Flammable Vapor Ignition Resistant Water Heaters Gas Water Heaters SERVICE MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qualified service providers) FEATURING For the Bradford White Defender Safety System® Models: MI30T*F(BN,CX,SX) MI30S*F(BN, CX,SX) MI303T*F(BN,CX,SX) MI40T*F(BN,CX,SX) MI403S*F(BN,CX,SX) MI404T*F(BN,CX,SX) MI503*F(BN,CX,SX) MI50L*F(BN,CX,SX) MI504S*F(BN,CX,SX) MI60T*F(BN,CX,SX) C(S,D)W2504T*F(BN,CX,SX) M430T*F(BN,CX,SX) M440T*F(BN, CX,SX) M4403S*F(B
The Bradford White DEFENDER Safety System® Flammable Vapor Ignition Resistant Water Heaters Table of Contents Page Service Procedure Introduction 3 --- Trouble shooting Chart 4 --- Inner Door Gasket Removal, Inspection, Replacement and Installation 7 RG-I Thermocouple/Thermopile Testing and Replacement 10 RG-II Pilot Assembly Inspection Cleaning and Replacement 13 RG-III Piezo Igniter, Electrode Testing and Replacement 14 RG-IV White Rodgers/Robertshaw Gas Valve Testing and Replacement
INTRODUCTION 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.
White Rodgers/Robertshaw Gas Valve Troubleshooting Chart Flammable Vapor Ignition Resistant Water Heaters SYMPTOM Pilot Will Not Light Pilot Will Not stay lit when button is released Pilot will light but the main burner will not come on Pilot goes out periodically (after heating cycles, once a day, once a week etc.) Not enough hot water PROBABLE CAUSE CORRECTIVE ACTION 1. No incoming gas or too low gas pressure. 2. Gas control knob set to wrong position. 3.
Honeywell Gas Control Troubleshooting Chart Flammable Vapor Ignition Resistant Water Heaters 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. LED Status Control Status LED on continuously (Solid) Two flashes and three second pause Service Procedure If the pilot will not stay lit replace pilot assembly. If problem persists replace Gas Control.
Honeywell Gas Control Troubleshooting Chart Flammable Vapor Ignition Resistant Water Heaters 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. LED Status Five flashes and three second pause Six flashes and three second pause Control Status Thermostat/well sensor fault. Water leak detected by accessory module.
The Bradford White DEFENDER Safety System® SERVICE PROCEDURE RG-I Inner Door/Gasket Removal, Inspection Replacement and Reinstallation For Honeywell Control, rotate knob counter-clockwise to the “OFF” position. Inner Door Removal Procedure Step 1. Rotate knob of the combination thermostat/gas valve to the “OFF” position. Step 2. Remove outer jacket burner access door Step 3. Inner Door Removal. For Robertshaw Control, rotate knob clockwise to the “OFF” position.
SERVICE PROCEDURE RG-I Inner Door/Gasket Removal, Inspection Replacement and Reinstallation GASKET OVERLAP MUST BE AS SHOWN ±1/32" RECOMMENDED PATTERN FOR RTV SEALANT ENLARGED VIEW OF FLANGE AREA PLACE FLANGE SECTIONS FIRST VIEW WITH GASKETS IN PLACE EXPANDED VIEW Installation of Inner Door With Gasket. Step 7. Clean any residual gasket residue or other debris from combustion chamber surface before installing the inner door/gasket assembly. Step 8.
SERVICE PROCEDURE RG-I Inner Door/Gasket Removal, Inspection Replacement and Reinstallation Step 10. Firmly place right side inner door flange against the left side inner door flange and secure with (2) hex drive screws from step 3c. 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.
The Bradford White DEFENDER SERVICE PROCEDURE RG-II Thermocouple/Thermopile Testing and Replacement Safety System® CLOSED CIRCUIT THERMOCOUPLE TESTING (White Rodgers Control) Step 1. Closed circuit testing is the preferred method for testing thermocouple. Following the lighting instruction label on the heater, proceed to light the pilot and allow to operate for three minuets.
