Flammable Vapor Ignition Resistant Water Heater SERVICE MANUAL Troubleshooting Guide and Instruction for Service (To be performed ONLY by qualified service providers) For the Bradford White Defender Safety System™ Models: MI30T*F(BN,CX)2 MI30S*F(BN,CX)2 MI303T*F(BN,CX)2 MI40T*F(BN,CX)2 MI403S*F(BN,CX)2 MI404T*F(BN,CX)2 MI503*F(BN,CX)2 MI50L*F(BN,CX)2 MI504S*F(BN,CX)2 M430T*F(BN,CX)2 M4403S*F(BN,CX)2 M4403T*F(BN,CX)2 M450S*F(BN,CX) M1XR403S*F(BN,CX)2 M1XR504T*F(BN,CX)2 M2XR504T*F(BN,CX)2 M2C504T*F(BN,CX)
Flammable Vapor Ignition Resistant Water Heater Table of Contents Page Service Procedure Introduction 3 --- Trouble shooting Chart 4 --- Inner Door Gasket Removal, Inspection, Replacement and Installation 5 RG-I Thermocouple Testing and Replacement 8 RG-II Pilot Assembly Inspection Cleaning and Replacement 10 RG-III Piezo Igniter and Electrode Testing 11 RG-IV Combination Thermostat/Gas Valve Testing and Replacement 12 RG-V Burner Operation Inspection, Adjustment, Cleaning and Replac
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.
Troubleshooting Chart Flammable Vapor Ignition Resistant Water Heaters SERVICE PROCEDURE SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION Pilot Will Not Light 1. No incoming gas or too low gas pressure. 2. Gas control knob set to wrong position. 3. Pilot light button not being fully depressed when attempting to light pilot. 4. Pilot orifice or pilot tube is obstructed or kinked. 5. Pilot electrode not sparking to pilot. 6. Piezo igniter not functioning. 1. Turn on gas supply and/or check line pressure. 2.
SERVICE PROCEDURE RG-I Inner Door/Gasket Removal, Inspection Replacement and Reinstallation Inner Door Removal Procedure Step 1. Step 2. Step 3. Rotate knob of the combination thermostat/gas valve to the “OFF” position. Remove outer jacket burner access door Inner Door Removal. a) Disconnect resettable thermal switch wire leads (leading from combination thermostat/gas valve). b) Remove (2) 1/4" hex drive screws from right side inner door. c) Remove (2) 1/4" drive screws from flange section of inner door.
SERVICE PROCEDURE RG-I Inner Door/Gasket Removal, Inspection Replacement and Reinstallation 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. Place the left side inner door into position first. Firmly position the radiused channel of the inner door around the feedline. Using the 1/4” hex drive screws from step 3d, secure left side inner door in place.
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 two 1/4” 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 chamber opening.
SERVICE PROCEDURE RG-II Thermocouple Testing and Replacement Closed Circuit Thermocouple Testing Step 1. Disconnect thermocouple from combination thermostat/gas valve. Step 2. Connect a thermocouple adapter (BWC P/N 239-44642-00, Robertshaw P/N 75036) at the thermocouple location in the combination thermostat/gas valve. Step 3. Reconnect thermocouple to adapter. make certain all connections are tight (finger tight plus 1/4 turn) Step 4.
SERVICE PROCEDURE RG-II Thermocouple Testing and Replacement Thermocouple Replacement Step 1. Turn off gas supply to water heater. Rotate knob of combination thermostat/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 from combination thermostat/gas valve (3/8" wrench). Locate other end of thermocouple inside of combustion chamber and remove from pilot bracket.
SERVICE PROCEDURE RG-III Pilot Assembly Inspection, Cleaning and Replacement Pilot/Electrode Assembly Inspection, Cleaning and Replacement Step 1. Turn off gas supply to water heater. Rotate knob of combination thermostat/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. Step 5. Disconnect thermocouple from combination thermostat/gas valve (3/8" wrench).
SERVICE PROCEDURE RG-IV Piezo Igniter, Electrode Testing and Replacement 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. If a spark is present, the circuit is OK.
SERVICE PROCEDURE RG-V Combination Thermostat/Gas Valve Testing and Replacement 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.
