Bradford-White Corp 07.05.228.00 Water Heater User Manual
Contents
1. a BRADFORD WHI TE C O R P O R A T Atmospheric Gas Water Heaters 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 MI75S BN CX M2XR75S BN CX MI100T BN CX 65T65 BN CX 75T80 BN CX Denotes Warranty Year Manual 238 46647 00A Save this manual for future reference lt BRADFORD WHI TE C O R P O R A T Table of Contents Trouble shooting Chart Thermocouple Testing and Replacement Pilot Assembly Inspection Cleaning and Replacement Combination Thermostat Gas Valve Testing and Replacement Burner Operation Inspection Adjustment Cleaning and Replacement Dip Tube and Anode Inspection and Replacement Page 3 4 10 13 Service Procedure AG I AG II AG III AG IV AG V Troubleshooting Chart 7 SYMPTOM v PROBABLE CAUSE a CORRECTIVE ACTION Y SERVICE PROCEDURE gt Pilot will not light 1 2 3 No incoming gas or too low gas pressure Gas control knob set to wrong position Pilot light button not being fully depressed when attempting to light pilot 4 Pilot orifice or pilot tube is obstructed or kinked lt gt 1 Turn on gas supply and or check line pressure 2 Review lighting instruction Set combination thermostat gas valve to co2. 20 to 30 millivolts indicates good thermocouple output THERMOCOUPLE REPLACEMENT Step 1 Turn off gas supply to water heater Rotate knob of combination thermostat gas valve to OFF position For Robertshaw Control rotate knob clockwise to the OFF For White Rodgers Control aa position depress knob slightly and rotate clockwise to the OFF position Step 2 Remove outer jacket door Step 3 Slide open inner combustion chamber door Step 4 Disconnect thermocouple from combination thermostat gas valve 3 8 wrench 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 combination thermostat gas valve finger tight 1 4 turn Step 6 Route carefully through the relief opening in the combustion chamber skirt 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 Step 8 Slide inner door closed when finished Thermocouple position BRADFORD WHITE Pilot Assembly Inspection Cleaning Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Step 12 SERVICE
3. Step 3 If continuity is indicated the ECO is OK If continuity is not indicated the ECO has opened and the combination thermostat gas valve must be replaced COMBINATION THERMOSTAT GAS VALVE REPLACEMENT Step 1 Rotate knob of the combination thermostat gas valve For White Rodgers Control to the OFF position depress knob slightly and rotate lockwise to the OFF ition Step 2 Turn off gas supply to water heater clockwise to the position Step 3 Disconnect gas supply line from combination thermostat gas valve For Robertshaw Control rotate Step 4 Turn off water supply and drain water heater completely se ees to the OFF position Step 5 Remove outer jacket burner access door Step 6 Slide open inner combustion chamber door u Z SERVICE PROCEDURE AG III BRADF ORD WHI TE Combination Thermostat Gas Valve C O R PO RATI Testing and Replacement Step 7 Removal of combination thermostat gas valve a Disconnect main burner feedline 4 wrench pilot tube 7 16 wrench and thermocouple 3 8 wrench from combination thermostat gas valve 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 Combination Thermostat Gas Valve from heater rotating counter clockwise using a control body wrench or a length of 2 NPT pipe threaded into inlet of control Wrench Boss
4. To remove or install control insert only 7 NPT threaded pipe into inlet mn ae use to loosen or tighten Onl Step 8 Installation of Combination Thermostat Gas Valve a Install new combination thermostat gas valve 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 combination thermostat gas valve Be certain not to damage the bundled wire leads NOTE Combination thermostat gas Valve 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 not reverse direction to align b Reattach main burner feedline pilot tube and thermocouple to combination thermostat gas valve 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 Combination Thermostat Gas Valve 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 opera
5. MOCOUPLE TESTING See SERVICE PROCEDURE AG I MAGNET ASSEMBLY TESTING White Rodgers Control Step 1 Step 2 Step 6 Step 7 MAGNET ASSEMBLY TESTING Robertshaw Control Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 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 Using a multimeter capable of measuring millivolts connect one lead using an alligator clip 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 combination thermostat gas valve r Probe top terminal on back of combination thermostat gas valve sheath of thermocouple i Alligator clip to copper j With a meter reading of 13 millivolts or greater rotate knob of combination thermostat gas valve to the OFF position 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 combination thermostat gas valve should be replaced Disconnect thermocouple from combination thermostat gas valve Connect a thermocouple tees l Robertshaw P N 75036 at the thermoco
