Bradford White HE440S*F User manual

Save this manual for future reference
Manual 238-50216-00A
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
HE440S*F(BN,SX)
HE450S*F(BN,SX)
(*) Denotes Warranty Years
Super High Efficiency
Atmospheric Vent Gas Water Heaters

Page 2
Table of Contents
Section Page
Introduction ______________________________________________ 5
How to Use this Manual _____________________________________ 6
Tools Required for Service___________________________________ 6
Specifications_____________________________________________ 7
Sequence of Operation _____________________________________ 9
Power Up Sequence
Normal Heating Sequence
Abnormal Operation
Troubleshooting __________________________________________ 13
Burner Maintenance_______________________________________ 15
Burner Inspection
Burner Cleaning Procedure
Pilot Maintenance_________________________________________ 17
Pilot Inspection, Testing and Replacement
Blower Replacement ______________________________________ 19
Temperature Sensor Testing ________________________________ 21
Determine Water Temperature Inside Tank ____________________ 23
Gas Control Removal ______________________________________ 25
Gas Control Disassembly/Assembly __________________________ 26
Flammable Vapor Sensor Testing ____________________________ 27
120 VAC Circuit Trace _____________________________________ 28
Diptube Inspection _______________________________________ 28
Anode Inspection_________________________________________ 29
Blower Removal__________________________________________ 30
Inner Door Removal ______________________________________ 32
Inner Door Gasket Replacement _____________________________ 33
Inner Door Installation ____________________________________ 34
Pressure Switch Testing & Replacement _______________________ 35
Arrestor Cleaning_________________________________________ 37
Common Terms __________________________________________ 38
Notes __________________________________________________ 38
Parts List _______________________________________________ 39
2

WARNING
Ifthe information inthese instructions isnot followedexactly, a fire or explosion may
resultcausing property damage, personal injury, or death.
Whatto do ifyou smell gas:
x Do not try to light any appliance
x Do not touch any electrical switch; do not use any phone inyour building
x Immediately call your gassupplierfrom a neighbor’sphone. Follow the gassupplier’s
instructions.
x Ifyou cannot reach your gassupplier, call the fire department.
Installation and service must be performedby a qualifiedinstaller, service agency, or the
gassupplier.
CAUTION
Incorrect operation of thiswaterheatermay create a hazard to life and property and will
nullify the warranty.
Ifsweatfittingsare to be used, DO NOT apply heatto the nippleson top of the water
heater. Sweatthe tubing to the adapterbefore fitting the adapterto the water
connections. Itisimperative thatheatisnot appliedto the nipplescontaining a plastic
liner.
Turn off or disconnect the electrical powersupply to the waterheaterbefore servicing.
Label all wiresprior to disconnection whenservicing controls. Wiring errors cancause
improperand dangerous operation. Verify properoperation afterservicing.
DANGER
Do not store or use gasoline or otherflammable, combustible, or corrosive vapors and
liquids inthe vicinity of thisor any otherappliance.
NOTICE
Before proceeding, please inspect the waterheaterand its components for possible
damage. DO NOT install any waterheaterwith damagedcomponents. Ifdamage is
evident, thenplease contact the supplierwhere the waterheaterwaspurchasedor the
manufacturerlistedon the rating plate for replacement parts.
Page 3
3

Page 4
WARNING
Waterheaters are heatproducing appliances. To avoiddamage or injury, do not store
materialsagainst the waterheateror any of its components. Use propercare to avoid
unnecessary contact, especially by children, with the waterheaterand its components.
Underno circumstancesmust flammable materials, such asgasoline or paint thinnerbe
usedor storedinthe vicinity of thiswaterheateror inany location inwhich the fumes
couldreach the waterheater.
Hydrogengascanbe producedinanoperating waterheaterthathasnot hadwaterdrawn
from the tank for a long period of time (generally twoweeks or more). Hydrogengasis
extremely flammable. To prevent the possibility of injury underthese conditions, we
recommend a hot waterfaucetto be openfor several minutesatthe kitchensink before
you use any electrical appliance which isconnectedto the hot watersystem. Ifhydrogenis
present, there will be anunusual sound such asairescaping throughthe pipesashot
waterbegins to flow. Do not smoke or have openflame nearthe faucetatthe time itis
open.
DO NOT ATTEMPTTO LIGHTANY GAS APPLIANCE IF YOU ARE NOT CERTAINOF THE
FOLLOWING:
Liquefiedpetroleum gases/propane gasand natural gashave anodorant addedby the gas
supplierthataids inthe detection of the gas. Most people recognize thisodor asa “sulfur”
or “rottenegg” smell. Otherconditions, such as“odorant fade” cancause the odorant to
diminish inintensity, or ”fade,” and not be asreadily detectable. Ifyou have a diminished
sense of smell, or are inany way unsure of the presence of gas, immediately contact your
gassupplierfrom a neighbor'stelephone. Gasdetectors are available. Contact your gas
supplier, or plumbing professional for more information.
FAILURE TO INSTALL AND MAINTAINANEW, LISTED3/4” X 3/4” TEMPERATURE AND
PRESSURE RELIEF VALVE WILL RELEASE THE MANUFACTURERFROM ANY CLAIMTHAT
MIGHTRESULTFROM EXCESSIVE TEMPERATURE AND PRESSURES.
4