SERVICE PROCEDURE RG-V Combination Thermostat/Gas Valve Testing and Replacement THERMOCOUPLE TESTING See SERVICE PROCEDURE II MAGNET ASSEMBLY TESTING Step 1. Disconnect thermocouple from combination thermostat/gas valve. Step 2. Connect a thermocouple adapter (BWC P/N 239-44642-00, Robertshaw P/N 75036) at the thermocouple location in the combination thermostat/gas valve. Step 3. Reconnect thermocouple to adapter. Make certain all connections are tight (finger tight plus 1/4 turn). Step 4.
SERVICE PROCEDURE RG-V Combination Thermostat/Gas Valve Testing and Replacement COMBINATION THERMOSTAT/GAS VALVE REPLACEMENT Step 1. Rotate knob of the combination thermostat/gas valve to the “OFF” position. Step 2. Turn off gas supply to water heater. Step 3. Disconnect gas supply line from combination thermostat/gas valve. Step 4. Turn off water supply and drain water heater completely. Step 5. Remove outer jacket burner access door. Step 6. Right side inner door removal.
SERVICE PROCEDURE RG-V Combination Thermostat/Gas Valve Testing and Replacement Step 7. Removal of combination thermostat/gas valve. a) Disconnect main burner feedline (3/4” wrench), pilot tube (7/16" wrench) and thermocouple (3/8" wrench) from combination thermostat/gas valve & remove from the combustion chamber. Refer to SERVICE PROCEDURE RG-IV to remove Piezo igniter b) Remove Piezo bracket with Piezo igniter (refer to SERVICE PROCEDURE RG-IV) from combination thermostat/gas valve.
SERVICE PROCEDURE RG-V Combination Thermostat/Gas Valve Testing and Replacement 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.
SERVICE PROCEDURE RG-VI Burner Operation Inspection, Adjustment, 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.
SERVICE PROCEDURE RG-VI 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-VI Burner Operation Inspection, Adjustment, Cleaning and Replacement BURNER CLEANING (cont.) Step 5. Disconnect (unscrew) main burner (stamped steel “B” burner) 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 (1/2” wrench on steel burner, 3/8" wrench on cast iron). Inspect and clean if necessary. Step 7.
SERVICE PROCEDURE RG-VII Resettable Thermal Switch Testing and Replacement 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-VII Resettable Thermal Switch Testing and Replacement RESETTABLE THERMAL SWITCH REPLACEMENT Step 1. Rotate knob of combination thermostat gas valve to the off position. Step 2. Remove outer jacket door. Step 3. Disconnect wire leads from resettable thermal switch. Step 4. Remove resettable thermal switch from inner door (Phillips screw driver). Step 5. Place new resettable thermal switch in place.
SERVICE PROCEDURE RG-VIII ScreenLok Flame Arrestor Cleaning ScreenLok Flame Arrestor Cleaning Step 1. Rotate knob of combination thermostat gas valve to the off position. Step 2. Remove outer jacket door. Step 3. Remove inner door per SERVICE PROCEDURE RG-I, step 3a through 3e. Step 4. Disconnect main burner feed line (3/4 wrench), pilot tube (7/16 wrench) and thermocouple (3/8) wrench from combination thermostat gas valve and remove burner assembly from combustion chamber. Step 5.
SERVICE PROCEDURE RG-IX Dip Tube and Anode Inspection and Replacement 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. Step 2. Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain.
SERVICE PROCEDURE RG-IX 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. Step 2. Turn off cold water supply to heater. Connect hose to drain spigot of water heater and route to an open drain.
PARTS LIST 1 Draft Hood 2 Hot Water Outlet/Anode 3 Cold Water Inlet Tube 4 Flue Baffle 5 T&P Relief Valve 6 Thermostat 7 Piezo Igniter 8 Brass Drain Valve 9 Screw-#8-18 x 3/4 Hex Washer Head 10 Screw-#10-12 x 3/4 Hex Washer Head 11 Left Side Inner Door with Gasket 12 Complete Right Side Inner Door 12A Right Side Inner Door with Gasket 13 Sight Glass Assembly 14 Resettable Thermal Switch 15 Screw#6-20 x 3/8 PHCR 16 Outer Door 17 Complete BN Burner Assembly 18 BN Burner Only 19 Main Burner Orifice 20 Pilot
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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 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 Fax on Demand: 888-538-7833 www. bradfordwhite.com Mississauga, ON Sales/866-690-0961 905-238-0100 Fax/905-238-0105 Technical Support/800-334-3393 Email parts@bradfordwhite.