Bradford-White Corp M4403S manual

The Bradford White Flammable V apor Ignition Resistant W ater Heater SER VICE MANU AL T roub leshooting Guide and Instr uction f or Ser vice (T o be perf or med ONL Y b y qualified ser vice providers) MI30T*F(BN,CX) MI30S*F(BN, CX) MI303T*F(BN,CX) MI40T*F(BN,CX) MI403S*F(BN,CX) MI404T*F(BN,CX) MI503*F(BN,CX) MI50L*F(BN,CX) MI504S*F(BN,CX) MI60T*F(B[...]

3 Table of Contents Page Service Procedure Introducti o n 3 --- T rouble shooting Ch art 4 - - - In ner Door Gasket Removal, Inspection, Replacement and Install ation T hermocouple Testing and Replaceme nt P ilot Assembly Inspection Cleaning and Replacement 10 RG-III Piezo Igniter and Electrode Testing 11 RG-IV Combination Thermostat/Gas Valve Test[...]

4 INTRODUCTION The Bradf ord White DEFENDER Safety System ® The Bradford White DEFENDER Safety System ® w as designed to resist the ignition of flammable v apors that can occur outside of the water heater . Use and installation are nearly identical to pre vious versions of atmosphericall y f ired and vented w ater heaters. A number of exclusi ve [...]

5 SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION Pilot Will Not Light 1. No incoming gas or too low gas pressure. 2. Gas control knob set to wrong position. 3. Pilot light button not being fully depressed when attempting to light pilot. 4. Pilot orifice or pilot tube is obstructed or kinked. 5 . Pilot electrode not sparking to pilot. 6 . Piezo igniter no[...]

6 Inner Door R emov al Procedure Step 1. Rotate knob of the c ombination thermostat/gas valve to the “O F F” p osition. Step 2. Remove outer jacket b urner a c cess door Step 3. Inner Door Removal. a) Disco nne ct resettable thermal switch wire l eads (l eading from comb i nat ion t hermostat/g as valve). b) Remove (2) 1/4" hex drive screw[...]

7 Installat ion 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 wa[...]

8 S tep 10. Firmly place r ight s ide inner door flange a gainst the left side inner door fl ange and se cure with two ¼” drive s crews from step 3 c. DO NOT OVER TIGHTEN SCREWS . S tep 11. A lign r ight side inner do or to comb ustion cham ber and verify the fastener holes of the combustion cha mber are a lig ned with the r ight side inner doo [...]

9 Step 1. C losed circuit t esting is the pref erred method for t esting t hermocoup le. Fol low in g the lightin g instruc tion label on the heate r, p roceed to light th e pi lot and a l low to oper ate f or three minue ts. If the pilot will not stay lit, hold the pilot button ( located on t he c ombi nation therm ost at/gas valve) down durin g t[...]

10 THERM OCOUPLE REPLACEMENT Step 1. Turn off gas supply to water heate r. Rot ate knob of c ombination therm ostat/gas valve to “O FF” position. Step 2. R emo ve outer jacket door. Step 3. R emo ve right side of inner door per SERVICE PROCEDURE RG-I, steps 3a through 3c. Step 4 Disconnect thermocouple f rom co mbina tion th ermostat/gas valve [...]

11 PILOT/ELECTRODE ASSEMBLY I NSPECTION, CLEA NING AND R EPLACEMENT S tep 1. Turn off gas sup ply to wa ter h eat er. Rotate knob of combination thermostat/gas valve to “O F F” position. Step 2. Remove outer jacket door. S tep 3. Remove r ight side of inner door per SERVICE PROCEDURE RG-I , steps 3a thro ugh 3c. Step 4 Disco nne ct thermocouple[...]

12 PIEZO IGNITER, ELECT RODE TESTING AND REP LACEMENT Wi th the pilot not in opera tion ( no pilot fl ame) you can check t he Piezo and e lect rode ci r cuit by v iew ing pilot thru the sight glass locat ed on the i nner do or and ob servi ng the spark a ction. S tep 1. R emove outer jack et door. Step 2. R epeatedly depr ess t he P iezo igniter wh[...]

13 The combination thermostat/gas valve is a n on repairable devi ce. If tr ouble sho otin g has de term ined a probl em with the combina tion t her mostat/gas valve, it must be r eplaced. If the burner and/or pilot do not function, service checks for gas pressu re, thermoco uple output, magnet assembly and ECO are to be performed. If these check O[...]

14 Se e SERVICE P ROCED URE RG-II THE RMOCOUPLE TESTING MAGNET ASSEMBLY TESTING (Whi te Rodgers Control) Step 1. Following the light ing i nstru ction l abel on t he h eat er, p roceed to light the pilot and allow to operate for three minuets. If the pilot will not stay lit, hol d the pilot button (lo cat ed on the c ombination thermosta t/gas v al[...]