6. PROCEDURE AG II C O R P O RA T I and Replacement k P PILOT ASSEMBLY INSPECTION For White Rodgers Control CLEANING AND REPLACEMENT depress knob slightly and rotate clockwise to the OFF position Turn off gas supply to water heater Rotate knob For Robenshaw Control rotate of combination thermostat gas valve knob clockwise to the OFF to OFF position position Remove outer jacket door Slide open inner combustion chamber door Disconnect thermocouple 3 8 wrench pilot tube 7 16 wrench and feedline 4 wench from combination thermostat gas valve NOTE Feedline nut for natural gas control uses right hand threads LP control uses left hand thread Remove burner assembly from combustion chamber Remove pilot assembly from feedline 4 drive tool 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 pet Air Inspect pilot orifice Opening a Remove 1 2 nut from bottom of pilot assembly b Remove pilot tube and pilot orifice t pilot orifice for blockage must be cleaned laced c inspect pilot orifice for blockage must be cleaned or replace TH Pict Orifice Install pilot assembly to feedline secure with screw from step 7 Re Install burner assembly into combustion chamber connect feedline
7. alve is out of calibration not functioning Out of spec dip tube is diluting hot water with cold water Integrated mixing device is set too low for desired water temperature N O N 1 Check dial on combination thermostat gas valve 2 Extremely cold water going into the heater will decrease the amount of hot water produced It may be necessary to temper incoming water supply 3 Adjust high demand usage 4 Contact Plumbing professional 5 Check combination thermostat gas valve for proper operation replace if necessary 6 Inspect dip tube and replace if necessary 7 Reset device using the procedure A in the instructions included with the device 5 See Service Procedure AG III Page 6 6 See Service Procedure AG V Page 13 f SERVICE PROCEDURE AG I BRADFORD WHITE COR PORATI Thermocouple Testing and Replacement of OPEN CIRCUIT THERMOCOUPLE TESTING Step 1 Disconnect thermocouple from combination thermostat gas valve Step 2 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 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 the pilot button down continuously throughout this test A reading of
8. ay result in soot formation Air Shutter Nut BRADFORD WHITE C O R PO R AT I Burner Operation Inspection Adjustment Cleaning and Replacement SERVICE PROCEDURE AG IV S MAIN BURNER Inspection Adjustment Cleaning and Replacement cont Step3 Fully inspect combustion chamber for debris or carbon build up Step 4 Burner should operate as adjusted in step 2 if not repeat procedure compensating air shutter position for proper burner operation with inner door closed Step 5 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 section in this procedure BURNER CLEANING Steel amp Cast Iron Step 1 Slide open inner combustion chamber door Step 2 Disconnect main burner feed line 74 wrench pilot tube 7 16 wrench and thermocouple 3 8 wrench from combination thermostat gas valve and remove burner assembly from combustion chamber NOTE Feedline nut for natural gas control uses right hand threads LP control uses left hand thread Step 3 Thoroughly inspect burner surface area and burner ports and remove any loose debris accumulation Burner Surface Area Burner Port Area Step 4 On cast iron burners inspect for any debris build up inside burner venturi If found disconnect feedline from burner and remove debris build up Burner Venturi Opening Feedli
9. ect manometer to pressure tap eee Step 4 Follow lighting instructions and proceed to light on ane main burner and observe manometer reading 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 combination thermostat gas valve to OFF 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 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 Step 10 Replace regulator access cap set combination thermostat gas valve to OFF Remove manometer and pressure tap and replace pressure tap plug Check for gas leaks before placing water heater back in operation BRADF ORD WHI TE Combination Thermostat Gas Valve O N C R P O R A T I SERVICE PROCEDURE AG III Testing and Replacement THER