Page 5
The Bradford White DEFENDER Safety System®
The Bradford White DEFENDER Safety System was designed to resist the ignition of
flammable vapors that can occur outside of the water heater. Use and installation are nearly
identical to previous versions of atmospherically fired and vented water heaters. A number of
exclusive design features are incorporated in the system that will require additional knowledge
on the part of the qualified service provider. The following information will instruct service
professionals on the function, proper diagnosis, and repair of water heaters employing the
Bradford White DEFENDER Safety System.
Introduction
The new Bradford White Super High Efficiency atmospheric vent gas water heaters are
designed to provide reliable performance with enhanced standard features. New design features
include reliable spark-to-pilot ignition system, enhanced diagnostics, simplified servicing, and
the 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 Thermal Well/Gas Control with LED - was developed for ease of
troubleshooting by providing simple diagnostic codes to pinpoint an installation or component
performance issue.
Rugged Wiring Connections - receptacle type connections promote error free wiring.
The gas control maintains water temperature, ignition sequence, and regulates gas flow. 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 gas control can be removed and replaced without
draining the water heater.
Please read the service manual completely before attempting service on this new series of super
high efficiency gas models.
How the Safety System Works
During normal operation, air for combustion is drawn into the water heater through the
openings 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 bottom. The air
then travels up through the flame arrestor 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 NOxemissions.
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
Introduction
5

Page 6
in sufficient quantity to prevent normal 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 prevents the flames from traveling backwards and igniting vapors outside of the
combustion chamber. And, the resettable thermal switch will open and shut down the pilot and
main burner.
How to Use this Manual
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 Super High Efficiency atmospheric gas
water heaters. Understanding the sequence of operation section of this manual will contribute
greatly to troubleshooting the water heater.
The Honeywell WV4462 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.
Contact the Bradford White technical support group immediately if diagnosis cannot be made
using the methods described in this service manual.
Tools RequiredforService
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.
ElectronicProbes: 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.
WaterPressure Gage: Used to measure water supply pressure. Also used to determine tank
pressure by adapting to the drain valve of the heater.
Various HandTools: Pipe wrench, channel locks, open end wrenches (3/8", 7/16", 1/2"), 12"
crescent wrench, Allen wrench set, screw drivers (common & Phillips), torx bits, 1/4" 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
6

Page 7
Power Supply Dedicated 120VAC, 60 Hz, 15A
Gas Supply Pipe
Minimum 1/2” (Schedule 40 black iron pipe
recommended)
Approved Gas Type Natural or Propane; unit must match gas type supplied
Gas Pressure 5” w.c. minimum for Natural Gas; 11” w.c. for Propane;
14” w.c. maximum for Natural Gas / Propane
Approved Vent Materials Single or Double Wall Metal Vent Pipe
Recommended Minimum
Clearance for Servicing 18” from top; 24” from front; 4” from sides and rear
Water Supply Pressure 150 psi maximum allowable working pressure; check local
codes for supply pressure
ECO Limit 188°F (87°C)
Temperature Setpoint Range 60°F (16°C) to 160°F (71°C); approximate temperatures
Pressure Switch Setting
(normal altitude) -0.20” w.c.
Specifications
7

Page 8
Ignition State Timing
Pre-purge 15 seconds
Trial for Ignition 90 seconds
Flame Stabilization Period 3seconds
Interpurge 15 seconds
Flame Failure Response Time 1.5 seconds (2 second maximum; 1second mini-
mum)
Postpurge 15 seconds
Pressure Switch FaultDelay(failedopen/close)Retry after2minutes
Soft Lockout Retry after5minutes
ECO LimitLockout Indefinite (See page 21 to reset)
Verify Resistive DelayRetry after2minutes(repeats 5times)
SimulatedResistive LoadLockout Indefinite (cycle powerto reset)
Hardware Error Lockout Indefinite (selfclears iffaultclears for atleast 15
seconds)
Specifications
Wiring Diagram
Control Timings
8