SERVICE PROCEDURE RG-II Thermocouple/Thermopile Testing and Replacement OPEN CIRCUIT THERMOCOUPLE TESTING (White Rodgers/Robertshaw Gas Valve) 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.
SERVICE PROCEDURE RG-II Thermocouple/Thermopile Testing and Replacement OPEN CIRCUIT THERMOPILE TESTING (Honeywell Gas Control) The following test should be performed while the pilot flame is on. Step 1. Turn knob to pilot position and depress. Step 2. Continue pressing knob and remove red (+) wire from resettable thermal door switch. Step 3. Using a multimeter capable of measuring millivolts, connect the positive side of the multimeter to the terminal of the resettable thermal door switch.
The Bradford White SERVICE PROCEDURE RG-III Pilot Assembly Inspection, Cleaning and Replacement DEFENDER Safety System® PILOT/ELECTRODE ASSEMBLY INSPECTION, CLEANING AND REPLACEMENT Step 1. Turn off gas supply to water heater. Rotate knob of gas control/gas valve to “OFF” position. Step 2. Remove outer jacket door. Step 3. Remove right side of inner door per SERVICE PROCEDURE RG-I, steps 3a through 3c. Step 4 Disconnect thermocouple/thermopile, pilot tube, and feedline from gas control/gas valve.
The Bradford White SERVICE PROCEDURE RG-IV Piezo Igniter, Electrode Testing and Replacement DEFENDER Safety System® PIEZO IGNITER, ELECTRODE TESTING AND REPLACEMENT With the pilot not in operation (no pilot flame) you can check the Piezo and electrode circuit by viewing pilot thru the sight glass located on the inner door and observing the spark action. Step 1. Remove outer jacket door. Step 2. Repeatedly depress the Piezo igniter while viewing the pilot thru the sight glass.
The Bradford White DEFENDER SERVICE PROCEDURE RG-V Gas Valve Testing and Replacement (White Rodgers/Robertshaw) Safety System® Gas Valve Testing and Replacement (White Rodgers/Robertshaw) The gas valve is a non repairable device. If trouble shooting has determined a problem with the 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 gas valve may be faulty.
SERVICE PROCEDURE RG-V Gas Valve Testing and Replacement (White Rodgers/Robertshaw) THERMOCOUPLE TESTING See SERVICE PROCEDURE RG-II MAGNET ASSEMBLY TESTING (White Rodgers Control) Step 1. Following the lighting instruction label on the heater, proceed to light the pilot and allow to operate for three minuets. If the pilot will not stay lit, hold the pilot button (located on the gas valve) down during this test. Step 2.
SERVICE PROCEDURE RG-V Gas Valve Testing and Replacement (White Rodgers/Robertshaw) ECO (Energy Cut Off) TESTING Step 1. Disconnect thermocouple from gas valve. Step 2. 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.
SERVICE PROCEDURE RG-V Gas Valve Testing and Replacement (White Rodgers/Robertshaw) Step 7. Removal of gas valve. a) Disconnect main burner feedline, pilot tube and thermocouple from gas valve & 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 piezo bracket with piezo igniter (refer to SERVICE PROCEDURE RG-IV) from gas valve.
SERVICE PROCEDURE RG-V Gas Valve Testing and Replacement (White Rodgers/Robertshaw) Step 9. Reinstallation of inner door assembly. (cont.) b) Clean any gasket residue or other debris from combustion chamber surface before installing the inner door/gasket assembly. c) Position thermocouple, pilot tube and Piezo wire against left side inner door flange gasket. DO NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEEDLINE.
The Bradford White SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) DEFENDER Safety System® Honeywell Gas Control Testing, Disassembly, and Replacement The Gas Control is made up of (5) major components; the control cover, the piezo igniter, the valve body, the temperature sensor, and the back plate. The Gas Control is designed so that any of these components may be replaced without replacing the entire Gas Control.
