Bradford White M2TW75T*BN Instruction manual

POWER VENTED GAS WATER HEATER

A Spanish language version of these instructions is available by contacting the company listed on the rating plate.

La version espanola de estas instrucciones se puede obtener al escribirle a la fabrica cuyo nombre aparece en la placa de especificaciones.

INSTALLATION AND OPERATING

INSTRUCTION MANUAL

WARNING:

If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury, or death.

FOR YOUR SAFETY

Do not store or use gasoline or other flammable, combustible, or corrosive vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any

phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire

department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

For your family’s comfort, safety and convenience we recommend this water heater be installed and serviced by a plumbing professional.

238-45917-00F REV 3/08

CONGRATULATIONS!

You have just purchased one of the finest water heaters on the market today!

This installation, operation and instruction manual will explain in detail the installation and maintenance of your new Power Vented Gas Water Heater. We strongly recommend that you contact a plumbing professional for the installation of this water heater.

We require that you carefully read this manual, as well as the enclosed warranty, and refer to it when questions arise. If you have any specific questions concerning your warranty, please consult the plumbing professional from whom your water heater was purchased. For your records we recommend that you write the model, serial number and installation date of your water heater in the maintenance section in the back of this manual.

This manual should be kept with the water heater.

2

TABLE OF CONTENTS

page

GENERAL INFORMATION................................................................. 4

INSTALLATION. ................................................................................. 5

Locating The Water Heater......................................................... 5

Vent Pipe Preparation and Joining ............................................

Electrical Connections................................................................ 31

Lighting and Shutdown Instructions......................................... 34

MAINTENANCE.................................................................................. 37

TROUBLESHOOTING ........................................................................ 40

PARTS LIST DRAWING ..................................................................... 42

PARTS LIST ....................................................................................... 42

INSTALLATION INSTRUCTIONS FOR POTABLE WATER AND

SPACE HEATING............................................................................... 43

NOTES ................................................................................................ 44

3

GENERAL INFORMATION

This gas-fired water heater’s design is certified by CSA International under the

American National Standard Z21.10.1, CSA 4.1-M, Z21.10.3 and CSA 4.3 most current editions at the time of manufacture.

This water heater must be installed in accordance with local codes or, in the absence of local codes, the National Fuel Gas Code, ANSI Z223.1-Latest

Edition) and/or in Canada CAN/CGA B149 Installation Codes (Latest Editions).

The warranty for this water heater is in effect only when the water heater is installed, adjusted, and operated in accordance with these Installation and

Operating Instructions. The manufacturer will not be held liable for any damage resulting from alteration and/or failure to comply with these instructions.

This water heater is not design certified for installation in a mobile home. Such an installation may create a hazardous condition and will nullify the warranty.

CAUTION

Incorrect operation of this appliance may create a hazard to life and property and will nullify the warranty.

Do not use this appliance if any external part to the tank has been submerged in water. You should contact a qualified service technician to inspect the appliance and to replace any part of the control system including the combination gas control which has been submerged in water.

DANGER


IMPORTANT

Before proceeding, please inspect the water heater and its components for possible damage. DO NOT install any water heater with damaged components. If damage is evident then please contact the supplier where the water heater was purchased or the manufacturer listed on the rating plate for replacement parts.

Make sure that you check the rating plate and combination gas control on the water heater to be certain that the type of gas being supplied corresponds with the marking on the rating plate and combination gas control.

4

General Information continued-

A sacrificial anode is used to extend tank life. The removal of this anode, for any reason, will nullify the warranty. In areas where water is unusually active, an odor may occur at the hot water faucet due to a reaction between the sacrificial anode and the impurities in the water. If this should happen, an alternative anode may be purchased from the supplier that installed this water heater. This will minimize the odor while protecting the tank. Additionally, the water heater should be flushed with appropriate dissolvers to eliminate any bacteria.

INSTALLATION

Locating The Water Heater

WARNING

Water heaters are heat producing appliances. To avoid damage or injury, do not store materials against the water heater or vent-air intake system. Use proper care to avoid unnecessary contact (especially by children) with the water heater and vent-air intake components. UNDER NO CIRCUMSTANCES

MUST FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT

THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER

HEATER, VENT-AIR INTAKE SYSTEM OR IN ANY LOCATION FROM

WHICH FUMES COULD REACH THE WATER HEATER OR VENT-AIR

INTAKE SYSTEM.

DO NOT install the water heater in any location where gasoline or flammable vapors are likely to be present.

Water Heaters in residential garages must be installed so that all burner(s) and burner ignition device(s) are located not less than 18 inches

(46 cm) above the floor and must be located or protected to avoid physical damage. For other installations refer to local codes. In the absence of local codes, the water heater must be installed in compliance with the National Fuel Gas Code, ANSI Z223.1 - (Latest Edition) and/or in

Canada, CAN/CGA B149 Installation Codes (Latest Editions).

The location of this water heater is of the utmost importance. Before installing this water heater, read the installation section of these instructions. After reading these installation and operating instructions, select a location for the water heater where the floor is level and is easily accessible to gas and water supply lines. DO NOT locate the water heater where water lines could be

subjected to freezing temperatures. Make sure the cold water pipes are not located directly above the gas control so that condensate during

humid weather does not drip on the controls.

5

Installation (Locating The Water Heater) continued-

Water heater corrosion and component failure can be caused by the heating and breakdown of airborne chemical vapors. Examples of some typical compounds that are potentially corrosive are: spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes and process chemicals. These materials are corrosive at very low concentration levels with little or no odor to reveal their presence. NOTE: DAMAGE TO THE WATER HEATER CAUSED

BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY THE

WARRANTY. DO NOT OPERATE THE WATER HEATER IF EXPOSURE

HAS OR WILL OCCUR. DO NOT STORE ANY POTENTIALLY CORROSIVE

COMPOUNDS IN THE VICINITY OF THE WATER HEATER.

To comply with NSF requirements this water heater is to be: a) Sealed to the floor with sealant, in a smooth and easily cleanable way, or b) Installed with an optional leg kit that includes legs and/or extensions that provide a minimum clearance of 6” beneath the water heater.

WARNING

Liquefied petroleum gases/propane gas are heavier than air and will remain at floor level if there is a leak. Basements, crawl spaces, closets, and areas below ground level will serve as pockets for accumulation of leaking gas. Before lighting, smell all around the appliance area for gas. Be sure to smell next to the floor.

IF YOU SMELL GAS:

•

Do not try to light any appliance.

•

Do not touch any electric switch; do not use any telephone in

your building.

•

Immediately call your gas supplier from a neighbor’s telephone. Follow the gas supplier’s instructions.

•

If you cannot reach your gas supplier, call the fire department.

DO NOT OPERATE APPLIANCE UNTIL THE LEAKAGE IS

CORRECTED!

6

Installation (Locating The Water Heater) continued-

WARNING

DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT

CERTAIN OF THE FOLLOWING:

•

Liquefied petroleum gases/propane gas and natural gas have an odorant added by the gas supplier that aids in the detection of the gas.

•

Most people recognize this odor as a “sulfur” or “rotten egg” smell.

•

Other conditions, such as “odorant fade” can cause the odorant to diminish in intensity, or ”fade”, and not be as readily detectable.

•

If you have a diminished sense of smell, or are in any way unsure of the presence of gas, immediately contact your gas supplier from a neighbor’s telephone.

•

Gas detectors are available. Contact your gas supplier, or plumbing professional, for more information.

The water heater must be located close enough to the outside wall to keep the venting distance within the maximum distance described in the installation instructions. Read the venting section in this installation instruction manual before locating the water heater.

This water heater must be located in an area where leakage of the tank or water line connections and the combination temperature and pressure relief valve will not result in damage to the area adjacent to the water heater or to lower floors of the structure. When such locations cannot be avoided, a suitable drain pan adequately piped for proper drainage must be installed under the water heater. The pan must not restrict combustion air flow. The drain pan must have a minimum length and width of at least 4 in. (10.2 cm) greater than the diameter of the water heater and must not restrict proper combustion air flow to the water heater. The drain pan, as described above, can be purchased from your plumbing professional. The drain pan must be piped to an adequate drain. The piping must be at least 3/4 inch (1.9 cm) in diameter and pitched for proper drainage.

It is recommended that a minimum clearance of four (4) inches (10.2 cm) be provided on the side of the water heater for servicing and maintenance of the combination temperature and pressure relief valve.

This water heater MUST be installed indoors out of the wind and weather.

Note: For California installation this water heater must be braced, anchored, or strapped to avoid falling or moving during an earthquake.

See instructions for correct installation procedures. Instructions may be obtained from DSA Headquarters Office, 1102 Q Street, Sacramento, CA

95811.

7

Minimum Clearances

WARNING

Failure to adhere to these installation and operating instructions may create a hazard to life and property and will nullify the warranty.

This installation must allow access to the front of the water heater and adequate clearance must be provided for servicing and operating this water heater. The water heater may be installed on either a combustible or noncombustible floor. If the water heater is to be installed directly on carpeting, it must be installed on top of a metal or wood panel extending beyond the full width and depth of the appliance by at least three (3) inches (7.6 cm) in any direction or, if the appliance is to be installed in an alcove or closet, the entire floor must be covered by the panel. The minimum clearances to combustibles for this water heater are: zero (0) inch (0 cm) from the sides and rear, five (5) inches (12.7 cm) from the front of the jacket, zero (0) inch (0 cm) from the vent connector and fifteen (15) inches (38.1 cm) from the jacket top.

Venting

This venting section is divided into two parts. Part I will cover venting specifications for 25 Gal (94.6 L), 48 Gal (181.6 L), 55 Gal (208.2 L), 65 Gal

(246.0 L), and 75 Gal (283.9 L) models. Part II will cover venting specifications for 40 Gal (151.4 L) and 50 gal (189.2 L) models. Refer to the rating plate located on the water heater for correct model identification.

Figure 1 - Vent Terminal Clearances

8

Venting continued-

A= Clearance above grade, veranda, porch, deck or balcony

B= Clearance to window or door that may be opened

Canadian

Installations

1

US Installations 2

12 inches (30

cm)

12 inches (30

cm)

12 inches

(30 cm)

4 feet (1.2 m) below or to the side of opening;

12 inches (30 cm) above opening

*b *b C= Clearance to permanently closed window

D= Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal

E= Clearance to unventilated soffit

F= Clearance to outside corner

G= Clearance to inside corner

*b *b

*b

*b

*b

*b

*b

*b

H= Clearance to each side of center line extended above meter/regulator assembly

I=

J=

Clearance to service regulator vent outlet or oil tank vent

Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance

K= Clearance to a mechanical air supply inlet

3 feet (91 cm) within a height

15 feet (4.6 m) above the meter/regulator assembly

36 inches

(91 cm)

12 inches (30

cm)

6 feet

(1.83 m)

*b

*b

4 feet (1.2m) below or to side of opening; 12 inches (30 cm) above opening.

3 feet (91 cm) above if within 10 feet horizontally

7 feet

(2.13 m)†

L= Clearance above paved sidewalk or paved driveway located on public property

M= Clearance under a veranda, porch,

7 feet

(2.13 m)†

12 inches (30 *b deck, or balcony cm) ‡

1

In accordance with the current CAN/CGA-B149 Installation Codes.

2

In accordance with the current ANSI Z223.1-(Latest edition)/NFPA 54 National Fuel Gas Code.

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two singlefamily dwellings and serves both dwellings.

‡ Permitted only if a veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.

*a) A minimum clearance value determined by testing in accordance with section 2.20.

*b) “Clearance in accordance with local installation codes and the requirements of the gas supplier”.

The vent system must terminate so that proper clearances are maintained as cited in local codes or the latest edition of the National Fuel Gas Code, ANSI

Z223.1.73.4e and 7.8a, b as follows:

1. Do not terminate near soffit vents or crawl space or other area where condensate or vapor could create a nuisance or hazard or cause property damage.

2. Do not terminate the exhaust vent terminal where condensate or vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment.

3. Do not terminate the exhaust vent terminal over public area or walkways where condensate or vapor can cause nuisance or hazard.

4. The vent shall terminate a minimum of 12” (25.4 cm) above expected snowfall level to prevent blockage of vent termination.

9

Venting continued-

Vent pipes serving power vented appliances are classified by building codes as

“vent connectors”. Required clearances from combustible materials must be provided in accordance with information in this manual under LOCATION OF

WATER HEATER and CLEARANCES, and with National Fuel Gas Code and local codes.