10. ne i 11 N j am SERVICE PROCEDURE AG IV BRADF ORD WHI TE Burner Operation Inspection Adjustment C O R PO RATI Cleaning and Replacement BURNER CLEANING Cont Step 5 Disconnect unscrew Main burner stamped steel burner from main burner orifice or on cast iron burners loosen air shutter amp disconnect unscrew feedline from burner Step 6 Remove main burner orifice from feed line 2 wrench on steel ya burner 3 8 wrench on cast iron Inspect and clean if necessary A Wa a rt Step 7 Inspect pilot assembly per service procedure AG II Step 8 _Reassemble burner Step 9 Inspect combustion chamber area of heater and clean if needed prior to reinstallation of burner assembly Step 10 Reinstall burner assembly into combustion chamber reconnect feedline thermocouple and pilot tube to the combination thermostat gas valve Step 11 Slide inner combustion chamber door closed 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 SERVICE PROCEDURE AG V BRADF ORD WHI TE Dip Tube and Anode C O R PO RATI Inspection and Replacement a a N DIP TUBE INSPECTION AND REPLACEMENT A WARNING Heater components and stored water may be HOT when performing the following steps in this procedure Take necessary precaution to prevent per
11. pilot tube and thermocouple to combination thermostat gas valve Slide inner combustion chamber door closed and re attach outer jacket door To resume operation follow the instructions located on the lighting instruction label or the lighting instructions located in the installation and operation manual r BRADFORD WHI TE C O R P O R A T I SERVICE PROCEDURE AG III Combination Thermostat Gas Valve Testing and Replacement N F Combination Thermostat Gas Valve Testing and Replacement The combination thermostat gas valve is a non repairable device If trouble shooting has determined a problem with the combination thermostat gas valve 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 combination thermostat gas valve may be faulty LINE PRESSURE The combination thermostat gas valve 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 Step 1 Set combination thermostat gas valve to OFF position Step2 Remove pressure tap plug 3 16 Allen wrench and install pressure tap 7 16 wrench Step 3 Conn
12. rature dial setting on combination thermostat gas valve 3 Check gas supply and line pressure 4 Check combination thermostat gas valve for proper operation replace if lt gt 4 See Service Procedure AG I Page 4 5 See Service Procedure AG III Page 6 6 See Service Procedure AG III Page 6 1 Combination thermostat gas valve set too 1 Adjust temperature dial on combination l 2 See Installation amp operation manual 3 See Service Procedure AG III Page 6 4 See Service Procedure Pilot goes out periodically after heating cycles once a day once a week etc wide differential or is out of calibration necessary 1 Insufficient combustion air supply 2 Incorrect clogged vent system vent terminal or location 3 Inconsistent gas supply or gas pressure 1 Verify adequate combustion air is available to the unit Check and clear Jacket slot openings of any dirt dust restrictions or other obstructions 2 Check venting for proper sizing and proper operation 3 Check gas supply and line pressure AG III Page 6 3 See Service Procedure AG III Page 6 lt gt Not enough hot water n 1 Combination thermostat gas valve set too low for desired water temperature Cold inlet water temperature is very cold 3 High demand periods 4 Incorrectly sized water heater for application 5 Combination thermostat gas v
13. rrect position 3 Review lighting instruction Fully depress pilot lighting button 4 Clean repair or replace lt gt 1 See Service Procedure AG III Page 6 4 See Service Procedure AG II Page 5 lt Pilot will not stay lit when button is released Pilot will light but the main burner will not come on lt gt 1 Poor thermocouple connection at combination thermostat gas valve 2 Thermocouple not fully engaged in pilot assembly bracket 3 Pilot flame is not fully enveloping the thermocouple hot junction 4 Weak or defective thermocouple 5 Open ECO on combination thermostat gas valve 6 Defective magnet in combination thermostat gas valve low for desired water temperature 2 Combination thermostat gas valve temperature is satisfied 3 Insufficient gas supply or low gas pressure 4 Combination thermostat gas valve has lt gt 1 Check connection at combination thermostat gas valve Proper tightness should be finger tight plus 1 4 turn 2 Inspect thermocouple to ensure that it is fully engaged into pilot bracket 3 Adjust tip of thermocouple to be fully engulfed by pilot flame 4 Check thermocouple and replace if necessary 5 Check ECO continuity and replace combination thermostat gas valve if necessary 6 Check magnet operation and replace combination thermostat gas valve if necessary thermostat gas valve 2 Check tempe
