Bradford White ECO-DEFENDER U130T*FRN Bedienungsanleitung

(To be performed ONLY by qualified service providers)

Save this manual for future reference

Manual 47132A

The Bradford White

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

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

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

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

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

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

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

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.

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.

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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