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Bradford-White Corp M1TW40S*F manual

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Table of contents for the manual

  • Page 1

    Save this manual for future reference Manual 238-46238A-00A SERVICE MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qualified service providers) Models Covered by This Manual: M1TW40S*F (BN,CX,SX) M1TW50S*F (BN,CX,SX) M1TW60T*F (BN,CX,SX) M4TW40T*F (BN,SX) M4TW50T*F (BN,SX) M4TW60T*F (BN,SX) M2TW50T*F (BN,CX,SX) M[...]

  • Page 2

    Page TTW Service Procedure Introduction 4 - - - How to use this manual 5 - - - Tool required for service 5 - - - Specifications 6 - - - Control Timings 9 - - - Sequence of Operation 10 - - - Troubleshooting 13 - - - Burner Inspection, Cleaning and Replacement 15 I Pilot Testing, Cleaning and Replacement 17 II Pressure Switch Testing and Replacement[...]

  • Page 3

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

  • Page 4

    Page 4 Introduction The new Bradford White TTW1, 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 Ignitio[...]

  • Page 5

    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 di[...]

  • Page 6

    Specifications Thermal well TCO Limit Residential 188°F (87°C), Commercial 199°F (93°C) Residential Temperature Set Point Range 60°F (16°C) to 160°F (71°C) (Ap proximate temperatures) Blower Temperature Switch Normally closed, opens @ 165°F (74°C), auto reset @ 130°F (54°C). Blower TTW1 (M1TW & M 4TW) Models: 115VAC, 60Hz, 3.1 amps,[...]

  • Page 7

    Specifications Venting Specifications for : 40 Gallon 50 Gallon 60 Gallon Through the Wall Terminating # of Elbows Maximum Straight Length ft (m) Minimum Straight Length ft (m) 2" Diameter (5.1 cm) PVC Vent Connector Lengths 1 45 (13.7) 2 (.6) Through the Wall 2 40 (12.2) 2 (.6) Through the Wall 3 35 (10.7) 2 (.6) Through the Wall 4 30 (9.2) 2[...]

  • Page 8

    Specifications Venting Specifications for : 48 Gallon 65 Gallon Through the Wall Terminating # of Elbows Maximum Straight Length ft (m) Minimum Straight Length ft (m) 3" Diameter (7.6 cm) PVC Vent Connector Lengths 1 55 (16.8) 2 (.6) Through the Wall 2 50 (15.2) 2 (.6) Through the Wall 3 45 (13.7) 2 (.6) Through the Wall 4 40 (12.2) 2 (.6) Thr[...]

  • Page 9

    Control Timings Ignition State Timing Pre-purge 2 Seconds Trial for Ignition 90 Seconds Flame Stabilization Period 3 Seconds Inter-purge 15 Seconds Flame Failure Response Time 1.5 Seconds (2 second. Maximum; 1 second minimum.) Post-purge 15 Seconds PS Fault Delay (failed open/close) Retry after 2 Minutes Soft Lockout Retry after 5 Minutes TCO Limit[...]

  • Page 10

    Sequence of Operation 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 [...]

  • Page 11

    Steady state operation. During Steady State Operation the Control Monitors: Thermostat temperature sensor- When set point temperature is satisfied, gas valve is shut down an d 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 swit[...]

  • Page 12

    Sequence of Operation 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 pressu r[...]

  • Page 13

    Short flash, once every four seconds “Heartbeat”, alternates bright/dim Thermostat calling for heat (no fault). Short flash once per second Weak pilot signal on last call for heat. Two flash, three second pause Pressure switch not working - closed position. Three flash, three second pause Pressure switch or blower temp. switch not working -open[...]

  • Page 14

    Six-four flash, three second pause Undesired-false pilot flame sensed. System auto resets. Seven flash, three second pause Eight-one flash, three second paus Eight-three flash, three second pause Thermal well sensor damaged or unplugged LED Status Control Status Service Procedure Probable Cause Pilot valve stuck in open position . Replace gas contr[...]

  • Page 15

    Step 1. With main burner in operation, remove outer jacket door and inner door per service procedure XIII on page 34. 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 ti[...]

  • Page 16

    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. Step 3. Remove outer jacket door and slide inner door open from left to right. Remove Outer door. Slide inner door ope n from left to right. Feedline nut Pilot tubing nut Igniter/flame [...]

  • Page 17

    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. Step 3. Remove outer jacket door and slide inner door open from left to right. Remove Outer do[...]

  • Page 18

    TTW SERVICE PROCEDURE III Pressure Switch Testing and Replacement Pressure Switch Testing WARNING 115 volt potential exposure. Use caution making voltage checks to avoid personal injury. 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[...]

  • Page 19

    Pressure Switch Replacement WARNING 115 volt potential exposure. Use caution to avoid personal injury. 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 [...]

  • Page 20

    TTW SERVICE PROCEDURE IV Blower Testing and Replacement WARNING 115 volt potential exposure. Use caution when making voltage checks to avoid personal injury. Blower Testing Is there 115VAC across terminals shown in photo 12 ? Incorrect supply voltage polarity Determine power source problem and correct. Does blower energize Within 2 minutes? Y Disco[...]

  • Page 21

    TTW SERVICE PROCEDURE IV Blower Testing and Replacement Step 1. Position gas control power switch to the “OFF” position. Step 2. Unplug blower power cord from wall outlet. 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.[...]