NOTICE

For installations in Canada, field supplied plastic vent piping must comply with CAN/CGA B149.1 (latest edition) and be certified to the Standard For

Type BH Gas Venting Systems, ULC S636. Components of this listed system shall not be interchanged with other vent systems or unlisted pipe/fittings. All plastic components and specified primers and glues of the certified vent system must be from a single system manufacturer and not intermixed with other system manufacturer’s vent system parts.

The supplied vent connector and vent termination are certified as part of the water heater.

Venting System Condensation

Condensate formation does not occur in all installations of power vented water heaters, but should be protected against on installations where condensation can form in the venting system.

Formation of condensation in the venting system of Power Vented water heaters is dependent upon installation conditions including, but not limited to: ambient temperature and humidity of installation location; ambient temperature and humidity of venting space; vent distance and slope; and product usage.

In order to effectively control condensate from adversely affecting the mechanical components of the water heater several methods may be employed:

1. For horizontal installations the vent pipe can be installed with a downward slope (not less than 1/8" (3 cm)) and away from the blower.

2. In order to prevent condensate from draining back into the blower

(vertical or horizontal runs), an optional condensate kit is available as a service part (Condensate kit, p/n 238-45875-00). A factory supplied exhaust adapter with drain outlet mounts directly to the blower outlet and is secured with two hose clamps, one to the blower and the other to the vent pipe. Plastic tubing is provided to drain any accumulated condensate away from the water heater and to a suitable drain. The kit comes complete with instructions for proper installation.

10

Part I - Venting Specifications for:

(94.6 L), 48 Gallon (181.6 L),

75 Gallon (283.9 L)

NOTE: Properly sized PVC, CPVC, or ABS* pipe must be used.

This water heater is a power vented appliance and is designed to vent its products of combustion through 3” (7.6 cm) or 4” (10.2 cm) diameter Schedule

40 (solid or cellular core) vent pipe to the outdoors. This water heater may be either vented horizontally through the wall or vertically through the roof. Use a

3” (7.6 cm) to 4” (10.2 cm) reducer to connect to the vent outlet when using 4”

(10.2 cm) vent pipe. Apply the proper cement at the joint locations. Table 1 lists the maximum vent lengths for this water heater using 3” (7.6 cm) vent pipe.

If possible, locate the water heater so that the venting length and number of elbows are kept to the minimum distance necessary to reach the outside. If the installation requires venting lengths that exceed the lengths listed for 3” (7.6

cm) vent pipe in Table 1, then use 4” (10.2 cm) vent pipe for the vent connector. Table 2 lists the venting distances allowed with 4” (10.2 cm) diameter vent pipe. When venting with 4” (10.2 cm) vent pipe, use a 4” (10.2

cm) to 3” (7.6 cm) reducer to exit through the building wall with 3” (7.6 cm) vent pipe. Use the 3” (7.6 cm) vent terminal supplied with the water heater to terminate on the outside of the building. If the length of 3” (7.6 cm) vent pipe needed to go through the wall is greater than 14” (35.5 cm), use 4” (10.2 cm) to go through the wall and reduce to 3” (7.6 cm) vent pipe immediately after exiting the outside wall. Refer to the venting illustrations on the following pages. Make sure the vent pipe terminal elbow fitting is at least 1” (2.5 cm) away from the edge of the wall.

*Only vent pipe certified to ULC S636 may be used in Canada.

TABLE 1 - VENT CONNECTOR LENGTHS

FOR 3” (7.6 cm) DIAMETER VENT PIPE

Elbows

Maximum straight

Length ft (m)

48, 65 gal. 25, 55 and

75 gal.

Minimum straight

Length ft (m)

Through the Wall

Through the Wall

Through the Wall

Through the Wall

Through the Roof

Through the Roof

Through the Roof

Through the Roof

3 45 (13.7) 35 (10.7)

3 45 (13.7) 35 (10.7)

2 (.6)

2 (.6)

2 (.6)

2 (.6)

7 (2.1)

7 (2.1)

7 (2.1)

7 (2.1)

11

Venting (Part I) continued-

TABLE 2 -VENT CONNECTOR LENGTHS

Terminating

FOR 4” (10.2 cm) DIAMETER VENT PIPE

# of 90

° Maximum straight

Elbows Length ft (m)

48, 65 gal. 25, 55 and

75 gal.

Min straight

Length ft (m)

Through the Wall

Through the Wall

Through the Wall

Through the Wall

Through the Wall

Through the Roof

Through the Roof

Through the Roof

Through the Roof

Through the Roof

1 175 (53.3) 175 (53.3)

2 170 (51.8) 170 (51.8)

3 165 (50.3) 165 (50.3)

4 160 (48.8) 160 (48.8)

5 155 (47.2) 155 (47.2)

0 180 (54.9) 180 (54.9)

1 175 (53.3) 175 (53.3)

2 170 (51.8) 170 (51.8)

3 165 (50.3) 165 (50.3)

4 160 (48.8) 160 (48.8)

10 (3.1)

10 (3.1)

10 (3.1)

10 (3.1)

10 (3.1)

15 (4.6)

15 (4.6)

15 (4.6)

15 (4.6)

15 (4.6)

NOTE: When using 4” (10.2 cm) vent pipe, use a 4” (10.1 cm) to 3” (7.6

cm) reducer and exit the building wall with 3” (7.6 cm) vent pipe using the

3” (7.6 cm) 90

° vent terminal supplied. Two 45° elbows are equivalent to one 90

° elbow.

CONNECTION TO 3” (7.6 CM)

VENT PIPE

CONNECTION TO A 3” (7.6 CM) TO

4” (10.2 CM) REDUCER

Figure 2

IMPORTANT

All of the Venting connections must be leak checked with a soap and water solution upon initial start up of the water heater. Any leaks must be repaired before continuing operation of the water heater.

12


THROUGH THE WALL VENTING: (HORIZONTAL VENTING)

Cut a 3 1/2 in. (8.9 cm) diameter hole in the wall at the point where the vent connector is going to pass through the wall. Use the proper cement to secure the 90° vent terminal provided with the water heater to the vent connector. The distance between the edge of the 90° vent terminal and the exterior wall (see

Figure 3) must be 1 in. (2.5 cm). Use the proper cement and assembly procedures to secure the vent connector joints between the terminal and the blower outlet. Provide support brackets for every 5 feet (1.5m) of horizontal vent.

Figure 3

13


THROUGH THE ROOF VENTING: (VERTICAL VENTING)

Cut the necessary holes through the roof and ceiling and install the vent connector as shown in Figure 4. Make sure that the installation meets the local codes and/or The National Fuel Gas Code ANSI Z223.1 (Latest Edition) or

CGA/CAN B149 Installation Code (latest edition).

Figure 4

NOTE: For installations requiring both horizontal and vertical runs, the following rule must be followed: Total length of straight pipe (both horizontally and vertically) must not exceed the allowable length listed in the “Through The Wall” section of the table for total number of elbows used.

14


THROUGH THE WALL VENTING WITH LOW GROUND CLEARANCE:

When venting cannot exit through the wall at a height greater than or equal to

12” (30.5 cm) above the ground, or anticipated snow level, the installation must be modified as shown below (see Figure 5). Refer to Table 3 for maximum venting lengths using 3” (7.6 cm) vent pipe or Table 4 for maximum lengths using 4” (10.2 cm) vent pipe.

Figure 5

15


TABLE 3

3” (7.6 cm) VENT CONNECTOR LENGTHS FROM INSIDE WALL FOR

LOW GROUND CLEARANCE INSTALLATIONS

(2) 90

° Elbows with (1) 90° Elbow

(2) 90


(2) 90


(2) 90


Elbows

1

2

3

4

Length ft (m)

48,65 gal.

25, 55 and 75 gal.

40 (12.2) 30 (9.1)

35 (10.7) 25 (7.6)

30 (9.1) 20 (6.1)

25 (7.6) 15 (4.6)

Min straight

Length ft (m)

5 (1.5)

5 (1.5)

5 (1.5)

5 (1.5)

TABLE 4

4” (10.2 cm) VENT CONNECTOR LENGTHS FROM INSIDE WALL FOR


Terminating (Reduce 4” to 3”)

(Reduce 10.1 cm to 7.6 cm)

(2) 90


(2) 90


(2) 90


(2) 90


(2) 90


# of

Elbows

1

2

3

4

5

160

(48.8)

155

(47.2)

150

(45.7)

145

(44.2)

140

(42.7)

Max straight

Length ft (m)

48,65 gal.

25, 55 and 75 gal.

160

(48.8)

155

(47.2)

150

(45.7)

145

(44.2)

140

(42.7)

Min straight

Length ft (m)

10 (3.1)

10 (3.1)

10 (3.1)

10 (3.1)

10 (3.1)

HIGH ALTITUDE INSTALLATIONS FOR ELEVATIONS OVER 2,500

FEET (762 m) ABOVE SEA LEVEL

The capacity of the induced draft blower declines with increasing altitude due to a reduction in the air density. In order to assure safe and reliable performance of the water heater, contact the supplier for high altitude kit.

16

Part II - Venting Specifications for:

40 Gallon (151.4 L)

50 Gallon (189.2 L)

This water heater is a power vented appliance and is designed to vent its products of combustion through 2” (5.1 cm) or 3” (7.6 cm) diameter Schedule

40 (solid or cellular core) vent pipe to the outdoors. The water heater may be either vented horizontally through the wall or vertically through the roof. Use a

3” (7.6 cm) to 2” (5.1 cm) reducer to connect to the vent outlet when using 3”

(7.6 cm) vent pipe. Apply proper cement at joint locations. Table 5 lists the maximum vent lengths for this water heater using 2” (5.1 cm) vent pipe. If possible, locate the water heater so that the venting length and number of elbows are kept to the minimum distance necessary to reach the outside. If the installation requires venting lengths that exceed the lengths listed for 2” (5.1

cm) vent pipe in Table 5 then use 3” (7.6 cm) vent pipe for the vent connector.

Table 6 lists the venting distances allowed with 3” (7.6 cm) diameter vent pipe.

When venting with 3” (7.6 cm) vent pipe, use a 3” (7.6 cm) to 2” (5.1 cm) reducer to exit through the building wall with 2” (5.1 cm) vent pipe. Use the 2”

(5.1 cm) vent terminal supplied with the water heater to terminate on the outside of the building. If the length of the 2” (5.1 cm) needed to go through the wall is greater than 14” (35.6 cm), use 3” (7.6 cm) vent pipe to go through the wall and reduce to 2” (5.1 cm) vent pipe immediately after exiting the outside wall. Refer to the venting illustrations on the following pages. Make sure the vent pipe terminal is at least 1” (2.5 cm) away from the edge of the wall.

TABLE 5

VENT CONNECTOR LENGTHS FOR 2” (5.1cm) DIAMETER VENT PIPE

Terminating # of 90

° Elbows Max straight Min straight

(excluding vent terminal)

Length ft (m)

Length ft (m)

Through the Wall

Through the Wall

Through the Wall

Through the Wall

1

2

3

4

Through the Roof

Through the Roof

Through the Roof

Through the Roof

Through the Roof

0

1

2

3

4

17

Venting (Part II) continued-

TABLE 6

VENT CONNECTOR LENGTHS FOR 3” (7.6 cm) DIAMETER VENT PIPE

Terminating # of 90

° Elbows Max straight Min straight

(excluding vent terminal)

Length ft (m)

Length ft (m)

Through the Wall

Through the Wall

Through the Wall

Through the Wall

Through the Wall

Through the Roof

Through the Roof

Through the Roof

Through the Roof

Through the Roof

1

2

3

4

5

0

1

2

3

4

NOTE: When using 3” (7.6 cm) vent pipe, use a 3” (7.6 cm) to 2” (5.1 cm) reducer and exit the building wall with 2” (5.1 cm) vent pipe using the 2”

(5.1 cm) 45

° vent terminal supplied. Two 45° elbows are equivalent to one

90

° elbow. Each 90° elbow is equivalent to 5 feet (1.5 m) of straight vent pipe.


VENT PIPE

Figure 6


VENT PIPE

18


IMPORTANT

All of the Venting connections must be leak checked with a soap and water solution upon initial start up of the water heater. Any leaks must be repaired before continuing operation of the water heater.

NOTE: Properly sized PVC, CPVC or ABS pipe must be used.

THROUGH THE WALL VENTING: (HORIZONTAL VENTING)

Cut a 2 1/2 in. (6.4 cm) diameter hole in the wall at the point where the vent connector is going to pass through the wall. Use the proper cement to secure the 45° vent terminal provided with the water heater to the vent connector. The distance between the edge of the 45° vent terminal and the exterior wall (see

Figure 7) must be at least 1 in. (2.5 cm). Use the proper cement and assembly procedures to secure the vent connector joints between the terminal and the blower outlet. Provide support brackets for every 5 feet (1.5 m) of horizontal vent.

