®
TTW Eco-Defender
Residential Ultra Low NOx Gas Water Heaters
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
U1TW40S*FRN
U1TW50S*FRN
U1TW60T*FRN
U2TW50T*FRN
U2TW65T*FRN
UTW450S60FR*N
UTW465S60FR*N
(*) Denotes Warranty Years
Manual 238-48385-00A
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WARNING
If the information in these instructions is not followed exactly, a fire or ex-
plosion may result causing property damage, personal injury, or death.
What to do if you smell gas:
x Do not try to light any appliance
x Do not touch any electrical switch; do not use any phone in your build-
ing
x Immediately call your gas supplier from a neighbor’s phone. Follow the
gas supplier’s instructions.
x 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 other flammable, combustible, or corrosive
vapors and liquids in the vicinity of this or any other appliance.
CAUTION
Incorrect operation of this water heater may create a hazard to life and
property and will nullify the warranty.
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.
Turn off or disconnect the electrical power supply to the water heater be-
fore servicing. Label all wires prior to disconnection when servicing con-
trols. Wiring errors can cause improper and dangerous operation. Verify
proper operation after servicing.
NOTICE
Before proceeding, please inspect the water heater and its components for
possible damage. DO NOT install any water heater with damaged compo-
nents. 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.
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WARNING
Water heaters are heat producing appliances. To avoid damage or injury,
do not store materials against the water heater or any of its components.
Use proper care to avoid unnecessary contact, especially by children, with
the water heater and its components. Under no circumstances must flam-
mable materials, such as gasoline or paint thinner be used or stored in the
vicinity of this water heater or in any location in which the fumes could
reach the water heater.
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 a hot water fau-
cet 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 hydro-
gen 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.
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CER-
TAIN 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 peo-
ple recognize this odor as a “sulfur” or “rotten egg” smell. Other condi-
tions, 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 con-
tact your gas supplier from a neighbor's telephone. Gas detectors are
available. Contact your gas supplier, or plumbing professional for more in-
formation.
FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED 3/4” X 3/4” TEM-
PERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE MANUFAC-
TURER FROM ANY CLAIM THAT MIGHT RESULT FROM EXCESSIVE TEM-
PERATURE AND PRESSURES.
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Introduction
The Bradford White ECO-DEFENDER Safety System®
The Bradford White ECO-DEFENDER Safety System was designed to resist
the ignition of flammable vapors that can occur outside of the water heater
and produce Ultra Low NOx emissions. Use and installation are nearly iden-
tical to previous versions of atmospherically fired and vented water heaters.
A number of exclusive design features are incorporated in the system that
will require additional knowledge on the part of the qualified service pro-
vider. The following information will instruct service professionals on the
function, proper diagnosis, and repair of water heaters employing the Brad-
ford White ECO-DEFENDER Safety System.
Introduction
The new Bradford White TTW ECO-DEFENDER water heaters are designed to provide reli-
able performance with enhanced standard features. New design features include reliable spark
to pilot ignition system, enhanced diagnostics, simplified servicing, quiet operation, additional
vent lengths, Bradford White ECO-DEFENDER Safety System ® and Ultra Low NOx emis-
sions.
Spark-to-Pilot Ignition System - Employing the spark-to-pilot ignition system promotes reli-
able and consistent pilot and main burner ignitions to provide hot water on demand.
Integrated Immersion Thermal Well/Gas Control 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 inte-
rior 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 En-
ergy Factor and FHSR performance.
The TTW1, TTW2 & TW4 water heaters use a combustion system were flue gases are com-
bined 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 main-
tains 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
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How to Use this Manual
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 with-
out 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
How the Safety System Works
During normal operation, most air for combustion is drawn into the water heater through the
openings in the jacket door. This air travels into the burner venturi, mixing with the gas jet.