  • Page 22

    TTW SERVICE PROCEDURE V Blower Temperature Switch Testing and Replacement Blower Temperature Switch Testing. WARNING 115 volt potential exposure. Use caution to avoid personal injury. 14 Disconnect wire leads to switch. Using a multi-meter set to the ohms setting, is there continuity between the switch terminals? Cool switch to below 130°F N Y Swi[...]

  • Page 23

    TTW SERVICE PROCEDURE V Blower Temperature Switch Testing and Replacement Blower Temperature Switch Replacement. WARNING 115 volt potential exposure. Use caution to avoid personal injury. 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) fr[...]

  • Page 24

    Thermal Well Testing Thermal well testing Position gas control power switch to the “OFF” position and disconnect thermal well harness from gas control. N Y Using a multi-meter set to the ohms setting, insert one meter probe (see caution) into center wire position of thermal well connector, insert the second probe (see caution) into either of th[...]

  • Page 25

    ° F 012345678 9 40 26109 25400 24712 24045 23399 22771 22163 21573 21000 20445 50 19906 19383 18876 18383 17905 17440 16990 16553 16128 15715 60 15314 14925 14548 14180 1382 3 13477 13140 12812 12494 12185 70 11884 11592 11308 11032 10763 10502 10248 1000 9760 9526 80 9299 9078 8862 8653 8449 8250 8057 7869 7685 7507 90 7333 716 5 7000 6839 6683 6[...]

  • Page 26

    TTW SERVICE PROCEDURE VI Gas Control & Thermal Well Testing and Replacement Gas Control & Thermal Well Removal From Water Heater 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. Step 3. Turn off gas supply to water heater and d[...]

  • Page 27

    Gas Control Assembly to Thermal Well 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. Step 8. To resume operation, follow the instruction located on the lighting instruction label or the lighting instruction located in the installation and [...]

  • Page 28

    P age 28 TTW SERVICE PROCEDURE VII Flammable Vapor Device Testing Flammable Vapor Sensor Step 1. Position power switch on gas control to the “OFF” position. Step 2. Disconnect flammable vapor sensor from gas control. Step 3. Using a multi-meter set to the ohms setting check resistance of flammable vapor sensor. (see caution below) Resistance mu[...]

  • Page 29

    TTW SERVICE PROCEDURE VIII Safety Circuit Voltage Trace Safety Circuit Voltage Trace WARNING 115 volt potential exposure. Use caution making voltage checks to avoid personal injury. 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 s[...]

  • Page 30

    TTW SERVICE PROCEDURE IX 115 VAC Trace WARNING 115 volt potential exposure. Use caution making voltage checks to avoid personal injury. Disconnect cord set as shown in photo 28 LED status None, Control LED not on or flashing. Step 1. Verify 115VAC and proper polarity at wall outlet. Step 2. With unit plugged in and control power switch in the “ON[...]

  • Page 31

    TTW SERVICE PROCEDURE X Dip Tube Inspection and replacement 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 [...]

  • Page 32

    TTW SERVICE PROCEDURE XI Anode Inspection and replacement 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 hea[...]

  • Page 33

    TTW SERVICE PROCEDURE XII Flue Baffle Inspection and replacement Step 1. Position gas control power switch to the “OFF” position and unplug blower from wall outlet. 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"[...]

  • Page 34

    Inner Door Removal Procedure Step 1. Position gas control power switch to the “OFF” position. Step 2. Remove outer jacket burner access door Step 3. Inner Door Removal. a) Remove (2) 1/4" hex drive screws from right side inner door. b) Remove (2) 1/4" drive screws from flange section of inner door. c) Remove (2) 1/4" drive screws[...]

  • Page 35

    Installation of Inner Door With Gasket. WARNING Stripped fastener connections may allow for seal breach of inner door. A seal breach may result in a fire or explosion causing property damage, personal injury or death. Do not over tighten screws in steps 8, 10 and 11. If a fastener connection is stripped, contact the manufacturer listed on the water[...]

  • Page 36

    Step 10. Firmly place right side inner door flange against the left side inner door flange and secure with two ¼” drive screws from step 3b. DO NOT OVER TIGHTEN SCREW S . Step 11. Align right side inner door to combustion chamber and verify the fastener holes of the combustion chamber are aligned with the right side inner door slotted opening. V[...]

  • Page 37

    P age 37 Scr eenLok ® Flame Arr estor Cleaning: Step 1. P osition Gas Control P o w er Switch to the OFF position. Step 2. Remo ve outer jack et. Step 3. Remo ve inner door per TTW SER VICE PR OCEDURE XIII, step 3a through step 3d. Step 4. Disconnect main bur ner feed line (3/4 wrench), pilot tube (7/16 wrench) and igniter/flame sensor wire from g[...]

  • Page 38

    NOTES Page 34 Glossary of Terms BTU British Thermal Units GPM Gallons per Minute Hz Hertz KW/h Killo-watts per hour LED Light Emitting Diode NPT National Pipe Thread Ohms Ohms of resistance PSI Pounds per Square Inch RPM Revolutions per Minute TCO Temperature Cut Off VAC Volts Alternating Current W.C. Inches of Water Column °C Degrees Centigrade ?[...]

  • Page 39

    Parts List 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 w/vent term. 8. Condensate Hose Kit 9. Flue Reducer (M2 only) 10. Heat Trap Out let 11. Hot Water Outlet Anode 12. Flue Baffle 13. Heat Trap Inlet 14. Inlet Dip Tube 15. Wire Harness 16. T&P Val[...]

  • Page 40

    Email parts@bradfordwhite.com techserv@bradfordwhite.com www .bradfordwhite.com[...]