Page 9
Power Up Sequence
1. Start-up: Upon power up, the gas control runs a safe start check with a typical
delay of 5 seconds.
2. Flammable Vapor Verification: The gas control verifies that the Flammable Vapor
Sensor is in the proper operating range prior to energizing any components. If the
sensor is within the proper range, the gas control resumes normal operation. If the
Flammable Vapor Sensor is out of range, the gas control LED immediately flashes
7 times with a 3 second pause.
Normal Heating Sequence
1. Thermostat Calls for Heat: Prior to energizing the blower, the gas control verifies
the safety circuit to see if it is in the correct state. Normal switch positions in the
safety circuit are as follows:
A) Pressure switch normally open;
B) Blower temperature switch normally closed.
If the safety circuit is closed, the gas control LED flashes 2 times with a 3 second
pause. The gas control waits 2 minutes. Then, the blower is energized for 30
seconds. This cycle repeats until the safety circuit opens.
2. Blower Energizes
3. Safety Circuit Check: If the safety circuit does not close within 30 seconds, the
gas control LED flashes 3 times with a 3 second pause. The blower runs for a
maximum of 30 seconds every 2 minutes trying to close the safety circuit. This
cycle repeats as long as there is a call for heat.
4. Blower Pre-Purge (15 seconds)
5. Trial for Pilot Ignition (90 seconds): The gas control lights the pilot by activating
the spark igniter and gas flow to the pilot burner. If flame is not sensed within 90
seconds, the spark igniter and gas flow are deactivated. The blower will postpurge,
and the gas control LED flashes 6 times then 1 time with a 3 second pause.
6. Main Burner Ignition: After pilot flame is sensed, the gas control activates the
main valve for main burner ignition. The gas control will ignore flame signals for 3
seconds to allow for the main burner to stabilize.
SequenceofOperation
9

Page 10
Normal Heating Sequence (cont’d)
7. Steady State Operation: During steady state operation, the gas control monitors:
Temperature Sensor: When the setpoint temperature is satisfied, the gas control is
shutdown, and the blower will postpurge for 15 seconds. The gas control LED
flashes a short flash once every 4 seconds (Idle status code).
Pressure Switch / Blower Temperature Switch: If either switch opens, the pilot and
main valves are shutdown. The blower continues to run for 30 seconds attempting
to close the circuit. The gas control LED flashes 3 times with a 3 second pause.
Flame Sensor: If flame is lost, the pilot and main valves are shutdown. The blower
runs for 15 seconds. The gas control attempts to re-light the pilot 4 times. If
unsuccessful, the blower is shutdown, and the gas control proceeds to a 5 minute
lockout. The gas control re-attempts to light the pilot starting at Normal Heating
Sequence #2.
8. Thermostat Satisfies: Gas control LED flashes once every 4 seconds.
9. Burner Off
10.Blower Postpurge (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. The gas 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 with a 3 second pause.
This process is repeated 5 times until the control either returns to normal operation
or proceeds to flammable vapor lockout.
B) If the resistance is below 240 ohms: The gas control immediately turns off all
outputs and proceeds to flash 8 times then 1 time with a 3 second pause. The error
self clears if the resistance returns to normal range for at least 15 seconds.
SequenceofOperation
10