14. ruction label or the lighting instructions located in the installation and operation manual 13 r Cn SERVICE PROCEDURE AG V BRADF ORD WHI TE Dip Tube and Anode C O R PO RATI Inspection and Replacement ANODE INSPECTION AND REPLACEMENT A WARNING 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 off water supply to water heater Rotate knob of combination thermostat gas valve to OFF position For White Rodgers Control depress knob slightly and rotate clockwise to the OFF position For Robertshaw Control rotate knob clockwise to the OFF position Step 2 Turn off cold water supply to heater Connect hose to drain spigot of water heater and route to an open drain Open a nearby hot water faucet to vent heater for draining Open drain spigot on water heater and allow heater to drain to a point below the outlet connection nipple Step 3 Disconnect outlet nipple from plumbing system Step 4 With an appropriate wrench remove outlet nipple anode from the water heater Use caution not to damage nipple threads Step 5 Visually Inspect outlet nipple anode Outlet nipple anode should show signs of depletion this is normal If depletion is 1 2 of the original anode diameter approximately 34 diameter replacement is recommended If any of the steel core of the anode is e
15. sonal injury Step 1 Rotate knob of combination thermostat gas valve to OFF position For White Rodgers Control depress knob slightly and rotate clockwise to the OFF position For Robertshaw Control rotate knob clockwise to the OFF position Step 2 Turn off cold water supply to heater Connect hose to drain spigot of water heater and route to an open drain Open a nearby hot water faucet to vent heater for draining Open drain spigot on water heater and allow heater to drain to a point below the inlet connection nipple Step 3 Disconnect inlet nipple from plumbing system Step 4 With an appropriate wrench remove inlet nipple dip tube from the water heater Use caution not to damage nipple threads Step 5 Visually Inspect inlet nipple dip tube Inlet nipple dip tube should be free of cracks and any blockage Hydro jets 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 dip tube into heater Connect nipple to plumbing system resume water supply and refill heater with water Step 7 To resume operation follow the instructions located on the lighting inst
16. tion manual SERVICE PROCEDURE AG IV BRADF ORD WHI TE Burner Operation Inspection Adjustment C O R PO RATI Cleaning and Replacement 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 adjusting 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 in this manual CAST IRON BURNER ADJUSTMENT A 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 Step 2 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 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 m
17. uple location in the combination thermostat gas valve Reconnect thermocouple to adaptor Make certain all connections are tight finger tight plus 1 4 turn Using a multimeter capable of measuring millivolts connect one alligator clip to the set screw of the adaptor and the other alligator clip to copper portion of the thermocouple Following the lighting instruction label on the heater proceed to light the pilot and allow to operate for three minuets With a meter reading of 13 millivolts or greater rotate knob of combination thermostat gas valve to the OFF position 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 combination thermostat gas valve should be replaced SERVICE PROCEDURE AG III BRADF ORD WHI TE Combination Thermostat Gas Valve C O R POR AT I Testing and Replacement ECO Energy Cut Off TESTING Step 1 Disconnect thermocouple from combination thermostat gas valve 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
18. xposed replacement 1s recommended Step 6 Upon completion of inspection or subsequent replacement reinstall outlet ntpple anode into heater Connect nipple to plumbing system resume water supply and refill heater with water 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 NOTES BRADFORD WHITE 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 Application amp Sizing 800 523 2931 Fax 215 641 1612 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 va D BRADFORD WHITE CANAD INC Mississauga ON Sales Technical Support 866 690 0961 905 238 0100 Fax 905 238 0105 Email parts bradfordwhite com techserv bradfordwhite com www bradfordwhite com www bradfordwhitecanada com
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