This air is then mixed with gas inside the burner and drawn to the burner screen and is effi-
ciently combusted producing Ultra Low NOx emissions. Additional air is drawn through the
openings in the jacket. This air travels down and around the combustion chamber and enters
through holes in the bottom of the corrosion-resistant combustion chamber. The air then travels
up through the oriented flame arrestor plate louvers, where the velocity of the air is increased
and its direction altered. The air then mixes in a normal manner with the combustion products
from the burner.
In the case where trace amounts of flammable vapors are present in the air flowing into the
combustion chamber and burner venturi, the vapors are harmlessly ignited by the burner / pilot
flame. If flammable vapors are in sufficient quantity to prevent normal combustion, the burner
and pilot flames are designed to shut down.
Should the flammable vapors continue to the burner, the flame arrestor plate and burner screen
prevent the flames from traveling backwards and igniting vapors outside of the combustion
chamber. This causes the thermopile to overheat and shuts down the main pilot and burner. The
thermopile powers the intelligent diagnostic control which is capable of recognizing restricted
airflow conditions caused by severe lint, dust and oil accumulation on the burner screen and
arrestor plate. The intelligent diagnostic control will deactivate the burner and pilot in the
unlikely event of restricted airflow.
How to Use this Manual
It is intended for this manual to be used by qualified service personnel for the primary purpose
of troubleshooting and repair of the Bradford White Residential Flue Damper water heaters.
Understanding the sequence of operation section of this manual will contribute greatly to trou-
bleshooting the water heater.
The Honeywell WV4460E Electronic Gas Control will display error codes in the event of ab-
normal operation. Error codes are listed in the troubleshooting chart beginning on page 13 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 abnor-
mal operation.
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Tools Required
Contact the Bradford White technical support group immediately if diagnosis cannot be made
using the methods described in this service manual.
Tools Required for Service
Manometer: 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.
Multi-Meter: 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.
Electronic Probes: 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 elec-
tronic “pin” type multi-meter probes. These probes are available at most electronic wholesale
outlets.
Thermometer: Used to measure water temperature. An accurate thermometer is recommended.
Water Pressure Gage: Used to measure water supply pressure. Also used to determine tank
pressure by adapting to the drain valve of the heater.
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: Pipe wrench, channel locks, open end wrenches (3/8", 7/16", 1/2"), 12"
crescent wrench, Allen wrench set, screw drivers (common & Phillips), 1/4" nut driver, pliers
(common & needle nose), socket set, side cutters, wire cutters, wire strippers, wire crimpers,
torpedo level, small shop vac, step ladder, flashlight, and 5 gallon pail.
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Specifications
Power Supply
Dedicated 115VAC, 60 Hz, 15A.
Gas Supply Pipe
Approved Gas Type
Gas Pressure
Minimum 1/2” NPT (schedule 40 black iron pipe recommended).
Natural Gas.
6.0” W.C. minimum, 11.0” W.C. maximum.
Power vent through the wall or vertical through the roof.
Venting System
Approved Vent Materials PVC, CPVC or ABS.
Minimum clearance for
Servicing
18” from top, 24” from front, 4” sides and rear.
150 PSI maximum allowable working pressure. Check local codes for
supply pressure.
Water Supply Pressure
TCO Limit
Residential 118oF (87oC), Commercial 199oF (93oC).
Residential Temperature
Set Point Range
60oF (16oC) to 160oF (71oC) (approximate temperatures).
Commercial Tempera-
ture Set Point Range
80oF (27oC) to 180oF (82oC) (approximate temperatures).
Blower Temperature
Switch
Normally closed, opens @ 165oF (74oC), auto reset @130oF (54oC)
UTW1 Models:
Normally open, closes on vacuum increase @ -0.68, opens on vacuum
decrease @ -0.65
Pressure Switch
U2TW Models:
Normally open, closes on vacuum increase @ -1.28, opens on vacuum
decrease @-1.25
UTW1 Models:
115VAC, 60Hz, 3.1 amps, 3000 RPM, 42 CFM @ 1.5” W.C.
U2TW Models:a,
Blower
115VAC, 60Hz, 3.1 amps, 3000 RPM, 68 CFM @ 0.4” W.C.