Page 11
Abnormal Operation (cont’d)
2. Temperature Sensor Fault:
A) Temperature Sensor Open Circuit: The gas control immediately turns off all
outputs and proceeds to flash 8 times then 2 times with a 3 second pause. The
error self clears if the fault clears for at least 15 seconds.
B) Temperature sensors not reading the same temperature within ±5°F: The gas
control immediately turns off all outputs and proceeds to flash 8 times then 2 times
with 3 second pause. The error self clears if the fault clears for at least 15 seconds.
C) Water Temperature in excess of ECO (Energy Cut Off) Limit: The gas control
immediately turns off the pilot and main valves. The gas control LED proceeds to
flash 4 times with a 3 second pause.
To reset the gas control, rotate the setpoint knob to the minimum setting for at least
6 seconds before returning to desired temperature setting.
3. Pressure Switch / Blower Temperature Switch (Safety Circuit) Fault:
A) Pressure Switch Closed at Start of Call for Heat: The gas control proceeds to
flash 2 times with a 3 second pause. The gas control waits 2 minutes, and then
turns the blower on for 60 seconds. The blower turns off after 60 seconds, and
the control waits for the pressure switch to open.
B) Pressure Switch Failed to Close: The gas control runs the blower for 60
seconds waiting for the pressure switch to close. If the switch does not close in
60 seconds, the blower turns off, and the control flashes 3 times with a 3 second
pause. The gas control waits two minutes before turning on the blower for
another 60 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 / Blower Temperature Switch Opens During Burner Operation:
The gas control turns off the pilot and main valve and runs the blower for 15
seconds (inter-purge) waiting for the 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 a 3 second
pause. The gas control waits 5 minutes before repeating the ignition sequence.
SequenceofOperation
11

Page 12
Abnormal Operation (cont’d)
4. Trial for Ignition Fault:
A) Pressure Switch / Blower Temperature Switch Opens During Trial: The gas
control stops the trial for ignition. The gas control monitors the pressure switch
until it closes. If the pressure switch closes within 30 seconds, the gas control
will continue with the 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
spark igniter turns off, the pilot valve is closed, and the gas control runs the
blower through postpurge. The gas control LED flashes 6 times then 1 time with
3 second pause. The control waits 5 minutes before repeating the ignition
sequence.
5. Flame Sensing Fault:
A) Flame Lost During Run: The gas control turns off pilot and main valves and runs
the 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 LED flashes 6 times
then 3 times with a 3 second pause. The gas control waits 5 minutes before
repeating the ignition sequence.
B)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 continues 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 a 3 second pause. The control waits 5 minutes before
repeating the ignition sequence.
SequenceofOperation
12

Page 13
LEDStatus Control Status ProbableCause Service Procedure
None (LED not
on or flashing)
Electrical powernot
present
Control powerswitch in"OFF"
position.
Su
pp
l
y
volta
g
e interru
p
ted.
Turn PowerOn
One short flash
every four
seconds
Stand-by mo d e,
Thermostatis
satisfied
(
no faults
)
Temperature demand issatisfied
(no call for heat) Normal operation
One short flash
every two
seconds
Stand-by mo d e,
Sabbath mo de (no
faults
)
Temperature on Setback Control is
adjusteddownto prevent burner
o
p
eration
Normal operation
Alternates
bright and dim
(
heartbeat
)
Thermostatcalling
for heat(no fault)
Tank temperature below setpoint of
thermostatNormal operation
Short flash once
every second
Weakpilot signal
on last call for heat
1. Unstable pilot
2. Pilot tube blockedor restricted
3. Oxidation build-up on pilot
electrode
4. Wire damage to pilot assemb lyor
badconnection at
g
ascontrol
1. See BurnerInspection on page
15
2-4. See Pilot Inspection, Testing
and Replacement on page 17
Twoflashes,
three second
pause
Pressure switch not
working -closed
position
1. Pressure switch tubing kinkedor
blocked
2. Blockedpressure tapon switch
or blower
3. Fault
yp
ressure switch
See Pressure Switch Testing and
Replacement on page 35
Three flashes,
three second
pause
Pressure switch or
temperature switch
not working -open
position
1. Vent blockage or impro p ervent
configuration
2. Pressure switch tubing kinkedor
blocked
3. Faulty pressure switch
4. Blowernot spinning up to speed
5. Damper(inside blower) not fully
opening
6. Faulty blowertemperature switch
1. Verify cord sets are fullyplugged
in
2. See Pressure Switch Testing and
Replacement on page 35
Four flashes,
three second
pause
Excessive tank
temperature,
systemmus t be
reset
1. Temperature sensor out of
calibration
2. Faulty gascontrol
1. Test GasControl &Temperature
Sensor
2. Replace gascontrol ifnecessary
Five flashes,
three second
p
ause
False pilot flame
present Pilot valve stuck inopenposition Replace gascontrol
Sixflashes, one
flash, three
second pause
(Soft Lockout)
Failedto light pilot,
systemresets after
(5) minutes
1. Unstable pilot
2. Pilot tube block or restricted
3. Oxidation build-up on pilot
electrode
4. Wire damage to pilot assemb lyor
badconnection at
g
asvalve
1. See BurnerInspection on page
15
2-4. See Pilot Inspection, Testing
and Replacement on page 17
Observe the greenLED on the waterheatergascontrol.Error
codesare displayedwith a 3second pause before repeating.
Once the error code isknown, check and repairthe waterheater,
asrecommendedinthe table below.
Troubleshooting
13