The Bradford White SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) DEFENDER Safety System® MANIFOLD PRESSURE TESTING (this procedure presumes a maximum line pressure of 14.0" w.c.) Step 1. Set the Gas Control to the “OFF” position. Step 2. Remove pressure tap plug and install 1/8" NPT pipe, coupling, & pressure tap. Step 3. Connect manometer to pressure tap. Step 4.
The Bradford White SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) DEFENDER Safety System® TEMPERATURE SENSOR TESTING CAUTION DO NOT use standard multimeter probes for this test. Doing so will damage connector. Use special pin type electronic probes or small diameter wire pins inserted into connector.
The Bradford White SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) DEFENDER Safety System® WARNING Stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. DETERMINE WATER TEMPERATURE INSIDE TANK Note: It is important to understand once the resistance for the temperature sensor is determined from the previous page, water flow through the water heater should not occur.
The Bradford White SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) DEFENDER Safety System® GAS CONTROL DISASSEMBLY/REASSEMBLY Step 1. Rotate knob of the Gas Control to the “OFF” position. Step 2. Turn off gas supply to water heater. Step 3. Disconnect gas supply line from Gas Control. Rotate knob counter-clockwise to the “OFF” posistion. Step 4. Disconnect piezo igniter wire. Step 5. Remove inner door assembly following SERVICE PROCEDURE RG-I, steps 1 through 3c.
The Bradford White SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) DEFENDER Safety System® GAS CONTROL DISASSEMBLY/REASSEMBLY Step 8. Disconnect temperature sensor from control board and remove wire from the temperature sensor wire routing clip. Temperature sensor wire routing clip Disconnect temperature sensor Step 9. Remove the piezo igniter from the control cover by releasing the lock tab on the control cover.
The Bradford White SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) DEFENDER Safety System® GAS CONTROL DISASSEMBLY/REASSEMBLY Step 10. Remove the valve body by removing screw located at the lower left corner then unclipping the lower right side from the backplate first followed by the lower left side using a flat head screwdriver. CAUTION Use caution not to bend or damage valve body pins.
The Bradford White SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) DEFENDER Safety System® GAS CONTROL DISASSEMBLY/REASSEMBLY Step 12. Remove temperature sensor from insertion stick by pulling apart as illustrated below. Pull in this direction Temperature sensor Insertion stick Pull in this direction Step 13. To reassemble Gas Control, follow the previous steps in reverse order.
The Bradford White SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) DEFENDER Safety System® GAS CONTROL REPLACEMENT Rotate knob counter-clockwise to the “OFF” position. Step 1. Rotate knob of the Gas Control to the “OFF” position. Step 2. Turn off gas supply to water heater. Step 3. Disconnect gas supply line from Gas Control. Step 4. Turn off water supply and drain water heater completely. Step 5. Remove outer jacket burner access door. Step 6.
The Bradford White SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) DEFENDER Safety System® GAS CONTROL REPLACEMENT Step 8. Install new Gas Control into water heater (contintued). b) Reattach main burner feedline, pilot tube, piezo igniter wire, inner door wire (red) and thermopile wire (white) to Gas Control. Attach inner door wire (red) to the positive (+) terminal and the thermopile wire (white) to the negative (-) terminal.
The Bradford White SERVICE PROCEDURE RG-VI Gas Control Testing, Disassembly & Replacement (Honeywell) DEFENDER Safety System® GAS CONTROL REPLACEMENT Step 9. Reinstallation of inner door assembly (continued). d) Firmly place right side inner door flange against the left side inner door flange and secure with (2) hex drive screws from step 6c. DO NOT OVER TIGHTEN SCREWS.
SERVICE PROCEDURE RG-VII Burner Operation Inspection, Adjustment Cleaning and Replacement The Bradford White DEFENDER Safety System® 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.
