page 3
INTRODUCTION
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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 ECO-DEFENDER Series of water heaters.
The Honeywell WV8860Q Gas Control will display error codes in the event of abnormal operation.
Error codes are listed in the troubleshooting chart beginning on page 5 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.
Contact the Bradford White technical support group immediately if diagnosis can not be made
using the methods described in this service manual.
Page 4
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-Meter: 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",½"),
12" crescent wrench, Allen wrench set, screw drivers (common &
Phillips), ¼" nut driver, pliers (common & needle nose), socket set, side
cutters wire cutters, wire strippers, wire crimpers, torpedo level, small
shop vac, step ladder, flashlight and 5 gallon pail.
How to Use This Manual
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Page 5
LED Status Control Status Probable Cause Service Procedure
None (LED not on
or flashing)
Gas valve is operating
normally. Pilot flame
may not be present.
Check for pilot flame
through sight glass and
light if necessary.
1. Gas valve is
functioning normally
2. Gas valve is not
powered. Light pilot
If the pilot will not stay lit
replace thermopile, see
page 10. If problem
persists replace gas
valve, see page 16.
One flash and
three second
pause.
If set point knob is in
"PILOT" position then
pilot flame is detected.
Turn set point knob to
desired setting
Gas valve is powered
and waiting for the set
point knob to be turned
to a water temperature
setting.
Normal operation. Adjust
thermostat to desired
temperature level.
LED on
continuously.
Set point knob has
been recently turned to
the "OFF" position.
Wait until LED goes out
before attempting to
relight
Set point knob was
turned to "OFF"
position.
LED will go out and the
control will function
normally when the pilot is
lit.
Two flashes and
three second
pause.
Weak pilot flame
detected. System will
reset when pilot flame
is sufficient.
1. Thermopile failure
2. Unstable pilot.
3. Pilot tube block or
restricted.
4. Resettable thermal
switch has opened.
1. See page 10.
2&3. See page 12.
4. See page 21.
Three flashes and
three second
pause.
Insufficient water
heating. System will
reset.
1. Thermowell sensor
and chamber
temperature sensor out
of calibration.
2. Possible short.
1&2. See pages 14 and
18.
Four flashes and
three second
pause.
Excessive tank
temperature. System
must be reset.
1. Thermowell sensor
out of calibration.
2. Faulty gas valve.
1. See page 14.
2. See page 16.
Observe red LED indicator on
gas control. Error flash codes are
displayed with a three second
pause before repeating. Check
and repair the system as noted in
the troubleshooting table below.
Gas Control Troubleshooting
Red LED
Indicator
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Page 6
LED Status Control Status Probable Cause Service Procedure
Five flashes
and three
second
pause.
Thermostat well fault.
1. Damage to the
thermowell wire.
2. Thermowell
sensor resistance
out of range.
See page 14.
Six flashes
and three
second
pause.
Chamber door
temperature sensor out
of specification.
Possible electrical
short.
1. Chamber door
temperature sensor
out of calibration.
2. Possible
electrical short.
See page 18.
Seven flashes
and three
second
pause.
Gas valve electronic
fault detected.
1. Control needs to
be reset
2. Control is wet or
physically damaged
1.Turn gas control knob
to "OFF" position and
then follow lighting
instructions.
2. Replace gas control,
see page 16.
Eight flashes
and three
second pause
False pilot flame
present.
Pilot valve stuck in
open position.
Replace gas control, see
page 16.
Ten flashes
and three
second pause
Insufficient combustion
air detected. Reset
system.
Insufficient
combustion air. See page 19 and 23.
Gas Control Troubleshooting
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Inner Door Removal Procedure
Step 1. Rotate the gas control knob to the “OFF”
position.
Step 2. Remove outer jacket burner access door
Step 3. Inner Door Removal.
a) Disconnect chamber door temperature sensor wire harness from the gas valve.
b) Disconnect resettable thermal switch white wire lead (leading from gas valve). Disconnect the red wire
leading from the gas valve from the red thermopile wire.
c) Disconnect main burner feed line (¾” wrench), pilot tube (7/16" wrench) and igniter wire from gas valve.
d) Remove (2) 1/4" hex drive screws from right side inner door.
e) Remove (2) 1/4" drive screws from flange section of inner door.
f) Remove (3) 1/4" drive screws from burner door. The burner door and burner are one-piece.
g) Remove burner and inner door and inspect per step 4.
Step 4. Fully inspect burner and inner door gaskets for the following:
>Tears >Other imperfections that will inhibit proper seal
>Missing Material >Gasket adhesion to inner door
>Cracks >Material left on combustion chamber (around opening)
>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.