Figure 7

19


THROUGH THE ROOF VENTING: (VERTICAL VENTING)

Cut the necessary holes through the roof and ceiling and install the vent connector as shown in Figure 8. Make sure that the installation meets the local codes and/or The National Fuel Gas Code ANSI Z223.1 (Latest Edition) or

CGA/CAN B149 Installation Code (latest edition).

Figure 8

20


THROUGH THE WALL VENTING WITH LOW GROUND CLEARANCE:

When venting cannot exit through the wall at a height greater than or equal to

12” (30.5 cm) from the ground or from the anticipated snow level, then the installation must be modified as shown below (see Figure 9). Refer to Table 7 for maximum venting lengths using 2” (5.1 cm) vent pipe or Table 8 for maximum lengths using 3” (7.6 cm) vent pipe.

Figure 9

NOTE: For installations requiring both horizontal and vertical runs, the following rule must be followed: Total length of straight pipe (both horizontally and vertically) must not exceed the allowable length listed in

the Table 7 and 8 for total number of elbows used.

21


TABLE 7

2” (5.1 cm) VENT PIPE LENGTHS FROM INSIDE WALL FOR LOW

GROUND CLEARANCE INSTALLATIONS

Elbows Length ft (m)

Min straight

Length ft (m)

(2) 90

° Elbows with Vent Terminal

(2) 90


(2) 90


(2) 90


TABLE 8

3” (7.6 cm) VENT CONNECTOR LENGTHS FROM INSIDE WALL FOR


Terminating (Reduce 3” to 2”)

(Reduce 7.6 cm to 5.1 cm)

(2) 90


(2) 90


(2) 90


(2) 90


(2) 90


# of

Elbows

Maximum

Length ft (m)

Minimum

Length ft (m)

HIGH ALTITUDE INSTALLATIONS FOR ELEVATIONS OVER 2,500

FEET (610 m) ABOVE SEA LEVEL

The capacity of the induced draft blower declines with increasing altitude due to a reduction in the air density. In order to assure safe and reliable performance of the water heater, contact the supplier for high altitude kit.

22

Vent Pipe Preparation and Joining

Most failures in vent systems result from improper preparation and joining of pipe and fittings. The guidelines below must be followed when installing the venting system. If you have any question about the application or installation of the venting system, contact the vent pipe manufacturer, supplier, or your plumbing professional.

1) Specific cleaners, solvents, primers and cements are available for PVC,

CPVC, and ABS pipe. Be sure these materials match the type of pipe to be installed. The vent pipe manufacturers joining instructions must be followed in all cases. Never use all-purpose cements, commercial glues and adhesives or ABS cement to join PVC or CPVC pipe and fittings. a) CLEANERS, SOLVENTS, PRIMERS AND CEMENTS ARE

FLAMMABLE. Do not store or use these materials near heat or

open flame, or in the vicinity of other appliances.

2) Use proper cutting, deburring and applicator tools to ensure proper preparation and joining of pipe and fittings. i) A square cut must be achieved with a miter box saw or pipe cutter to ensure a proper mating with the female. If a pipe cutter is used, the burr created at the outer edge of the pipe must be removed. i) A file, knife or plastic deburring tool can be used to remove burrs.

Burrs must be removed from the inside and outside edges of the pipe to ensure a proper seal. i) A natural bristle paintbrush or roller may be used to apply cement.

Prompt application of the cement is important due its fast drying properties.

3) Inspection, Cleaning, Priming and Cementing a) Inspect the pipe inside and out for dirt, dust, moisture or grease etc.

Check pipe and fittings for splits or cracks and replace if found. b) Clean pipe and fittings are imperative for proper joining. Following cutting and deburring, wipe away any foreign material with a clean dry rag. If wiping fails to thoroughly clean surfaces, chemical cleaning is necessary. c) Primer must be applied to the pipe surface and fitting socket with a natural bristle brush. This serves to soften and prepare the PVC,

CPVC or ABS for cementing.

23

Vent Pipe Preparation and Joining continued- d) Cementing must be done quickly to avoid over-drying before joining. i) Apply one coat to the outside end of the pipe at a width slightly greater than the depth of the socket. ii) Apply a coat around the inside of the fitting socket. iii) Apply a second coat around the end of the pipe.

4) Joining a) Joints should be made immediately after cement is applied. b) After fully inserting pipe into fitting socket, hold joint together for about

15 to 20 seconds. c) Remove excess cement from around pipe and fitting with a clean rag. d) Cement drying times may vary. Be sure to allow for the recommended drying time before disturbing joints.

For more specific and detailed information about the above, contact the vent pipe manufacturer, supplier, or competent professional.

24

Combustion Air Supply

WARNING

Liquefied petroleum gases/propane gas are heavier than air and will remain at floor level if there is a leak. Basements, crawl spaces, closets and areas below ground level will serve as pockets for accumulation of leaking gas.

Before lighting, smell all around the appliance area for gas. Be sure to smell next to the floor.

IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any telephone in your building.

• Immediately call your gas supplier from a neighbor’s telephone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

DO NOT OPERATE APPLIANCE UNTIL LEAKAGE IS CORRECTED!

IMPORTANT

The flow of combustion and ventilating air must not be obstructed.

Provide adequate air for combustion and ventilation. An insufficient supply of air will cause recirculation of combustion products resulting in air contamination that may be hazardous to life. Such a condition often will result in a yellow, luminous burner flame, causing carbon build up or sooting of the combustion chamber, burners, and flue tubes with possible damage to the water heater.

When an exhaust fan is installed in the same room with a water heater, sufficient openings for air must be provided in the walls. Undersized openings will cause air to be drawn into the room through the venting, causing recirculation of combustion products.

Unconfined Spaces

In unconfined spaces in buildings, infiltration may be adequate to provide air for combustion, ventilation, and dilution of flue gases. However, in buildings of tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), additional air may need to be provided using the methods described under CONFINED SPACES: All Air From Outdoors or Specially

Engineered Installations.

Confined Spaces

Confined spaces are spaces defined as having less than 50 ft.

3 m

3

/0.29 kw-hr).

/1000 BTU (1.4

25

Installation (Combustion Air Supply) continued-

All Air From Inside the Building: The confined space must be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space must be considered in making this determination. Each opening must have a minimum free area of 1 square inch per 1000 BTU (6.5 cm

2

/0.29 kw) per hour of the total input rating of all gas utilization equipment in the confined space, but not less than 100 square inches

2

(645 cm ). One opening must be within 12 inches (31 cm) of the top and one within 12 inches (31 cm) of the bottom of the enclosure.

All Air From Outdoors: The confined space must be provided with two permanent openings, one commencing within 12 inches (31 cm) of the top and one commencing within 12 inches (31 cm) from the bottom of the enclosure.

The openings must communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

1. When directly communicating with the outdoors, each opening must have a

2 minimum free area of 1 square inch per 4000 BTU (6.5 cm /1.2 kw) per hour of total input rating of all equipment in the enclosure.

2. When communicating with the outdoors through vertical ducts, each opening must have a minimum free area of 1 square inch per 4000 BTU

(6.5 cm

2

/1.2 kw) per hour of total input rating of all equipment in the enclosure.

3. When communicating with the outdoors through horizontal ducts, each opening must have a minimum free area of 1 square inch per 2000 BTU

(6.5 cm

2

/0.6 kw) per hour of total input rating of all equipment in the enclosure.

4. When ducts are used, they must be of the same cross-sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts must be not less than 3 inches (7.5 cm).

Specially Engineered Installations

The requirements noted under CONFINED SPACES above must not necessarily govern when special engineering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion, ventilation, and dilution of flue gases.

26

Water Connections

NOTE: BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE

MAIN WATER SUPPLY VALVE.

After shutting off the main water supply, open a faucet to relieve the water line pressure to prevent any water from leaking out of the pipes while making the water connections to the water heater. After the pressure has been relieved, close the faucet. The COLD water inlet and HOT water outlet are identified on the top of the water heater. The fittings at the cold water inlet and hot water outlet are dielectric waterway fittings with 3/4” NPT male thread. Make the proper plumbing connections between the water heater and the plumbing system to the house. Install a shut-off valve in the cold water supply line.

CAUTION

If sweat fittings are to be used DO NOT apply heat to the nipples on top of the water heater. Sweat the tubing to the adapter before fitting the adapter to the water connections. It is imperative that heat is not applied to the nipples containing a plastic liner.

WARNING

FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED 3/4” X 3/4”

TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE

MANUFACTURER FROM ANY CLAIM THAT MIGHT RESULT FROM

EXCESSIVE TEMPERATURE AND PRESSURES.

If this water heater is installed in a closed water supply system, such as one having a back-flow preventer in the cold water supply, provisions must be made to control thermal expansion. DO NOT operate this water heater in a closed system without provisions for controlling thermal expansion. Your water supplier or local plumbing inspector should be contacted on how to control this situation

After installation of the water lines, open the main water supply valve and fill the water heater. While the water heater is filling, open several hot water faucets to allow air to escape from the water system. When a steady stream of water flows through the faucets, close them and check all water connections for possible leaks. NEVER OPERATE THE WATER HEATER WITHOUT FIRST

BEING CERTAIN IT IS FILLED WITH WATER.

27

Water Connections continued-

WARNING

For protection against excessive temperatures and pressure, install temperature and pressure protective equipment required by local codes, but not less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials as meeting the requirements of the

Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water

Supply Systems, ANS Z21.22 or the Standard CAN1-4.4. Temperature and

Pressure and the Standard CAN1-4.4, Temperature, Pressure, Temperature

and Pressure Relief Valves and Vacuum Relief Valves. The combination temperature and pressure relief valve must be marked with a maximum set pressure not to exceed the maximum working pressure of the water heater.

The combination temperature and pressure relief valve must also have an hourly rated temperature steam BTU discharge capacity not less than the hourly rating of the water heater.

Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose on the water heater.

Note: Some models may already be equipped or supplied with a combination temperature and pressure relief valve. Verify that the combination temperature and pressure relief valve complies with local codes. If the combination temperature and pressure relief valve does not comply with local codes, replace it with one that does. Follow the installation instructions above on this page.

Install a discharge line so that water discharged from the combination temperature and pressure relief valve will exit within six (6) inches (15.2 cm) above, or any distance below the structural floor and cannot contact any live electrical part. The discharge line is to be installed to allow for complete drainage of both the combination temperature and pressure relief valve and the discharge line. The discharge opening must not be subjected to blockage or freezing. DO NOT thread, plug or cap the discharge line. It is recommended that a minimum clearance of four (4) inches (10.2 cm) be provided on the side of the water heater for servicing and maintenance of the combination temperature and pressure relief valve.

Do not place a valve between the combination temperature and pressure relief valve and the tank.

28

Water Connections continued-

WARNING

Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the possibility of injury under these conditions, we recommend the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system. If hydrogen is present, there will be an unusual sound such as air escaping through the pipes as hot water begins to flow. Do not smoke or have open flame near the faucet at the time it is open.

This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water. By setting the thermostat on this water heater to obtain the increased temperature water required by these appliances, you may create the potential for scald injury. To protect against injury, you should install an ASSE approved mixing valve in the water system. This valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines. Such valves are available from the manufacturer of this water heater or a local plumbing supplier. Please consult with a plumbing professional.

APPROXIMATE TIME/TEMPERATURE RELATIONSHIPS IN SCALDS

120°F More than 5 minutes

125°F 1½ to 2 minutes

130°F

135°F

140°F

145°F

150°F

155°F

About 30 seconds

About 10 seconds

Less than 5 seconds

Less than 3 seconds

About 1½ seconds

About 1 second

29

Gas Connections

The gas supply lines must meet all requirements of the National Fuel Gas Code (ANSI

Z223.1-Latest Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation Code

(Latest Edition) or CAN/CGA B149.2 Propane Installation Code (Latest Edition).

The minimum permissible gas supply pressure for the purpose of input adjustment is one (1.0) inch (0.25 kPa) water column above the operating manifold pressure. See the rating plate and gas valve for the manifold pressure and gas type. The maximum permissible gas supply pressure is fourteen (14.0) inches (3.5 kPa) water column for natural gas and liquefied petroleum gases/propane gas.