15 COMBI NATION THE RMOSTAT/GAS VALVE REPLACEMENT Step 1. Rotate knob of the comb i nati on t hermostat/ gas valve to the “OFF” p osition. Step 2. Turn off gas supply to water heater. Step 3. Disconne ct gas s upply line from combina tion t hermostat/ gas valve. Step 4. Turn off water supply and drain water heater completely. Step 5. Remove out[...]

16 Step 7. Removal of combination thermostat/gas valve. a) Disconnect main burner feed line (¾” wrench), pilot tube (7/16" wrench) and thermocouple (3/8" wrench) from combination thermostat/gas valve & remove burner from combustion chamber. NOTE: Feed line nut for natural gas control uses right hand threads, LP control uses left ha[...]

17 Step 9. Reinstallation of inner door assembly. (cont.) b) Clean an y gasket residue or other debris from comb ustion cha mber surface before installing the inner door/gasket assembly. c) Position thermocouple, pilot tube and Pie zo wi re a gain st left side inn er door flange g asket. DO NOT ROUTE THROUGH RADIUSED CHANNEL WITH FEED LINE. Be s ur[...]

18 S tep 1. With ma in burn er in o perati on, rem ove right side inner door p er s erv ice p rocedu re I, s teps 3b & 3c. Be sure to maintain wire connection to reset table th er mal s witch for this a djustm ent proce dure. Step 2. To ad just for proper burning, loosen the air sh utte r n ut, r ota te the s hutter to clos e the opening in the[...]

19 Step 3. Fully inspect inner gasket pe r S ERVICE PROCED URE R G-I, s tep 4. Replace g asket if r equi red f ollowing SERVICE PROCEDURE I, steps 5 & 6. Step 4. Be ce rtain t hat thermo couple, pilot tube and piezo wire are routed by inner door flange as shown and Reinstall inner door per SERVICE P ROCEDURE R G-I, s tep 1 0 and 11. Step 5. Obs[...]

20 S tep 5. D isconn ect ( unscr ew) M ain burner (stamped steel “B” burner) from m ain burner orifi ce or on cast ir on burners (“C” burner), loosen air shutter & disconnect ( unscrew) feedline from b urner. Step 6. Remove main b urner orifi ce f rom feed line (½” wrench on steel b urner, 3/8 " wrench on cast iron). Inspe ct an[...]

21 Step 1. Remove outer jacket door. Step 2. Disconnect wire leads fro m r esetta ble thermal s witch. Step 3. Using a m ultimeter capa ble of meas uring continuity (Ohms), pl ace one probe of m eter on one of the brass con nec tion tabs of the resettab le thermal switch, a nd the re maini ng p robe on the other connection tab. Step 4. If continuit[...]

22 RESETTABLE THERMAL SWITCH REPLACEMENT S tep 1. Rotate k nob of combination thermostat gas valve to the off position. S tep 2. Remove outer jacket door. Step 3. D isconne ct wire l eads from resetta ble thermal switch. S tep 4. Remove resettable th erm al swi tch from inner door (Phillips screw driver) Step 5. Pla ce new resettable thermal switc [...]

23 Step 1. R otate knob of c ombination thermostat gas valve to the off position. Step 2. R emove outer jacket door. S tep 3. Remove inner door per S ERVI CE PROCEDURE RG -I, step 3a through 3e. Step 4. Disconnect main b urn er feed line (¾ wrench), pilot tube (7/16 wre nch) a nd t hermocoup le (3/8) wrench from com bination thermostat gas valve a[...]

24 S tep 1. Rotate knob o f combina tion ther mostat/ gas valve to “OFF” position. S tep 2. Turn off cold water supply to heater. Connect ho se to dra in spigot of w ater h eater a nd route to an open drain. Open a nearby hot water faucet to vent he ater f or drainin g. Open drain sp igot of hot water h eat er and a l low heater to drain to a p[...]

25 S tep 1. Turn off wa ter sup ply to water h eat er. Ro ta te knob of c ombinat ion t hermostat/ga s valve to “OFF” position. S tep 2. Turn off cold water supply to heater. Connect ho se to dra in spigot of w ater h eater a nd route to an open drain. Open a nearby hot water faucet to vent he ater f or drainin g. Open drain sp igot of hot wate[...]

26 1 Draf t Hood 2 Hot Water Outlet/Anode 3 Cold Water Inlet Tube 4 Flue Baffle 5 T&P Relief Valve 6 Thermostat 7 Piezo Igniter 8 Brass Drain Valve 9 Screw-#8-18 x 3/4 Hex Washer Head 10 Screw-#10-12 x 3/4 Hex Washer Head 11 Left S ide Inner Door with Gasket 12 Complete Right Si de Inner Door 14 Resetta ble Thermal Switch 15 Screw #6-20 x 3/8 P[...]

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