Bradford White Eco-Magnum Series User manual

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Manual 238-50628-00A
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
U175S*RN
U2XR75S*RN
U100T*RN
U75T80R*N
U100T88R*N
(*) Denotes Warranty Years
Ultra Low NOx Gas Water Heaters
Atmospheric ECO-MAGNUM SERIES™

The Bradford White
Atmospheric ECO-MAGNUM
Ultra Low NOx Gas Water
Heaters
Table of Contents
Page Service Procedure
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Page 2
2

WARNING
If the information in these instructions is not
followed exactly, a fire or explosion may result
causing property damage, personal injury, or
death.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
x Do not touch any electrical switch; do not use any
phone in your building.
x Immediately call your gas supplier from a neighbor's
phone. Follow the gas supplier's instructions.
x 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.
FOR YOUR SAFETY
Do not store or use gasoline or other flammable,
combustible, or corrosive vapors and liquids in
the vicinity of this or any other appliance.
CAUTION
Incorrect operation of this appliance
may create a hazard to life and
property and will nullify the warranty.
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.
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
manufacturer listed on the rating plate
for replacement parts.
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.
WARNING
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU
ARE NOT CERTAIN OF THE FOLLOWING:
x Liquefied petroleum gases/propane gas and natural
gas have an odorant added by the gas supplier that
aids in the detection of the gas.
x Most people recognize this odor as a “sulfur” or
“rotten egg” smell.
x Other conditions, such as “odorant fade” can cause
the odorant to diminish in intensity, or ”fade”, and
not be as readily detectable.
x If you have a diminished sense of smell, or are in
any way unsure of the presence of gas, immediately
contact your gas supplier from a neighbor's
telephone.
Gas detectors are available. Contact your gas supplier,
or plumbing professional, for more information.
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. 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.
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.
Page 3
ECO-MAGNUM
75/100-Gallon Atmospheric
3

Tools Required for Service
It is intended for this manual to be used by qualified service personnel for the primary purpose of
troubleshooting and repair of the Bradford White Atmospheric Ultra Low NOx Series of water
heaters.
The Honeywell 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 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.
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 ECO-MAGNUM
75/100-Gallon Atmospheric
Introduction
4

Page 5
LED Status Control Status Probable Cause Service Procedure
None (LED not on
or flashing)
Gas valve is not
powered.
1. Pilot flame is not
present. Light pilot.
If the pilot will not stay lit
replace thermopile, see
page 11. If problem
persists replace gas
valve, see page 15.
One flash and
three second
pause.
1. If set point knob is in
"PILOT" position then
pilot flame is detected.
Turn set point knob to
desired setting
2. If set point knob is at
desired setting the gas
valve is waiting for a
call for heat (no faults).
1. Gas valve is
powered and waiting
for the set point knob to
be turned to a water
temperature setting.
2. Temperature
demand is satisfied.
Normal operation. Adjust
thermostat to desired
temperature level.
LED strobe (two
quick flashes) and
three second
pause.
Thermostat calling for
heat (no faults).
Tank temperature
below setpoint of
thermostat.
Normal operation.
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 18.
Observe green LED indicator on
gas control. Error flash codes are
displayed with a three second
pause before repeating. Check
and repair the system as noted in
the troubleshooting table below.
Gas Control Troubleshooting
Green LED
Indicator
ECO-MAGNUM
75/100-Gallon Atmospheric
5

Page 6
LED Status Control Status Probable Cause Service Procedure
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. Replace gas
control, see page 15.
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. Replace gas control,
see page 15.
Five flashes
and three
second
pause.
Thermostat well fault.
1. Damage to the
thermowell wire.
2. Thermowell
sensor resistance
out of range.
1&2. Replace gas
control, see page 15.
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 15.
Eight flashes
and three
second pause
False pilot flame
present.
Pilot valve stuck in
open position.
Replace gas control, see
page 15.
Gas Control Troubleshooting ECO-MAGNUM
75/100-Gallon Atmospheric
6