1. Connect this water heater only to the type of gas (Natural or Propane gas) as shown on the rating plate. Use clean black iron pipe or equivalent material approved by local codes and ordinances. (Dirt and scale from the pipe can enter the gas valve and cause it to malfunction). The inlet gas line must have a minimum length of three (3) inches (7.6 cm) drip leg (sediment trap) installed as close to the water heater’s gas valve as possible. A ground joint union must be installed as close to the water heater as possible in the gas supply line feeding the water heater to permit servicing of the water heater. Compounds used on the threaded joints of the gas piping must be resistant to the action of liquefied petroleum gases/propane gas. DO NOT apply pipe dope to the gas valve inlet and make certain that no pipe dope has become lodged in the inlet screen of the gas valve. Extreme care must be taken to ensure no pipe dope enters the gas valve. Avoid excessive torque when tightening the gas supply line to the gas valve. Excessive torque may result in cracking of the gas valve housing and could create a gas leak. The suggested maximum torque is 31.5 ft. lbs. (4.4 kg-m).

WARNING

The manufacturer of this water heater will not be liable for any damage or injury caused as a result of a cracked gas inlet as a result of excessive torque.

2. This water heater and its gas connection must be leak tested before placing the water heater in operation. Check for gas leaks with a soap and water solution and a brush or a commercial leak detector fluid. NEVER USE A MATCH OR OPEN

FLAME FOR TESTING!

CAUTION

The water heater and individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of the system at test pressures in excess of 1/2 psi (3.5 kPa). The water heater must be isolated from the gas supply piping system by closing its manual shutoff valve during any pressure testing of the gas supply system at test pressures equal to or less than 1/2 psi (3.5

kPa). The supply line must be capped when not connected to the water heater.

3. While checking for leaks care must be taken to prevent solution from contacting the electrical connections at the control. If electrical connections at the control become wet, they must be thoroughly dried before attempting to operate the water heater.

30

Electrical Connections

All electrical wiring and connections must be in accordance with the National

Electric Code ANSI/NFPA No. 70 (latest edition), or the Canadian Electrical

Code C22.1 (latest edition) and any local codes which may apply. The water heater must be electrically grounded.

If a flexible line cord and plug is permitted by local code, then provide a (3) three wire grounding type receptacle within 6 feet (1.9 m) of the water heater and use the flexible cord provided. Do not plug the line cord into a receptacle that can have its power supply interrupted by a switch that is used to turn on and off lights.

If wiring in conduit is required, cut the flexible line cord flush with the bushing.

Remove the junction box cover and pull the pressure switch outside of the junction box. Cut the three wires from the line cord at the bushing inside of the junction box. Drill a hole to receive the ½” electrical conduit connector on the backside of the blower. Wire the power supply into the circuit at the appropriate locations. Replace the pressure switch and junction box cover.

CAUTION

Turn off or disconnect the electrical power supply to the water heater before servicing. Label all wires prior to disconnection when servicing controls.

Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

31

Wiring Diagram

Figure 10

32

GENERAL OPERATION

WARNING

Water heaters are heat producing appliances. To avoid damage or injury there must be no materials stored against the water heater or vent-air intake system, and proper care must be taken to avoid unnecessary contact

(especially by children) with the water heater and vent-air intake system.

UNDER NO CIRCUMSTANCES MUST FLAMMABLE MATERIALS,

SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN

THE VICINITY OF THIS WATER HEATER, VENT-AIR INTAKE SYSTEM

OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE

WATER HEATER OR VENT-AIR INTAKE SYSTEM.

TO FILL THE WATER HEATER

1. Close the water heater drain valve by turning the stem clockwise.

2. Open the cold water supply shut-off valve.

3. Open several hot water faucets to allow air to escape from the system.

4. When a steady stream of water flows from the faucets, the water heater is filled. Close the faucets and check for water leaks at the water heater drain valve, combination temperature and pressure relief valve and the hot and cold water connections.

TO DRAIN THE WATER HEATER

Should it become necessary to completely drain the water heater, make sure you follow the steps below:

1. Shut off the gas supply to the water heater.

2. Turn off/disconnect all electric power to the water heater.

3. Close the cold water supply shut-off valve.

4. Open the drain valve on the water heater by turning the stem counterclockwise. The drain valve has threads on the end that will allow the connection of a standard hose coupling.

5. Open a hot water faucet to allow air to enter the system.

To refill the water heater, refer to “To Fill the Water Heater.”

33

Lighting and shutdown instructions

⌧ ⌧

⌧

⌧

⌧

34

Thermostat Adjustment

The thermostat dial is adjusted to approximately 120°F (49°C) when shipped from the factory. When adjusting the thermostat, it should be remembered that lower temperature settings are more energy efficient. To adjust the thermostat turn the dial clockwise until the minimum acceptable temperature is set. It is suggested that the starting point setting not exceed the 120°F (49°C) or “HOT” setting on the thermostat.

Figure 11

DANGER

Hotter water increases the risk of scald injury. Scalding may occur within five (5) seconds at a temperature setting of 140°F (60°C). To protect against hot water injury, install an ASSE approved mixing valve in the water system. This valve will reduce point of discharge water temperatures by mixing cold and hot water in branch water lines. A licensed plumbing professional or local plumbing authority should be consulted.

Note: This water heater is equipped with an energy cut out device to prevent overheating. Should overheating occur, turn off the electrical supply to the water heater and contact a qualified service technician.

35

Burner Flame Check

Cast Iron Burner: At the time of installation and at periodic intervals (not more than 6 months), a visual check of the main burner and pilot flames should be made to determine if they are burning properly. For ideal operation, the gas and air must be properly proportioned. The proper air-gas mixture is obtained by adjusting the air shutter on the mixer face of the main burner (See Figure

12). To adjust for proper burning, loosen the air shutter nut (if provided), rotate shutter to close the opening in the burner then slowly rotate the shutter until the yellow tips disappear and the flame becomes blue. On 75 gallon models fired on LPG or propane, adjust the air shutter as described above until the yellow flame is minimized (note-the burner flame may contain a mixture of yellow and blue). Tighten the air shutter nut (if provided). Too much air will cause the flame to lift off the burner ports and create noisy operation. Too little air will result in soot formation. The main burner flame should light smoothly from the pilot.

Steel Burner: These models are equipped with self adjusting air mixture and do not have an adjustable air shutter (See Figure 12). At periodic intervals a visual check of the main burner and pilot flames should be made to determine if they are burning properly. The main burner flame should light smoothly from the pilot.

Figure 12

36

MAINTENANCE

WARNING

Water heaters are heat producing appliances. To avoid damage or injury there must be no materials stored against the water heater or vent-air intake system, and proper care must be taken to avoid unnecessary contact

(especially by children) with the water heater and vent-air intake system.

UNDER NO CIRCUMSTANCES MUST FLAMMABLE MATERIALS, SUCH

AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE

VICINITY OF THIS WATER HEATER, VENT-AIR INTAKE SYSTEM OR IN

ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER

HEATER OR VENT-AIR INTAKE SYSTEM.

IMPORTANT

The water heater should be inspected at a minimum annually by a qualified service technician for damaged components and/or joints not sealed. DO NOT operate this water heater if any part is found damaged or if any joint is found not sealed.

The following maintenance should be performed by a qualified service technician at the minimum periodic intervals suggested below. In some installations, the maintenance interval may be more frequent depending on the amount of use and the operating conditions of the water heater. Regular inspection and maintenance of the water heater and vent-air intake system will help to insure safe and reliable operation.

1. Annually check the operation of the thermostat.

2. The flow of combustion and ventilation air MUST NOT be restricted. Clear the combustion air openings of any dirt, dust, or other restrictions.

WARNING! The ventilation air system may be HOT.

3. At all times keep the water heater area clear and free from combustible materials, gasoline and other flammable vapors and liquids.

4. Bi-annually conduct a visual check of the main and pilot burner flames to determine that they are burning properly. See Burner Flame Check section on page 36. If sooting or other burner anomalies are evident, shut down the water heater by turning off the gas per the instructions listed in this manual or as listed on the water heater.

37

Maintenance continued-

5. Annually remove the inner door and main burner assembly to clean orifices and related parts of any dirt or other foreign material. Inspect the burner ports for obstructions or debris and clean with a wire brush as needed.

Wire brush and/or vacuum clean the combustion chamber as needed to remove scale deposits and debris. NOTE: It is imperative for proper operation of the water heater that the inner door be replaced in the original location.

WARNING

When lifting lever of the combination temperature and pressure relief valve, hot water will be released under pressure. Be careful that any released water does not result in bodily injury or property damage.

6. At least once a year, check the combination temperature and pressure relief valve to insure that the valve has not become encrusted with lime.

Lift the lever at the top of the valve several times until the valve seats properly without leaking and operates freely.

7. Monthly drain off a gallon of water to remove silt and sediment.

WARNING!

THIS WATER MAY BE HOT.

8. If the combination temperature and pressure relief valve on the appliance discharges periodically, this may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation. Do not plug the combination

temperature and pressure relief valve outlet.

9. A combination sacrificial anode rod/hot water outlet nipple has been installed to extend tank life. The anode rod should be inspected periodically (every 2 years) and replaced when necessary to prolong tank life. Water conditions in your area will influence the time interval for inspection and replacement of the anode rod. Contact the plumbing professional who installed the water heater or the manufacturer listed on the rating plate for anode replacement information. The use of a water softener may increase the speed of anode consumption. More frequent inspection of the anode is needed when using softened (or phosphate treated) water.

10. The blower has sealed motor bearings and does not require adding oil.

38

Maintenance continued-

CAUTION

FOR YOUR SAFETY. DO NOT ATTEMPT REPAIR OF COMBINATION

GAS CONTROL, BURNERS OR GAS PIPING. REFER REPAIRS TO A

QUALIFIED SERVICE TECHNICIAN.

Contact your supplier or plumbing professional for replacement parts or contact the company at the address given on the rating plate of the water heater.

Provide the part name, model and serial numbers of the water heater when ordering parts.

READ THE WARRANTY FOR A FULL EXPLANATION OF THE LENGTH OF

TIME THAT PARTS AND THE WATER HEATER ARE WARRANTED.

Manufactured under one or more of the following U.S. Patents: RE.34,534;

B1 5,341,770; 4,416,222; 4,628,184; 4,669,448; 4,672,919; 4,808,356; 4,829,983;

4,861,968; 4,904,428; 5,000,893; 5,023,031; 5,052,346; 5,081,696; 5,092,519;

5,115,767; 5,199,385; 5,277,171; 5,372,185; 5,485,879; 5,574,822; 5,596,952;

5,660,165; 5,682,666; 5,761,379; 5,943,984; 5,954,492; 5,988,117; 6,142,216;

6,684,821; 7,063,132;

Other U.S. and Foreign patent applications pending. Current Canadian Patents:

1,272,914; 1,280,043; 1,289,832; 2,045,862; 2,092,105; 2,107,012; 2,108,186;

2,112,515

Complete the following information and retain for future reference:

Model No:

Serial No:

Service Phone

Days: Nights:

Address:

Supplier:

Supplier Phone No:

39

TROUBLESHOOTING

LED Status Control Status Probable Cause

None (LED not on or flashing)

Six flashes-one flash, three second pause

(Soft lockout)

Electrical power not present.

Failed to light pilot.

System auto resets after 5 minutes.

Control power switch in “OFF” position.

Supply voltage interuppted.

One short flash every four seconds

Alternates bright and dim (Heartbeat)

Stand-by mode,

Thermostat is satisfied

(no faults).

Thermostat calling for heat (no fault).

Temperature demand is satisfied (no call for heat).

Tank temperature below set point of thermostat.

Short flash once every second

Two flashes, three second pause

Three flashes, three second pause

Four flashes, three second pause

Five flashes, three second pause

Weak pilot signal on last call for heat.

Pressure switch not working-closed position.

Pressure switch or blower temperature switch not working open position.

1. Unstable pilot.

2. Pilot tube block or restricted.

3. Oxidation build up on pilot electrode.

4. Wire damage to pilot assembly or bad connection

at gas valve.

1. Pressure switch tubing kinked or blocked.

2. Blocked pressure tap on switch.

3. Faulty pressure switch.

1. Vent blockage or improper vent configuration.


3. Blower not spinning up to speed.

4. Vent temperature too high

5. Faulty pressure switch or vent limit switch.

Excessive tank temperature.

System must be reset.

False pilot flame present.

1. Thermowell sensor out of calibration.

2. Faulty gas valve.

1. Pilot valve stuck in open position.

1. Unstable pilot.

2. Pilot tube blocked or restricted.


4. Wire damage to pilot assembly or bad connection

at gas valve.

Six flashes-two flashes, three second pause

(Soft lockout)

Pressure switch or blower temperature switch opened during burner operation.

System auto resets after 5 minutes.



3. Vent termination being affected by windy

conditions.