Page 7
Gas Control Knob Shown In
“OFF” Position
¼” Hex Drive Screws Right
and Left Side Inner Door
¼” Hex Drive Screws at
Flange Area of Inner Door
White Wire Lead
Red Wire Lead
Feed Line Nut
Pilot Nut
Chamber Door
Temperature Sensor
Wire Harness
SERVICE PROCEDURE ED-I
Burner and Inner Door/Gasket Removal,
Inspection, Replacement and
Reinstallation
White Thermopile
Wire
Red Thermopile
Wire
Chamber Door
Temperature
Sensor
7

Installation of Inner Door With Gasket.
WARNING
Stripped fastener connections may allow
for seal breach of inner door. A seal
breach may result in a fire or explosion
causing property damage, personal injury
or death. Do not over tighten screws in
steps 8, 10 and 11.
If a fastener connection is stripped,
contact the manufacturer listed on the
water heater rating plate.
Step 7. Clean any residual gasket residue or other debris
from combustion chamber surface before
installing the inner door/gasket assembly.
SERVICE PROCEDURE ED-I
Burner and Inner Door/Gasket Removal,
Inspection, Replacement and
Reinstallation
Step 8. Place the burner door into position first. Tighten
the feed line nut to the gas valve. Use the ¼” hex
drive screw without the built-in washer to secure
the right side of the burner door to the chamber.
Use the ¼” hex drive screws with the built-in
washer to secure the left side of the burner door in
place. DO NOT OVER TIGHTEN SCREWS.
Step 9. Position thermopile wires, pilot tube and igniter wire
against burner door flange gasket.
Page 8
Inner Door Gasket Replacement
Procedure.
WARNING
If the information in these instructions is not
followed exactly, a fire or explosion may result causing
property damage, personal injury or death.
Step 5. After inspection of inner door as noted in step 4, completely remove gasket and adhesive residue from burner
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 & burner). The burner door gasket must be sliced in the location shown on the illustration below in
order to slide the gasket over the burner venturi. Refer to illustration below for proper RTV sealant
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.
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Step 10. Firmly place right side inner door flange against the burner door flange and secure with two ¼” drive
screws from step 3e. DO NOT OVER TIGHTEN SCREWS.
Step 11. Align right side inner door to combustion chamber and verify the fastener holes of the combustion
chamber are aligned with the right side inner door slotted opening. Verify seal integrity around combustion
opening. Secure right side inner door using 1/4” hex drive screws from step 3b. DO NOT OVER TIGHTEN
SCREWS. Verify both burner and right sides of the inner door are properly positioned and sealed against
the combustion chamber.
Step 12. Reconnect lead wires from gas valve to resettable thermal switch (See photo in step 3). Note, the white wire
needs to be connected to the thermal switch and the red wire needs to be connected to the red wire from the
thermopile.
Step 13. Reconnect the wire harness from the chamber door temperature sensor to the gas valve (See photo in step 3).
Step 14. Tighten the pilot nut to the gas valve.
Step 15. Replace outer jacket burner access door.
Step 16. To resume operation follow the instructions located on the lighting instruction label or the lighting instructions
located in the installation and operation manual.
Verify threaded hole
alignment with slotted
openings in inner door.
SERVICE PROCEDURE ED-I
Burner and Inner Door/Gasket Removal,
Inspection, Replacement and
Reinstallation
Page 9
Position Thermopile Wire,
Pilot Tube and Igniter Wire
Secure flange with
¼" drive screws.
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Step 1. Closed circuit testing is the preferred method for testing thermopile. 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 (rotate the gas control knob to the pilot position, push and hold in) during this test
Step 2. Using a multimeter capable of measuring millivolts, place one lead of the multi meter on the left side of the
wire harness and place the second lead of the multi meter on the right side of the wire harness.
Step 3. If meter reads 300 millivolts or higher, the thermopile is OK. If reading is below 300 millivolts,
replace the thermopile. For maximum thermopile life the thermopile should be replaced with a genuine
Honeywell thermopile (BWC P/N 233-47063-00).
CLOSED CIRCUIT THERMOPILE TESTING (Honeywell Control)
SERVICE PROCEDURE ED-II
Thermopile Testing and Replacement
Page 10
Step 1. Disconnect red thermopile wire from wire harness leading to the gas valve. Disconnect the white thermopile
wire from the resettable thermal switch
Step 2. Using a multimeter capable of measuring millivolts,
connect one lead to the red thermopile wire and one
lead to the white thermopile wire.
Step 3. Following the lighting instruction label on the heater, proceed to light the pilot and allow to operate for
three minutes. It will be necessary to hold gas control knob down in the “PILOT” position continuously
throughout this test. Any reading over 400 millivolts indicates good thermopile output.
OPEN CIRCUIT THERMOPILE TESTING
Left Side of Wire Harness Right Side of Wire Harness
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