Page 7
Step 5. Fully inspect burner door and right side 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.
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. Remove wire clip from main burner feedline.
Step 4. Inner Door Removal.
a) Disconnect red thermopile lead and red gas control lead from
resettable thermal switch. Disconnect white thermopile lead
from the gas valve (see photos 1 and 2).
b) Disconnect main burner feed line (¾” wrench), pilot tube
(7/16" wrench) and igniter wire from gas control (see photo 2).
c) Remove (2) ¼” hex drive screws from right side inner door
(see photo 3).
d) Remove (2) ¼” hex drive screws from flange section of
inner door (see photo 3).
e) Remove (3) 1/4" hex drive screws from burner door
(see photos 4&5). The burner door and burner are
one-piece.
f) Remove burner and inner door and inspect per step 5.
ECO-MAGNUM
75/100-Gallon Atmospheric
SERVICE PROCEDURE I
Burner and Inner Door/Gasket Removal,
Inspection, Replacement and
Reinstallation
Gas Control Knob Shown In
“OFF” Position
1
2
3
4
5
Red Thermopile Lead
Red Gas
Control Lead
White Thermopile
Lead
Main Burner
Feedline
Pilot Tube
Igniter Wire
Right Side
Hex Drive
Screws
Flange Hex
Drive
Screws
Burner Door
Hex Drive
Screws
Position #1
Position #2
Position #3
7

SERVICE PROCEDURE I
Burner and Inner Door/Gasket Removal,
Inspection, Replacement and
Reinstallation
Page 8
Re-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 9, 11 and 12.
If a fastener connection is stripped,
contact the manufacturer listed on the
water heater rating plate.
Step 8. Clean any residual gasket residue or other debris
from combustion chamber surface before
re-installing the inner door/gasket assembly.
Step 9. Place the burner door into position first. Tighten
the feed line nut to the gas control. Use the ¼”
hex drive screw without the built-in washer to
secure burner door to the chamber at position #1.
Use the ¼” hex drive screws with the built-in
washer to secure the door at positions #2 & #3
(see photos 4&5, on page 7).
DO NOT OVER TIGHTEN SCREWS.
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 6. After inspection of inner door as noted in step 5, completely remove gasket and adhesive residue from burner
door and right side inner door as needed.
Step 7. 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. Ensure that the chamfer of
the gasket faces outward. Set the flange section first, this will help to achieve the proper overlap position.
ECO-MAGNUM
75/100-Gallon Atmospheric
8

SERVICE PROCEDURE I
Burner and Inner Door/Gasket Removal,
Inspection, Replacement and
Reinstallation
Page 9
Step 11. Firmly place right side inner door flange against the burner door flange and secure with two ¼” drive
screws from step 4d (see photo 7). DO NOT OVER TIGHTEN SCREWS.
Step 12. 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 (see photo 7). Verify seal integrity around
combustion opening. Secure right side inner door using 1/4” hex drive screws from step 4c.
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 13. Reconnect red gas valve lead and red thermopile lead to resettable thermal switch. Reconnect white gas
control lead to the gas valve (See photos 1&2 on page 7).
Step 14. Reconnect the pilot tube to the gas control and tighten. Reconnect the igniter wire to the gas control.
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.
Position Thermopile Wire,
Pilot Tube and Igniter Wire
Step 10. Position thermopile wires, pilot tube and igniter wire
against burner door flange gasket
(see photo 6).
Secure flange with ¼"
drive screws.
Verify threaded hole
alignment with slotted
openings in inner door.
7
6
ECO-MAGNUM
75/100-Gallon Atmospheric
9

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. Open the thermopile wire access covers. Using a multimeter capable of measuring DC 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 the meter reads 300 DC millivolts or higher, the thermopile is OK. If reading is below 300 DC
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
SERVICE PROCEDURE II
Thermopile Testing and Replacement
Page 10
Step 1. Disconnect white thermopile wire from wire harness leading to the gas valve. Disconnect the red thermopile
wire from the resettable thermal switch
Step 2. Using a multimeter capable of measuring DC 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 DC millivolts indicates good thermopile output.
Open Circuit Thermopile Testing
Left Side of Wire Harness Right Side of Wire Harness
Thermopile Access Covers
ECO-MAGNUM
75/100-Gallon Atmospheric
10