5. Vent temperature too high

6. Faulty pressure switch or blower temp. switch.

40

Troubleshooting continued-

LED Status Control Status Probable Cause

Six flashes-three flashes, three second pause (Soft lockout)

Six flashes-four flashes, three second pause

Seven flashes, three second pause

Eight flashes-one flash, three second pause

Pilot flame extinguished.

System resets after 5 minutes.

1. Unstable pilot.



4. Wire damage to pilot assembly or bad

connection at gas valve.

5. Insufficient combustion air.

Undesired-false pilot flame sensed.

System auto resets.

Simulated Resistive

Device Harness out of specification or disconnected, or

Flammable vapor sensor fault detected.

Simulated Resistive

Device Harness, or

Flammable vapor sensor out of specification possible short.


Simulated resistive load out of specification, or

Flammable vapor sensor failure.

Simulated resistive load out of specification, or

Flammable vapor sensor out of specification.

Eight flashes-three flashes, three second pause

T'stat well & sensor damaged or unplugged or

Gas valve electronics fault detected

1. Damage to thermowell wire.

2. Thermowell sensor resistance out of range.

3. Replace thermowell.

4. Verify control is not wet or physically damaged

5. Reset control on/off switch.

6. Replace electronic module if 8-3 error persists

Eight flashes-four flashes, three second pause

Gas valve fault detected.

1. Verify control is not wet or physically damaged

2. Reset control on/off switch.

3. Replace gas control if 8-4 error persists

Control Sequence of Operation

Start up Sequence

Upon powering up, the control checks for the presence of the resistive plug, if the resistance is in the expected range the control will begin normal operation after 5 to 8 seconds.

Normal Heating Sequence

1. The thermostat senses a need for heat.

2. The control checks the pressure switch condition.

3. If the pressure switch is open, the control sends power to the blower motor.

4. The blower starts moving combustion air through the combustion system.

5. The pressure switch closes.

6. The control senses the closed pressure switch and starts the ignition process by providing a spark at the pilot electrode and allowing gas to flow to the pilot.

7. When the pilot is lit the gas control senses the pilot flame and opens the main gas valve.

8. The main burner is lit.

9. The main burner and blower continue to operate until the thermostat is satisfied.

10. When the thermostat is satisfied the main and pilot gas valves close.

11. The blower operates for a short post purge period before shutting down.

12. The water heater remains in the stand-by mode until the next call for heat.

41

PARTS LIST DRAWING

(ACTUAL WATER HEATER VISUAL REPRESENTATION MAY VARY)

PARTS LIST

PART NAME AND DESCRIPTION

1. Blower Assembly

2. Pressure Switch (not shown)

3. Blower temp. switch (not shown)

4. Flue Baffle or Flue Core

5. Water heater control

6. Drain Valve

7. Fiberglass Insulation

8. Foam Insulation

9. Outer Door

10. Steel Burner

11. Diptube–Nipple

12. Anode–Nipple

13. Air Shutter (Cast Iron Only)

14. T&P Relief Valve Opening

15. Pilot Assembly

16. Cast Iron Burner

17. Main Burner Orifice

18. Gas Feedline

19. Resistive device

20. Thermal well

42

THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION OF:

GAS WATER HEATERS SUITABLE FOR WATER (POTABLE)

HEATING AND SPACE HEATING

1. All piping components connected to this water heater for space heating applications must be suitable for use with potable water. In Massachusetts, space heating piping length must not exceed 50 feet.

2. Toxic chemicals, such as those used for boiler treatment, must not be introduced into potable water used for space heating.

3. This water heater must not be connected to an existing heating system or component(s) previously used with a non-potable water heating appliance.

4. When the system requires water for space heating at temperatures higher than required for other means, such as an ASSE approved mixing valve must be installed to temper the water for those uses in order to reduce the scald hazard potential.

Please refer to the illustration below for the suggested piping arrangement.

43

NOTES

44

Manual 47150A

TTW 75 SERIES

Gas Water Heaters

SERVICE

MANUAL

Troubleshooting Guide and Instructions for Service

(To be performed ONLY by qualified service providers)

For Bradford White

TTW

®

Series Models:

M2TW75T*(BN,CX)

TW475S76(B,C)* (N,X)

(*) Denotes Warranty Years

Save this manual for future reference

2

Bradford White

TTW Series

Gas Water Heaters

Introduction

How to use this manual

Tool required for service

Specifications

Control Timings

Sequence of Operation

Troubleshooting

Burner Inspection, Cleaning and Replacement

Pilot Testing, Cleaning and Replacement

Pressure Switch Testing and Replacement

Blower Testing and Replacement

Blower Temperature Switch Testing and Replacement

Gas Control & Thermal well Testing & Replacement

Simulated Resistive Device Testing and Replacement

Safety Circuit Voltage Trace

115VAC Circuit Trace

Dip Tube inspection and Replacement

Anode Inspection and Replacement

Flue Baffle Inspection and Replacement

Glossary of Terms

Parts List

Table of Contents

19

21

23

27

28

29

30

31

32

8

9

12

14

16

17

Page

4

5

5

6

33

35

TTW Service Procedure

- - -

- - -

- - -

- - -

- - -

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I

- - -

II

III

X

XI

XII

IV

V

VI

VII

VIII

IX

- - -

- - -

Page 2

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury, or death.

CAUTION appliance may create a hazard to life and property and will nullify the warranty.

FOR YOUR SAFETY


WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electrical switch; do not use any

phone in your building.

Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

DANGER

Do not store or use gasoline or corrosive vapors and liquids in the appliance.

IMPORTANT

Before proceeding, please inspect the water heater and its components for possible damage.

DO NOT install any water heater with damaged components. If damage is evident then please contact the supplier where the water heater was purchased or the manufacturer listed on the rating plate for replacement parts.

WARNING

Water heaters are heat producing appliances. To avoid damage or injury, do not store materials against the water heater or vent-air intake system.

Use proper care to avoid unnecessary contact

(especially by children) with the water heater and vent-air intake components.

UNDER NO

CIRCUMSTANCES MUST FLAMMABLE

MATERIALS, SUCH AS GASOLINE OR PAINT

SYSTEM OR IN ANY LOCATION FROM WHICH

OR VENT-AIR INTAKE SYSTEM.

WARNING

Liquefied petroleum gases/propane gas and natural gas have an odorant added by the gas supplier that aids in the detection of the gas.

Most people recognize this odor as a “sulfur” or

“rotten egg” smell.

Other conditions, such as “odorant fade” can cause the odorant to diminish in intensity, or

”fade”, and not be as readily detectable.

any way unsure of the presence of gas, immediately contact your gas supplier from a neighbor's telephone.

Gas detectors are available. Contact your gas

CAUTION

If sweat fittings are to be used DO NOT apply heat to the nipples on top of the water heater. Sweat the tubing to the adapter before fitting the adapter to the water connections. It is imperative that heat is not applied to the nipples containing a plastic liner.

WARNING

FAILURE TO INSTALL AND MAINTAIN A NEW,

LISTED 3/4” X 3/4” TEMPERATURE AND PRESSURE

RELIEF VALVE WILL RELEASE THE

MANUFACTURER FROM ANY CLAIM THAT MIGHT

RESULT FROM EXCESSIVE TEMPERATURE AND

PRESSURES.

WARNING

Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the possibility of injury under these conditions, we recommend the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system. If hydrogen is present, there will be an unusual sound such as air escaping through the pipes as hot water begins to flow. Do not smoke or have open flame near the faucet at the time it is open.

CAUTION

Turn off or disconnect the electrical power supply to the water heater before servicing. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

Page 3

3

4

Introduction

The new Bradford White TTW2 & TW4 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, significantly quiet operation and additional vent lengths.

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 Thermostat/Gas Control Valve with LED - was developed for ease of troubleshooting by providing simple diagnostic codes to pinpoint an installation or component performance issue.

New Powerful Blower - will eliminate problems with difficult venting situations.

Quieter and Cooler Blower Operation - blower noise is significantly reduced for both interior and exterior environments. Cooler operation increases blower life by reducing bearing wear and noise.

Rugged Wiring Connections - receptacle type connections promote error free wiring.

Increased Vent Lengths - increased venting performance is achieved while maintaining

Energy Factor & FHSR performance.

The TTW2 & TW4 water heaters use a combustion system were flue gases are combined with dilution air to reduce the flue gas temperature in the blower. The diluted flue gases are evacuated to the exterior through low temperature vent materials. The gas control maintains water temperature, ignition sequence and regulates gas flow. A safety circuit consisting of a pressure switch and blower temperature switch verifies proper conditions exist for safe and reliable operation. 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 new gas valve can be removed and replaced without draining the water heater. A special tool is required and will be provided with each gas valve kit shipped from our Service Parts department.

Please read the service manual completely before attempting service on this new series of power vent models.

Page 4

How to Use This Manual

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 TTW Series water heaters. Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting the water heater.

The Honeywell WV4460E Electronic Gas Control will display error codes in the event of abnormal operation. Error codes are listed in the troubleshooting chart beginning on page 12 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.

In some difficult to diagnose conditions, it may be necessary to isolate the heater from the vent system to determine the problem.

Contact the Bradford White technical support group immediately if diagnosis can not be made using the methods described in this service manual.

Tools Required for Service

Manometer:

Multi-Meter:

Electronic Probes:

Thermometer:

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.

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.

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.

Used to measure water temperature. An accurate thermometer is recommended.

Water Pressure Gage:

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:

Used to measure water supply pressure. Also used to determine tank pressure by adapting to the drain valve of the heater.

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, and flashlight, 5 gallon pail.

Page 5

5

6

Specifications

Power supply

Gas Supply Pipe

Approved Gas Type

Gas Pressure

Venting System

Dedicated 115VAC, 60 Hz, 15A

Minimum 1/2" NPT (schedule 40 black iron pipe recommended)

Natural or Propane. Unit must match gas type supplied.

5.0" W.C. min. for Nat gas, 11.0" W.C. min. for L.P. gas, 14.0" W.C. maximum (Nat. & L.P.)

Power vent through the wall or vertical through the roof

Approved Vent Materials PVC, CPVC or ABS

Minimum Clearance for Servicing

18" from top, 24" from front, 4" sides and rear.

Water Supply Pressure 150 PSI maximum allowable working pressure. Check local codes for supply pressure

Thermal well TCO Limit

Residential Temperature

Set Point Range

Commercial Temperature

Set Point Range

Blower Temperature

Switch

Residential 188°F (87°C), Commercial 199°F (93°C)

60°F (16°C) to 160°F (71°C) (Approximate temperatures)

80°F (27°C) to 180°F (82°C) (Approximate temperatures)

Normally closed, opens @ 165°F (74°C), auto reset @ 130°F (54°C).

Pressure switch

M2TW75 and TW475S Models:

Normally open, closes on vacuum increase @ -1.28, opens on vacuum decrease @ -1.25

Blower

M2TW75 and TW475S Models:

115VAC, 60Hz, 3.1 amps, 3000 RPM, [email protected]" W.C.

Page 6

Specifications

Vent Tables

Venting Specifications:

3" Diameter (7.6 cm) PVC Vent Connector Lengths

Terminating

Through the Wall

Through the Wall

Through the Wall

Through the Wall

Through the Roof

Through the Roof

Through the Roof

Through the Roof

# of

Elbows

3

4

1

2

0

1

2

3

Maximum

Length ft (m)

45 (13.7)

40 (12.2)

35 (10.7)

30 (9.1)

50 (15.2)

45 (13.7)

40 (12.2)

35 (10.7)

Minimum

Length ft (m)

2 (.6)

2 (.6)

2 (.6)

2 (.6)

7 (2.1)

7 (2.1)

7 (2.1)

7 (2.1)

4" Diameter (10.2 cm) PVC Vent Connector Lengths

Terminating

Through the Wall

Through the Wall

Through the Wall

Through the Wall

Through the Wall

Through the Roof

Through the Roof

Through the Roof

Through the Roof

Through the Roof

# of

Elbows

1

2

3

4

5

0

1

2

3

4

Maximum

Length ft (m)

175 (53.3)

170 (51.8)

165 (50.3)

160 (48.8)

155 (47.2)

180 (54.9)

175 (53.3)

170 (51.8)

165 (50.3)

160 (48.8)

Minimum

Length ft (m)

10 (3.1)

10 (3.1)

10 (3.1)

10 (3.1)

10 (3.1)

15 (4.6)

15 (4.6)

15 (4.6)

15 (4.6)

15 (4.6)

Page 7

7

8

Specifications

Control Timings

Ignition State

Pre-purge

Trial for Ignition

Flame Stabilization Period

Inter-purge

Flame Failure Response Time

Post-purge

PS Fault Delay (failed open/close)

Soft Lockout

TCO Limit Lockout

Verify Resistive Delay

Simulated Resistive Load Lockout

Hardware Error Lockout

Pilot

Timing

2 Seconds

90 Seconds

3 Seconds

15 Seconds

1.5 Seconds (2 second. Maximum; 1 second minimum.)

15 Seconds

Retry after 2 Minutes

Retry after 5 Minutes

Indefinite (cycle power to restart)

Retry after 2 Minutes (repeats 5 times)

Indefinite (cycle power to restart)

Indefinite (self clears if fault clears for at least 15 seconds)

Wiring Diagram

Blower

Motor

Blower

Temperature

Switch

Blower

Housing

Pressure

Switch

A

B

C

Simulated

Resistive

Device

Thermal

Well

Page 8

Sequence of Operation

Power up Sequence

1 Start Up.

Upon power up, the control runs a safe-start check with a typical start-up delay of 1-5 seconds.