Page 14
LEDStatus Control Status ProbableCause Service Procedure
Sixflashes, two
flashes, three
second pause
(So ft Lockout)
Pressure switch or
blowertemp switch
openedduring
burneroperation,
systemauto resets
after(5) minutes
1. Vent blockage or impro pervent
configuration
2. Pressure switch tubing kinkedor
blocked
3. Faulty pressure switch
4. Blowernot spinning up to speed
5. Damper(inside blower) not fully
opening
6. Faulty blowertemperature switch
1. See BurnerInspection on
page 15
2-4. See Pressure Switch Testing
and Replacement on page 35
Sixflashes, three
flashes, three
second pause
(So ft Lockout)
Pilot flame
extinguished,
systemauto resets
after(5) minutes
1. Unstable pilot
2. Pilot tube block or restricted
3. Oxidation build-up on pilot
electrode
4. Wire damage to pilot assemblyor
badconnection atgascontrol
5. Insufficient combustion air
6. Insufficient
g
as
p
ressure
1. See BurnerInspection on
page 15
2-4. See Pilot Inspection, Testing
and Replacement on page 17
5. Referto Installation &
Operation Manual
Sixflashes, four
flashes, three
second
p
ause
Undesiredfalse
pilot flame sensed,
s
y
stemauto resets
Pilot valve stuck inopenposition Replace gascontrol
Sevenflashes,
three second
pause
Flammable vapor
sensor or
resettable thermal
switch fault
detected, see
warning label
1. Flammable vapor present
2. Flammable vapor sensor exposed
to excessive mo isture
3. Flammable vapor sensor exposed
to extreme amb ient temperature
4. Resettable thermal switch open
See Flammable Vapor Sensor
Testing on page 27
Eight flashes,
one flash, three
second pause
Flammable vapor
sensor out of
specification,
possible short
1. Flammable vapor sensor out of
specification; ve rify Flammable Vapor
Sensor (FVS) resistance isnot below
25,000 Ohms.
2. Possible short inflammable vapor
sensor or resettable thermal switch
wirin
g
See Flammable Vapor Sensor
Testing on page 27
Eight flashes,
two flashes,
three second
pause
Temperature
sensor fault
detected
1. Damage to temperature sensor
wires
2. Temperature sensor resistance
out of range
3. Re
p
lace tem
p
erature sensor
See Temperature Sensor Te sting
on page 21
Eight flashes,
three flashes,
three second
pause
Gascontrol
electronics fault
detected
1. Verify control isnot wetor
physicallydamaged
2. Resetcontrol on/off switch
3. Replace gascontrol if8-3 error
p
ersists
See GasControl Remo val on
page 25
Eight flashes,
four flashes,
three second
pause
Gascontrol fault
detected
1. Verify control isnot wetor
physicallydamaged
2. Resetcontrol on/off switch
3. Replace gascontrol if8-4 error
p
ersists
1. Replace gascontrol ifwetor
physicallydamaged
2. Cycle power
3. Replace gascontrol
Troubleshooting
14

Page 15
Burner Inspection
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. The
pilot flame should be stable. Some causes for an unstable pilot flame are:
a) Gas pressure is out of specification.
b) Pilot flame not fully engulfing spark/flame sensor.
The main burner should light smoothly from the 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. The main burner must be free from any debris accumulation that may
effect burner operation (See Burner Cleaning Procedure below).
Burner Cleaning Procedure
Step 1. Move the gas control power switch to the “OFF”
position.
Step 2. Unplug the water heater from the wall outlet.
Step 3. Turn off the gas supply to the water heater.
Step 4. Remove the outer door.
Burner Maintenance
Gascontrol power
switch
Blower(waterheater)
powercord
Outerdoor
15

Page 16
Burner Cleaning Procedure (cont’d)
Step 5. Remove the (4) 1/4” hex drive screws holding the
right side inner door in place.
Step 6. Disconnect the pilot tube
using a 7/16” wrench and the main burner
feedline with a 3/4” wrench from the gas
control.
Step 7. Disconnect the spark igniter/flame sensor wire
from gas control.
Step 8. Remove the burner assembly from the combustion
chamber.
Step 9. Thoroughly inspect the burner surface area and
burner port area and remove any loose debris.
Step 10. Unscrew the burner from the main burner orifice.
Step 11. Remove the main burner orifice from the main
feedline using a 1/2” wrench. Inspect the orifice and clean or
replace, if necessary.
Burner Maintenance
(4) 1/4”hex drive
screws Right side
innerdoor
Pilot and mainfeed-
lines
Spark igniter/flame
sensor wire
Gascontrol
Burnerassembly
Burnersurface area
and burnerports
1/2”wrench
Mainburner
orifice
Mainfeedline
16