SERVICE PROCEDURE RG-VII Burner Operation Inspection, Adjustment Cleaning and Replacement MAIN BURNER: Inspection, Adjustment, Cleaning and Replacement (cont.) Step 3. Fully inspect inner gasket per SERVICE PROCEDURE RG-I, step 4. Replace gasket if required following SERVICE PROCEDURE I, steps 5 & 6. Step 4. Be certain that thermocouple, pilot tube and piezo wire are routed by inner door flange as shown and Reinstall inner door per SERVICE PROCEDURE RG-I, step 10 and 11.
SERVICE PROCEDURE RG-VII Burner Operation Inspection, Adjustment Cleaning and Replacement BURNER CLEANING (Cont.) Step 5. Disconnect (unscrew) Main burner (steel) from main burner orifice or on cast iron burners (“C” burner), loosen air shutter & disconnect (unscrew) feedline from burner. Step 6. Remove main burner orifice from feed line. Inspect and clean if necessary. Step 7. Remove pilot assembly, refer to SERVICE PROCEDURE RG-III for cleaning and inspection. Step 8. Reassemble burner. Step 9.
SERVICE PROCEDURE RG-VIII Resettable Thermal Switch Testing and Replacement The Bradford White DEFENDER Safety System® RESETTABLE THERMAL SWITCH CONTINUITY TESTING Step 1. Remove outer jacket door. Step 2. Disconnect wire leads from resettable thermal switch. Step 3. Using a multimeter capable of measuring continuity (Ohms), place one probe of meter on one of the brass connection tabs of the resettable thermal switch, and the remaining probe on the other connection tab. Step 4.
SERVICE PROCEDURE RG-VIII Resettable Thermal Switch Testing and Replacement RESETTABLE THERMAL SWITCH REPLACEMENT Step 1. Rotate knob of combination thermostat gas valve to the off position. For White Rodgers Control, depress knob slightly and rotate clockwise to the “OFF” position. For Honeywell Control, rotate knob counter-clockwise to the “OFF” position. For Robertshaw Control, rotate knob clockwise to the “OFF” position. Step 2. Remove outer jacket door. Step 3.
The Bradford White SERVICE PROCEDURE RG-IX ScreenLok® Flame Arrestor Cleaning DEFENDER Safety System® ScreenLok® Flame Arrestor Cleaning Step 1. Rotate knob of combination thermostat gas valve to the off position. For White Rodgers Control, depress knob slightly and rotate clockwise to the “OFF” position. For Honeywell Control, rotate knob counter-clockwise to the “OFF” position. For Robertshaw Control, rotate knob clockwise to the “OFF” position. Step 2. Remove outer jacket door. Step 3.
SERVICE PROCEDURE RG-X Dip Tube and Anode Inspection and Replacement The Bradford White DEFENDER Safety System® DIP TUBE INSPECTION AND REPLACEMENT 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. Rotate knob of combination thermostat/gas valve to “OFF” position. For White Rodgers Control, depress knob slightly and rotate clockwise to the “OFF” position.
SERVICE PROCEDURE RG-X Dip Tube and Anode Inspection and Replacement ANODE INSPECTION AND REPLACEMENT 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.
The Bradford White DEFENDER Generic Parts List Safety System® 16 1 34 32 33 2 17 3 4 18 19 21 20 5 28 6A 6B 6C 30 7 23 8 24 25 11 1 2 3 4 5 6A 6B 6C 7 8 9 10 11 12 14 15 27 26 Draft Hood Hot Water Outlet/Anode Cold Water Inlet Tube Flue Baffle T&P Relief Valve Gas Control (Honeywell) Gas Valve (Robertshaw) Gas Valve (White Rodgers) Piezo Igniter (White Rodgers/Robertshaw) Brass Drain Valve Screw-#8-18 x 3/4 Hex Washer Head Screw-#10-12 x 3/4 Hex Washer Head Left Side Inner Door with Ga
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