2 Simulated Resistive Load Device Check.

To assure no outputs are energized if the “Simulated Resistive device” is out of range, the control will test the the device for proper operating range. If the device is within range the control resumes normal operation with no perceptible delay. If the device is out of range, the control LED immediately flashes 7 times with 3 second pause.

Normal Heating Sequence

1

Thermostat calls for heat.

Prior to energizing blower, gas control checks safety circuit to insure the circuit is open. 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 control waits 4 seconds, gas control LED flashes 2 times with 3 second pause.

Gas control waits 2 minutes then, blower runs for 30 seconds. This cycle repeats until safety circuit opens.

2

Blower energizes.

3

Blower pre-purge period (2 seconds)

4

Pressure switch proves blower/vent system operation.

If the pressure switch does not close within 30 seconds, the control LED Flashes 3 times with 3 second pause.

The blower runs for 30 seconds every 2 minutes trying to get the pressure switch or blower temperature switch to close. This cycle repeats as long as there is a call for heat.

5

Trial for pilot ignition (90 seconds).

a) The gas control lights the pilot by activating spark igniter and gas flow to pilot burner.

b) If flame is not sensed within 90 seconds, igniter and gas flow are deactivated, blower will post purge and control LED flashes 6 times with 3 second pause.

6

Main burner Ignition

After pilot flame is sensed, gas control activates main valve for main burner ignition. The gas control will ignore flame and pressure switch signals for 3 seconds allowing for main burner to stabilize.

Page 9

9

10


Normal Heating Sequence (cont.)

7

Steady state operation.

During Steady State Operation the Control Monitors:

Thermostat temperature sensor- When set point temperature is satisfied, gas valve is shut down and blower will post purge for 15 seconds. Control LED flashes a short flash once every 4 seconds (idle) status code.

Pressure switch / Blower temperature switch- If either switch opens, pilot valve and main valve is shut down. The blower continues to runs for 30 seconds attempting to close the circuit. The control LED Flashes

3 times with 3 second pause.

Flame Sensor- If flame is lost, pilot & main valve are shut down, blower runs for 15 seconds. Control attempts to re-light pilot 4 times. If unsuccessful, Blower is shut down and control proceeds to 5 minute lockout. Control re-attempts to light pilot starting at normal heating sequence #2.

8

Thermostat satisfies.

9

Burner off.

10

Blower post purge (15 seconds).

Abnormal Operation

1. Simulated Resistive Device Fault:

a) If the resistance is greater than 70,000 Ohms - the gas control immediately turns off all outputs. Control waits and monitors resistance for 30 seconds. If the resistance is greater than 70,000 ohms after 30 seconds, the gas control proceeds to verify resistive delay for 2 minutes and flashes 8 times then once with a three second pause. This process is repeated 5 times until the control either returns to normal operation or proceeds to flashing

7 times with a 3 second pause.

b) If the resistance is below 3000 ohms - The gas control immediately turns off all outputs and proceeds to flash

8 times then once with three second pause. The error self clears if the resistance returns to normal range for at least 15 seconds.

2. Temperature Sensor Fault:

a) Temperature sensor detected open circuit - The gas control Immediately turns off all outputs and proceeds to flash 8 times then twice with three second pause. The error self clears if the fault clears for at least 15 seconds.

b) Temperature sensors not reading the same temperature within ±5.5 °F - The gas control Immediately turns off all outputs and proceeds to flash 8 times then three times with three second pause. The error self clears if the fault clears for at least 15 seconds.

c) Water temperature in excess of TCO (Temperature Cut Off) limit - The gas control immediately turns off pilot & main valve and proceeds to flash 4 times with 3 second pause. Blower continues to run until gas control is reset.

Power needs to be cycled to remove gas control from TCO lockout.

Page 10


Abnormal Operation (cont.)

3. Pressure Switch/Blower Temperature Fault:

a) Pressure switch closed at start of call for heat - The gas control waits four seconds then, proceeds to flash

2 times with 3 second pause. The control waits 2 minutes and then turns on blower for 30 seconds. The blower turns off after 30 seconds and the control waits for pressure switch to open. Any time the Pressure switch opens, the blower turns on (or stays on) and the control proceeds to waiting for pressure switch to close.

b) Pressure switch or blower temperature switch failed open - The gas control runs the blower for 30 seconds waiting for the pressure switch and/or blower temperature switch to close. If either switch does not close in 30 seconds, the blower turns off and the control flashes 3 times with 3 second pause. The gas control waits two minutes before turning on the blower for another 30 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 or blower temperature switch opens during burner operation - The gas control turns off the pilot and main valve, runs blower for 15 seconds (inter-purge) waiting for 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 3 second pause. The gas control waits 5 minutes before repeating ignition sequence.

4. Trial For Ignition Fault:

a) Pressure switch opens during trial - The gas control turns off igniter and pilot valve. The gas control proceeds as described in 3b above. If the pressure switch closes within 30 seconds the gas control will continue with 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 igniter turns off, the pilot valve is closed and the gas control runs the blower through post purge and flashes 6 times then once with 3 second pause. The control waits 5 minutes before repeating the ignition sequence.

5. Flame Sensing Fault:

b) Flame lost during run - The gas control turns off pilot and main valves, runs 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 turns off the blower and flashes 6 times

then 3 times with 3 second pause. The gas control waits 5 minutes before repeating the ignition sequence.

c) 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 proceeds 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 3 second pause. The control waits 5 minutes before repeating the ignition sequence.

Page 11

11

12

Troubleshooting

Observe green LED indicator on

Electronic 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.

Green LED

Indicator

LED Status

None, control LED not on or flashing

Control

Status

No electrical power

Probable Cause

Control power switch in “OFF” position.

Supply voltage interrupted.

Short flash, once every four seconds

Stand-by mode,

Waiting for call for heat (no fault).

Temperature demand is satisfied

“Heartbeat”, alternates bright/dim

Thermostat calling for heat (no fault).

Tank temperature below set point of thermostat.

Short flash once per second

Two flash, three second pause

Three flash, three second pause

Four flash, three second pause

Five flash, three second pause

Weak pilot signal on last call for heat.

1. Unstable pilot.

2. Pilot tube block or restricted.




Pressure switch not workingclosed position.

Pressure switch or blower temp.

switch not working

-open position.


2. Blocked pressure tap on switch or blower.






5. Blower temp or exhaust temp too high

6. Faulty blower temperature switch.

Excessive tank temperature.

System must be reset.

Undesired-false pilot flame present.

1. Thermal well sensor out of calibration.

2. Faulty gas control.

3. Pluming leak


Service

Procedure

Turn power on

Normal operation.

Adjust thermostat to temp level

Normal operation.

Adjust thermostat to temp level

1. Page 14

2-4. Page 16

Page 17

1. Check vent or vent tables.

2 & 3 Page 18

4. Page 19

5 & 6 Page 21

1. Page 23

2. Replace gas control,

page 23

Replace gas control, page 23

Page 12

Troubleshooting

LED Status

Control

Status

Probable Cause

Service

Procedure

Six-one flash, three second pause

Failed to light pilot.

System auto resets.

1. Unstable pilot.





1. Page 14

2-4. Page 16

Six-two flash, three second pause

Six-three flash, three second pause

Pressure switch or blower temp switch opened during burner operation.

System auto resets.

Pilot flame extinguished.

System auto resets.




4. Vent termination being affected by wind


6. Blower temp or exhaust temp too high

7. Faulty blower temperature switch.

1. Unstable pilot.





5. Insufficient combustion air.

6. Gas pressure is out of specification.

Six-four flash, three second pause

Seven flash, three second pause

Eight-one flash, three second pause

Eight-three flash, three second pause

Undesired-false pilot flame sensed.

System auto resets.

Simulated

Resistive Device

Harness out of specification.

Simulated

Resistive Device

Harness specification check.

Thermal well sensor damaged or unplugged

Gas valve electronics fault detected

Eight-four flash, three second pause

Gas valve fault detected.

Pilot valve stuck in open position.

Simulated resistive device out of specification.

Simulated resistive device out of specification.

1. Damage to thermal well wire.

2. Thermal well sensor resistance out of range.

1. Control needs to be reset.

2. Control is wet or physically damaged.

1. Control needs to be reset.

2. Control is wet or physically damaged.

1. Check vent or vent tables.

2 & 3 Page 17

4. Refer to venting section of

installation manual

5. Page 19

6 & 7 Page 21

1. Page 14

2-4. Page 16

5. Refer to installation manual

Replace gas control, page 25

Page 27

Page 27

Page 23

1. Interrupt power supply


page 25

1. Interrupt power supply


page 25

Page 13

13

14

TTW SERVICE PROCEDURE I

Burner Operation Inspection,

Adjustment, Cleaning and Replacement

Burner Inspection and Air Shutter Adjustment.

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.

Pilot flame should be stable, some causes for an unstable pilot flame are: a) Water heater vent is less than the allowable vent length.

b) Gas pressure is out of specification.

c) Pilot flame not fully engulfing spark/flame sensor.

Main burner should light smoothly from 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. 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 cast iron burner adjustment below).

Main burner must be free from any debris accumulation that may effect burner operation (see burner cleaning procedure on page 15).

Cast Iron Burner Air Shutter Adjustment

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, remove outer jacket door and slide inner door from left to right to open.

Step 2.

To adjust for proper burning, loosen the air shutter nut, rotate the air shutter to close the opening in the burner, then slowly rotate the air shutter open until flame becomes as blue as possible with a minimum of yellow tips. 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 will result in soot formation.

Step 3.

Close inner door and observe burner operation. Burner should operate as adjusted in step 2. If not, repeat air shutter adjustment compensating for proper burner operation with inner door closed.

Air Shutter Nut

Air Shutter

Page 14

TTW SERVICE PROCEDURE I

Burner Operation Inspection,

Adjustment, Cleaning and Replacement

Burner Cleaning

Step 1.

Position gas control power switch to the

“OFF” position and unplug heater from wall outlet.

Step 2.

Turn off gas supply to water heater.

Remove Outer door.

Step 3.

Remove outer jacket door and remove inner door.

Step 4.

Disconnect pilot tube (7/16 wrench) and feedline (¾ wrench) from gas control.

Step 5.

Disconnect igniter/flame sensor wire from gas control.

Step 6.

Remove burner assembly from combustion chamber.

Igniter/flame sense wire

Step 7.

Thoroughly inspect burner surface area and burner port area and remove any loose debris.

Step 8.

For cast iron burners, inspect for any debris build up inside burner casting.

Burner surface area

Remove inner door

Feedline nut

Pilot tubing nut

Burner port area

Step 9.

Unscrew burner from main burner orifice. On cast iron burners, loosen air shutter nut and unscrew feedline from burner.

Step 10. Remove main burner orifice from feedline (½" wrench on steel burners, 3/8" wrench on cast iron) inspect orifice, clean or replace if necessary.

Step 11. Reassemble burner and reinstall into water heater. Restore gas supply and check for gas leaks.

Main burner orifice

Step 12 To resume operation follow the instruction located on the lighting instruction label or the lighting instruction located in the installation and operating manual.

L.P. Main burner orifice. Left hand thread

Page 15

15

16

TTW SERVICE PROCEDURE II

Pilot testing, Cleaning and Replacement

Pilot Inspection, Testing and Replacement

Step 1.

Position gas control power switch to the

“OFF” position and unplug heater from wall outlet.

Step 2.

Turn off gas supply to water heater.

Remove Outer door.

Step 3.

Remove outer jacket door and remove inner door.

Remove inner door

Step 4.

Disconnect pilot tube nut (7/16 wrench) and feedline nut

(¾ wrench) from gas control.


Step 5.