Page 17
Burner Cleaning Procedure (cont’d)
Step 12. Reassemble the burner assembly and reinstall into the water heater.
Restore gas supply and check for gas leaks.
Step 13. To resume operation, follow the instructions located on the water heater
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.
Pilot Inspection, Testing and Replacement
Step 1. Move the gas control power switch to the “OFF”
position
Step 2. Unplug the water heater from the wall outlet.
Step 3. Turn off the gas supply to the water heater.
Step 4. Remove the outer door.
Step 5. Remove the (4) 1/4” hex drive screws holding the
right side inner door in place.
Step 6. Disconnect the pilot tube
using a 7/16” wrench and the main burner
feedline with a 3/4” wrench from the gas
control.
Pilot Maintenance
(4) 1/4”hex drive
screws Right side
innerdoor
Gascontrol power
switch
Blower(waterheater)
powercord
Outerdoor
Pilot and mainfeed-
lines
17

Page 18
Pilot Inspection, Testing and Replacement (cont’d)
Step 7. Disconnect the spark igniter/flame sensor wire
from gas control.
Step 8. Remove the burner assembly from the combustion
chamber.
Step 9. Remove the pilot assembly from the main feedline
using a 1/4" nut driver.
Step 10. Visually inspect the spark igniter/flame sense wire for damage. Replace
the pilot assembly, if damage is found.
Step 11. With a multi-meter set to the ohms setting, check
continuity through the spark igniter/flame sense wire. Replace
the pilot, if there is no continuity.
Step 12. Visually inspect the spark igniter/flame sense electrode for deterioration.
Replace the pilot assembly, if necessary. The electrode should not be in contact with
pilot hood. If it is in contact with the pilot hood, carefully adjust electrode to a gap
distance of 3/32" from the pilot hood.
Step 13. Visually inspect the spark igniter/flame sense electrode for oxidation build
up. Carefully clean any oxidation using very fine emery cloth.
Pilot Maintenance
Burnerassembly
Pilot assembly
1/4”nut driver
Multi-meter
Spark igniter/flame
sensor wire
Gascontrol
18

Page 19
Pilot Inspection, Testing and Replacement (cont’d)
Step 14. Visually inspect the pilot tubing for kinks or cracks. If damage is found,
replace the pilot assembly.
Step 15. Inspect the pilot tubing and pilot orifice for blockages:
a) Remove ferrule nut from the bottom of the pilot
assembly using a 7/16" wrench.
b) Remove the pilot tube and pilot orifice.
c) Inspect the pilot tubing and pilot orifice for
blockages. Clean or replace, as necessary.
Step 16. Reassemble the pilot assembly and install it on the main feedline.
Reinstall the burner assembly into the combustion chamber. Restore the gas supply
and check for gas leaks.
Step 17. To resume operation, follow the instructions located on the water heater
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.
Blower Removal & Installation
Step 1. Move the gas control power switch to the “OFF”
position.
Step 2. Unplug the water heater from the wall outlet.
Blower Replacement
Gascontrol power
switch
Blower(waterheater)
powercord
19

Page 20
Blower Removal & Installation (cont’d)
Step 3. Disconnect the vent system from the draft hood
that is mounted on top of the blower.
Step 4. Remove the draft hood from the blower and retain
it for use on the new blower.
Step 5. Unplug the cord sets from the blower.
Step 6. Remove the three blower mounting screws using a
1/4” nut driver and retain for later use.
Step 7. Remove the blower from the top of the water
heater.
Step 8. Clean any debris from the jacket head of the water heater.
Step 9. Set the new blower in place using the water heater tank flue and the
screw holes in the jacket head.
Step 10 Secure the blower in place using the screws from Step 6.
Step 11. Re-install the draft hood from Step 4.
Step 12. Reconnect the vent system to the draft hood.
Blower Replacement
Vent system
Draft hood
Blower
Cord sets
1/4”nut driver
Blower
Top of water
heater
Waterheatertank flue
20