Disconnect igniter/flame sense wire from gas control.

Step 6.

Remove burner assembly from combustion chamber.

Feedline nut

Pilot tubing nut

Step 7.

Remove pilot assembly from feedline (¼" nut driver).

Step 8.

Visually inspect igniter/flame sense wire for damage. Replace pilot if damage is found.

Step 9.

With a multi-meter set to the ohms setting, check continuity through igniter/flame sense wire. Replace pilot if no continuity.

Step 10. Visually inspect igniter/flame sense electrode for deterioration.

Replace pilot as necessary. Electrode should not be in contact with pilot hood, If so, carefully adjust electrode to a gap distance of 3/32" (.09) from pilot hood.

Step 11. Visually inspect igniter/flame sense electrode for oxidation build up. Carefully clean any oxidation using very fine emery cloth.

Step 12. Visually inspect pilot tubing for kinks or cracks. If damage is found replace pilot.

Ferrule nut

Pilot tubing

Pilot orifice


Pilot hood

Igniter/flame sense electrode

Step 13. Inspect pilot tubing and pilot orifice for blockage: a) Remove ferrule nut from bottom of pilot assembly (7/16" wrench).

b) Remove pilot tube and pilot orifice.

c) Inspect pilot tubing and pilot orifice for blockage. Clean

or replace as necessary.

Step 14. Reassemble pilot and install to feedline. Reinstall burner assembly to water heater. Restore gas supply and check for gas leaks.

Step 15 To resume operation follow the instruction located on the lighting instruction label or the lighting instruction located in the installation and operating manual.

Page 16

TTW SERVICE PROCEDURE III

Pressure Switch Testing and

Replacement

Pressure Switch Testing

Step 1.

Position power switch on gas control to the “OFF” position.

WARNING

120 volt potential exposure. Use caution making voltage checks to avoid personal injury.

Step 2.

Remove the three screws (Phillips screw driver) from control access cover on blower assembly and remove cover (see photo 1).

Step 3.

Carefully remove pressure switch from blower housing (see photo 2)

1

2

With steps 1,2 & 3 complete, disconnect wire leads from pressure switch.

Pressure Switch

Pressure switch wire leads

Slide pressure switch in direction of arrow while tilting slightly away from blower housing.

Use a multi-meter set to the ohms setting. With blower off, check across pressure switch terminals.

Are switch contacts open?

(no electrical continuity)

Y

N

Position gas valve power switch to the “ON” position and adjust thermostat to call for heat, this will start the blower.

Check with multi-meter, do pressure switch contacts close with blower running?

Y

N

Switch contacts are OK.

See safety circuit trace

(page 28)

Y

Check tubing and pressure tap on switch for blockage.

Is there blockage?

N

Check tubing and pressure tap on switch for blockage.

Is there blockage?

N

Y

Clear blockage

Y

Is vent system blocked

N

Replace switch

(see page 18)

Is vent system length within vent table specifications listed on page 7

N

Y

Reconfigure vent system to be compliant with vent tables.

Y

See blower testing

(page 19)

Is blower OK?

N

Correct blower problem.

Page 17

17

18

TTW SERVICE PROCEDURE III

Pressure Switch Testing and

Replacement

Pressure Switch Replacement

WARNING

120 volt potential exposure. Use caution to avoid personal injury.

Step 1.

Position gas control power switch to “OFF” position.

Step 2.

Remove the three screws (Phillips screw driver) from control access cover on blower assembly and remove cover (see photo 3).

Pressure Switch

3 4

Step 3.

Carefully remove pressure switch from blower housing (see photo 4)

Slide pressure switch in direction of arrow while tilting slightly away from blower housing.

6

Step 4.

Disconnect tubing from pressure switch.

(see photo 5)

Step 5.

Disconnect yellow wires from pressure switch

(see photo 6)

5

Step 6.

Reconnect wires from step 5 to new pressure switch.

Step 7.

Reconnect tubing to new pressure switch.

Step 8.

Carefully position pressure switch into blower housing.

Step 9.

Position gas control power switch to “ON” position and verify proper heater operation.

Step 10. Replace control access cover from step 2.

Page 18

TTW SERVICE PROCEDURE IV


Blower Testing

WARNING

115 volt potential exposure. Use caution when making voltage checks to avoid personal injury.

Step 1.

Position gas control power switch to “ON” position and adjust control to call for heat.

7

Step 2.

Remove the three screws (Phillips Screw driver) from control access cover on blower assembly and remove cover (see photo 7).

Does blower energize

Within 2 minutes?

N

8

Does blower energize after

2 minutes, run for 30 seconds and shut down?

N

Y

Y

Disconnect pressure switch tubing from blower.

(see photo 8)

Pressure tap

Pressure switch tubing

See pressure switch testing

Page 17

Remove exhaust adapter

Connect manometer to pressure tap of blower.

(see photo 8)

Disconnect vent system from top of blower and remove vent adapter.

(see photo 10)

10

9

Determine voltage problem and correct.

11

With blower running, and exhaust adapter removed from top of blower, is there a negative pressure of -2.15" to -2.30" W.C.?

N

Y

N

Is there 115vac across blue and green wires

(see photo 13)

Y

Blower OK

Replace blower

12

Disconnect cord set shown in photo 9. Is there 115VAC across terminals shown in photo 11

N

Y

Is there 115VAC across terminals shown in photo 12 ?

N

Incorrect supply voltage polarity

Y

Is there 115 VAC at wall outlet?

Y

N

Check power cord for damage.

N

Y

Replace blower

Determine power source problem and correct.

Repair or replace power cord

Replace cord set

Reconnect cord set shown in photo 9, is there 115VAC between blue wire and green ground wire

(see photo 13)

N

Y

N

Does cord set have electrical continuity?

Y

Replace gas control

Replace blower

Green ground wire

Shown with pressure switch removed.

13

Blue wire

Page 19

19

20

TTW SERVICE PROCEDURE IV


Blower removal

Step 1.

Position gas control power switch to the “OFF” position.

Step 2.

Unplug blower power cord from wall outlet.

Remove exhaust adapter and retain for use on new blower.

Step 3.

Disconnect vent system from exhaust adapter on top of blower.

Step 4.

Remove exhaust adapter from blower (blade screw driver) and retain for use on new blower

Step 5.

Unplug cord sets from blower.

Step 6.

Remove the three blower mounting screws

(¼" nut driver).

Step 7.

Remove blower with gasket from water heater.

Blower

Cord Sets

Blower Mounting

Screws

Blower Installation

Step 8.

Clean any debris from jacket head of water heater.

Step 9.

Set new blower with gasket in place using locating pins on blower flange to line up with location holes in jacket head.

Be sure not to damage gasket.

Step 10 Secure blower in place using mounting screws from step 6.

Step 11. Re-install exhaust adapter from step 4.

Step 12. Reconnect vent system to exhaust adapter.

Locating Pins on blower flange

Step 13. Reconnect cord sets from step 5.

Pin location holes in jacket head

Step 14. Plug blower power cord into wall outlet.

Step 15. Position gas control power switch to the “ON” position.

Step 16. Verify proper blower operation.

Page 20

TTW SERVICE PROCEDURE V


Blower Temperature Switch

Testing.

Step 1.

Position power switch on gas control to the “OFF” position.

Step 2.

Remove the three screws (Phillips screw driver) from control access cover on blower and remove cover (see photo 14).

WARNING


14

Step 3.

Locate blower temperature switch (see photo 15)

15

Switch Setting

Opens on rise @ approximately 165°F

Auto resets on fall @ approximately 130°F

Blower temperature switch location

Cool switch to below 130°F

Air mixing inlet

Disconnect wire leads to switch. Using a multi-meter set to the ohms setting, is there continuity between the switch terminals?

N

Y

Reconnect wire leads and observe heater operation.

Do exhaust gas temperatures rise to or above 165°F?

N

Y

Do switch contacts open?

N

Y

Replace switch

(see page 22)

N

Do switch contacts open?

Replace switch

(see page 22)

Y

Switch OK

Exhaust temperature is too hot.

Common causes for high exhaust temperature

1. Vent length is below minimum allowable.

2. Vent diameter not to specification.

3. Restricted dilution air inlet.

4. Missing or deteriorated flue baffle.

5. Gas pressure is out of specification.

Page 21

21

22

TTW SERVICE PROCEDURE V


Blower Temperature Switch

Replacement.

WARNING


Step 1.

Position gas control power switch to the “OFF” position and unplug heater from wall outlet.

Step 2.

Remove the three screws (Phillips screw driver) from the control access cover on blower and remove cover.

(see photo 16)

16

Step 3.

Locate blower temperature switch (see photo 17)

Step 4.

Disconnect red and yellow wire leads from switch.

Step 5.

With an appropriate tool such as side cutters, snip the retaining lug from the blower housing to allow removal of temperature switch (see photo 18).

Step 6.

Remove switch from blower housing.

Step 7.

Install new switch. Be sure switch is properly seated in mounting area.

Step 8.

Reconnect red and yellows wires to new switch. Wires are interchangeable with either terminal.

Step 9.

Position gas control power switch to the “ON” position and verify proper heater operation.

Step 10. Replace control access cover from step 2.

17

18

Blower temperature switch location

Snip retaining lug from blower housing

Page 22

Gas Control Testing

See pages 24 & 25 for gas control input & output testing.

Thermal Well Testing

Position gas valve power switch to the “OFF” position and disconnect thermal well harness from gas control.

Using a multi-meter set to the Ohms setting, determine the resistance of thermal well sensors 1 & 2

(see photos 19 & 20)

Disconnect thermal well wire harness

19

TTW SERVICE PROCEDURE VI

Gas Control/Thermal Well Testing and

Replacement

20

Using a multi-meter set to the ohms setting, insert one meter probe into center wire position of thermal well connector, insert the second probe into either of the outside wire positions (see photo 19).

Alternate the probe on the outside position to the opposite outside wire position

(see photo 20).

Once the thermal well resistance values are known, the water temperature must also be known to determine if the resistance values are correct. See page 24 to obtain water temperature.

Are thermal well resistance values correct?

Y

N

Thermal well OK

Replace thermal well

(see page 25)

Page 23

23

24


Gas Control/Thermal Well Testing and

Replacement

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 thermal well is determined from page 23, water flow through the heater should not occur. Prior to performing the steps below, turn off the cold water supply to the water heater. This will prevent cold water flow into the tank affecting the resistance value of thermal well.

90

100

110

120

130

140

150

160

170

180

190

200

°F

40

50

60

70

80

Step 1.

Position gas control power switch to “OFF” position.

Step 2.

Draw approximately 4 gallons of water from drain valve into a container and discard. Draw an additional gallon and immediately measure water temperature using an accurate thermometer. It may be necessary to open a hot water faucet to allow heater to drain.

Step 3.

Using the chart below, determine correct resistance value for the water temperature from step 2.

Example: If temperature of water is 84°F, then the resistance through the sensor would be

8449 (see shaded area). NOTE: Sensor resistance increases as the temperature falls.

Sensor Resistance at Various Temperatures

In Degrees F

7333

5827

4663

3758

3048

2488

2043

1688

1402

1170

982

828

0 1 2 3 4 5 6 7 8

26109 25400 24712 24045 23399 22771 22163 21573 21000

19906 19383 18876 18383 17905 17440 16990 16553 16128

15314 14925 14548 14180 13823 13477 13140 12812 12494

11884 11592 11308 11032 10763 10502 10248

9299 9078 8862 8653 8449 8250 8057

1000

7869

9760

7685

7165

5697

4562

3679

2986

2439

2004

1656

1376

1150

965

814

7000

5570

4464

3602

2925

2391

1966

1625

1351

1129

949

801

6839

5446

4368

3527

2866

2344

1928

1595

1327

1110

933

788

6683

5326

4274

3453

2808

2298

1891

1566

1303

1090

917

775

6531

5208

4183

3382

2752

2253

1856

1537

1280

1071

901

762

6383

5094

4094

3312

2697

2209

1820

1509

1257

1953

886

749

6238

4982

4006

3244

2643

2166

1786

1481

1235

1035

871

737

6098

4873

3922

3177

2590

2124

1753

1454

1213

1017

857

725

9

20445

15715

12185

9526

7507

5961

4767

3839

3112

2538

2083

1720

1427

1191

999

842

713

Page 24


Gas Control & Thermal Well Testing and Replacement

Gas Control & Thermal Well Removal From Water Heater

Gas Control

Step 1.

Position gas valve power switch to the “OFF” position and Unplug Heater from power supply.

Step 2.

Drain heater to a point below the gas control level.

Thermal

Well

Step 3.

Turn off gas supply to water heater and disconnect gas piping from gas control.

Step 4.

Disconnect wire harnesses and burner assembly from gas control.

Step 5.

Remove gas control & thermal well by rotating flats of Thermal Well counter clockwise (1-5/16"wrench).

Gas Control Removal From Thermal Well

Follow the steps below allows removal gas control from thermal well without removing thermal well from tank.

Step 1.

Position gas control power switch to the “OFF” position and unplug water heater from power supply.

Step 2.

Turn off gas supply to water heater and disconnect gas piping from gas control.

Step 3.

Disconnect wire harnesses & burner assembly from gas control.

Step 4.

Using gas control service tool (239-45991-00) available from your BWC parts supplier, Insert tool into back of gas control (see photos below)

View from back of control for clarity

Insert tool from back of control Service tool shown inserted in to back of control

Step 5.

Pivot tool towards heater as far as possible (see photo below). Lift straight up on gas control. The control should move about 1/8". Hold control in position and remove tool. Lift straight up on control to remove completely from Thermal Well.

With service tool inserted, pivot tool back towards heater as far as possible. Lift straight up on control, control will move 1/8". Remove tool and continue to lift straight up on control to remove from Thermal Well.

Page 25

25

26


Gas Control & Thermal Well Testing and Replacement

Gas Control Assembly to Thermal Well

Step 1.

Install threaded end of thermal well into tank. Be sure thermal well flange is positioned as shown in photo 24 for proper control alignment.

Step 2.

Route wire leads back into relief opening.

(see photo 24)

Step 3.

Align slots located on thermal well flange with tabs located on back of gas control (see photos 24 & 25)

Thermal well flange slots

24

Step 4.

Carefully push control back onto thermal well flange as far as possibletowards water heater. Slide control down to lock into position.

Step 5.

Install burner and connect pilot and feedline to gas control.

25

Route wires through relief opening

Gas control Tabs

Igniter/sensor connection

Ground Wire connection

5 pin blower harness connection

Step 6.

Reconnect wire harnesses to gas control per the illustration.

Step 7.

Reconnect gas piping to gas control.

Restore gas supply and check for gas leaks.

3 pin thermal well connection

Step 8.

To resume operation, follow the instruction located on the lighting instruction label or the lighting instruction located in the installation and operation manual.

Simulated Resistive device

Page 26

TTW SERVICE PROCEDURE VII

Simulated Resistive Device Testing

Simulated Resistive Device Testing

Step 1.

Position power switch on gas control to the

“OFF” position.

Step 2.

Disconnect simulated resistive device from gas control.

Step 3.

Using a multi-meter set to the ohms setting check resistance of simulated resistive device. Resistance must be within 25,000 ohms and 45,000 ohms. If outside of this range replace simulated resistive device.


Multi-meter set to ohms setting

Electronic

“pin type”

Meter Probes


Page 27

27

28

TTW SERVICE PROCEDURE VIII

Safety Circuit Voltage Trace

Safety Circuit Voltage

Trace

NOTE: This procedure assumes a cool tank.

WARNING


26

Step 2.

Remove three screws (Phillips Screw driver) from control access cover on blower and remove cover (see photo 26).

Position gas control switch to the “ON” position and adjust thermostat dial to call for heat, Is there 10 to 13 VAC between red wire leading to blower temperature switch and green ground wire?

Blower must be running during this voltage check.

(see photo 27)

Y

N

Is LED on gas valve flashing the “heartbeat” code

(alternating bright/dim)

Y

N

Verify 120VAC to gas control (see page 29)

No voltage from gas control, call for technical support.

Is there 10 to 13 VAC between yellow wire leading from pressure switch and green ground wire?

(see photo 27)

Y

N

Do you hear or can you see the igniter sparking?

Y

Safety circuit voltage is OK.

N

Is there continuity through blower temperature switch?

(see page 21)

N

Y

Determine cause of blower temperature switch activation and correct.

Correct igniter/ sensor problem.

Check igniter/sensor

(see page 16) is igniter/sensor OK?

Y Faulty cord set or gas control.

27

Check for loose or broken wire connection at switch terminals

Green ground wire

Red wire leading to blower temp. switch

If burner does not light, observe LED flash code on gas valve and refer to troubleshooting section on page 12 Yellow wire leading from pressure switch

Page 28

TTW SERVICE PROCEDURE IX

120 VAC Trace

120 VAC Circuit Trace

WARNING


Step 1. Verify 120VAC and proper polarity at wall outlet.

Step 2. With unit plugged in and control power switch in the “ON” position verify LED status.

LED status

None, Control LED not on or flashing.

LED status

Short flash, once every four seconds.

LED status

“Heartbeat”, alternates bright/dim.

LED status

Various flashing error codes.

Waiting for call for heat.

28

Thermostat calling for heat

29

Verify error code as listed on page 12

30

Disconnect cord set as shown in photo 28

Using a volt meter set to volts AC, is there

120VAC across terminals shown in photo 29 ?

Y

N

Is there 120VAC across terminals shown in photo 30 ?

N

Y

Incorrect supply voltage polarity

Reconnect cord set shown in photo 28.

Disconnect wire harness from gas control

(see photo 31).

Locate black & white wires at connector, It may be necessary to pull back wire sheath to identify wire colors.

(see photo 32)

Is there 120VAC across black & white wires as shown in photo 32?

N

Call for technical support.

Y Replace gas control.

Check for damage to

AC supply power cord.

N

Replace Blower

Y

Repair damage

Wire harness

32

Wire sheath pulled back to identify wire colors

Check for 120VAC between black & white wires.

-NOTE-

Electronic meter probes required. Use care not to damage connector during this check.

31

Page 29

29

30

TTW SERVICE PROCEDURE X

Dip Tube

Inspection and replacement

Dip Tube Inspection and Replacement

WARNING

Water 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.

Position on/off switch of gas control valve to “OFF” position and unplug water heater from wall outlet.

Step 2.

Turn off cold water supply to water heater. Connect hose to drain valve of water heater and route to an open drain. Open a nearby hot water faucet to vent heater for draining. Open drain valve of 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 tool such as a pipe wrench, remove inlet nipple/dip tube from the water heater.

Use caution not to damage pipe threads.

Step 5.

Visually inspect inlet nipple/dip tube. Inlet nipple/dip tube should be free of cracks and any blockage.

Hydro-jet slots should be open and 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 water heater. Connect nipple to plumbing system, resume water supply and refill 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.

Page 30

TTW SERVICE PROCEDURE XI

Anode


Anode Inspection and Replacement

WARNING

Water 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.

Position on/off switch of gas control valve to the “OFF” position and unplug water heater from wall outlet.

Step 2.

Turn off cold water supply to water heater. Connect hose to drain valve of water heater and route to an open drain. Open a nearby hot water faucet to vent water heater for draining. Open drain valve of water heater and allow water heater to drain to a point below the outlet connection nipple.

Step 3.

Disconnect outlet nipple from plumbing system.

Step 4 With an appropriate tool such as a pipe wrench, remove outlet nipple/anode from the water heater. Use caution not to damage pipe threads.

Step 5.

Visually inspect outlet nipple/anode. Outlet nipple/anode should show signs of depletion, this is normal. If depletion is ½ of the original anode diameter (approximately ¾” diameter), replacement is recommended. If any of the steel core of the anode is exposed, replacement is recommended.

Step 6.

Upon completion of inspection or subsequent replacement, reinstall outlet nipple/anode into water heater. Connect nipple to plumbing system, resume water supply and refill 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.

Page 31

31

32

TTW SERVICE PROCEDURE XII

Flue Baffle


Remove blower to gain access to flue baffle

Disconnect vent system from exhaust adapter.

Step 1.

Position gas control power switch to the “OFF” position and unplug blower from wall outlet.

33

Step 2.

Disconnect vent system from exhaust adapter on top of blower.

Step 3.

Unplug cord sets from blower. (see photo 33).

Step 4.

Remove the three blower mounting screws

(¼" nut driver) (see photo 33).

Step 5.

Remove blower with gasket from water heater.

Step 6.

Remove flue baffle from Heater (see photo 34).

Blower

Cord Sets

34

Step 7.

Inspect baffle for deterioration, missing restrictors.

Clean any scale or debris build up. Replace with new baffle as necessary.

Step 8.

Reinstall baffle into flue tube. Be sure baffle hanger tab are inserted into notch location at the top of the flue tube (see photos 35 & 36).

Step 9 Check Burner to insure no scale has accumulated during this operation. See burner cleaning procedure on page 14.

Step 10. Reinstall blower on water heater. Connect vent system and cords set to blower. Plug water heater into wall outlet.

Step 11. To resume operation follow the lighting instruction located on the lighting instruction label or the lighting instruction located in the installation and operation manual.

Flue tube notch

35

36

Blower Mounting

Screws

Flue Baffle

Baffle shown installed in flue tube notch.

Page 32

BTU

GPM

Hz

KW/h

LED

NPT

Ohms

PSI

RPM

TCO

VAC

W.C.

°C

°F

NOTES

British Thermal Units

Gallons per Minute

Hertz

Kilowatts per hour

Light Emitting Diode

National Pipe Thread

Ohms of resistance

Pounds per Square Inch

Revolutions per Minute

Temperature Cut Off

Volts Alternating Current

Inches of Water Column

Degrees Centigrade

Degrees Fahrenheit

Glossary of Terms

Page 33

33

NOTES

34

Page 34

Parts List

Optional

1. Blower Complete

2. Air Mixing Inlet cover

3. Pressure Switch

4. Blower Temp. Switch

5. Blower Gasket

6. Blower Power Cord

7. Vent Adapter

8. Condensate Hose Kit

9. Flue Reducer

10. Heat Trap Outlet

11. Hot Water Outlet Anode

12. Flue Baffle

13. Heat Trap Inlet

14. Inlet Dip Tube

15. Wire Harness

16. T&P Valve

17. ¾ NPT Plug

18. Burner Assy. (Nat)

19. Burner Head

20. Main Burner Orifice

21. Pilot Assy. (Nat)

22. Pilot Orifice

23. Feedline

24. Burner Assy. (L.P.)

25. Cast Iron Burner

26. Pilot Assy. (L.P.)

27. Pilot Orifice (L.P.)

28. Feedline

29. Jam Nut

30. Air Shutter

31. Main Burner Orifice (L.P.)

32. Outer Door

33. Inner Door

34. Brass Drain Valve

35. Resistive Load Device

36. Thermal well

37. Gas Control

38. Gas Control Service

Tool

39. Kit-Gas Control

40. ASSE App’vd Mixing

Valve

41. Kit-Heat Trap Insert

42. Exhaust Termination

Elbow

Page 35

35

Email [email protected]

[email protected]

www.bradfordwhite.com

Bradford White M2TW75T*BN Instruction manual

Assistant Bot

POWER VENTED GAS WATER HEATER

INSTALLATION AND OPERATING

INSTRUCTION MANUAL

WARNING:

FOR YOUR SAFETY

CONGRATULATIONS!

You have just purchased one of the finest water heaters on the market today!

This installation, operation and instruction manual will explain in detail the installation and maintenance of your new Power Vented Gas Water Heater. We strongly recommend that you contact a plumbing professional for the installation of this water heater.

This manual should be kept with the water heater.

TABLE OF CONTENTS

GENERAL INFORMATION

CAUTION

DANGER

IMPORTANT

INSTALLATION

WARNING

WARNING

WARNING

WARNING

IMPORTANT

IMPORTANT

WARNING

IMPORTANT

CAUTION

WARNING

WARNING

WARNING

WARNING

CAUTION

CAUTION

GENERAL OPERATION

WARNING

DANGER

MAINTENANCE

WARNING

IMPORTANT

WARNING

WARNING!

CAUTION

TROUBLESHOOTING

Manual 47150A

TTW 75 SERIES

Gas Water Heaters

SERVICE

MANUAL

Troubleshooting Guide and Instructions for Service

For Bradford White

TTW

Series Models:

Save this manual for future reference

Bradford White

TTW Series

Gas Water Heaters

Table of Contents

Introduction

Tools Required for Service

Vent Tables

Control Timings

Power up Sequence

Normal Heating Sequence

Normal Heating Sequence (cont.)

Abnormal Operation

Abnormal Operation (cont.)

Observe green LED indicator on

Electronic 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.

Burner Inspection and Air Shutter Adjustment.

Cast Iron Burner Air Shutter Adjustment

Burner Cleaning

Pilot Inspection, Testing and Replacement

Pressure Switch Testing

Pressure Switch Replacement

Blower Testing

Blower removal

Blower Installation

Blower Temperature Switch

Testing.

Blower Temperature Switch

Replacement.