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Specifications
Vent Tables
Venting Specifications for:
40 Gallon—40,000 BTU/hr.
50 Gallon—40,000 BTU/hr.
60 Gallon—42,000 BTU/hr.
2” Diameter (5.1 cm) PVC Vent Connector Lengths
Maximum Straight
# of Elbows
Minimum Straight
Length ft (m)
Terminating
Length ft (m)
Through the Wall
Through the Wall
Through the Wall
Through the Wall
1
2
3
4
45 (13.7)
40 (12.2)
35 (10.7)
30 (9.2)
2 (0.6)
2 (0.6)
2 (0.6)
2 (0.6)
Through the Roof
Through the Roof
Through the Roof
Through the Roof
Through the Roof
0
1
2
3
4
50 (15.2)
45 (13.7)
40 (12.2)
35 (10.7)
30 (9.2)
7 (2.1)
7 (2.1)
7 (2.1)
7 (2.1)
7 (2.1)
3” Diameter (7.6 cm) PVC Vent Connector Lengths
Maximum Straight
# of Elbows
Minimum Straight
Length ft (m)
Terminating
Length ft (m)
Through the Wall
Through the Wall
Through the Wall
Through the Wall
Through the Wall
1
2
3
4
5
115 (35.0)
110 (33.5)
105 (32.0)
100 (30.5)
95 (29.0)
10 (3.1)
10 (3.1)
10 (3.1)
10 (3.1)
10 (3.1)
Through the Roof
Through the Roof
Through the Roof
Through the Roof
Through the Roof
0
1
2
3
4
120 (36.6)
115 (35.0)
110 (33.5)
105 (32.0)
100 (30.5)
15 (4.6)
15 (4.6)
15 (4.6)
15 (4.6)
15 (4.6)
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Specifications
Vent Tables
Venting Specifications for:
48 Gallon—60,000 BTU/hr.
65 Gallon—60,000 BTU/hr.
3” Diameter (7.6 cm) PVC Vent Connector Lengths
Maximum Straight
# of Elbows
Minimum Straight
Length ft (m)
Terminating
Length ft (m)
Through the Wall
Through the Wall
Through the Wall
Through the Wall
1
2
3
4
55 (16.8)
50 (15.2)
45 (13.7)
40 (12.2)
2 (0.6)
2 (0.6)
2 (0.6)
2 (0.6)
Through the Roof
Through the Roof
Through the Roof
Through the Roof
0
1
2
3
60 (18.3)
55 (16.8)
50 (15.2)
45 (13.7)
7 (2.1)
7 (2.1)
7 (2.1)
7 (2.1)
4” Diameter (10.2 cm) PVC Vent Connector Lengths
Maximum Straight
# of Elbows
Minimum Straight
Length ft (m)
Terminating
Length ft (m)
Through the Wall
Through the Wall
Through the Wall
Through the Wall
Through the Wall
1
2
3
4
5
175 (53.3)
170 (51.8)
165 (50.3)
160 (48.8)
155 (47.2)
10 (3.1)
10 (3.1)
10 (3.1)
10 (3.1)
10 (3.1)
Through the Roof
Through the Roof
Through the Roof
Through the Roof
Through the Roof
0
1
2
3
4
180 (54.9)
175 (53.3)
170 (51.8)
165 (50.3)
160 (48.8)
15 (4.6)
15 (4.6)
15 (4.6)
15 (4.6)
15 (4.6)
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Specifications
Control Timings
Ignition State
Timing
Pre-purge
15 seconds
90 seconds
3 seconds
15 seconds
Trial for Ignition
Flame Stabilization Period
Inter-purge
Flame Failure Response Time
Post-purge
1.5 seconds (2 second maximum, 1 second minimum)
15 seconds
PS Fault Delay (failed open/close)
Soft Lockout
Retry after 2 minutes
Retry after 5 minutes
TCO Limit Lockout
Indefinite (see page 34 to reset)
Retry after 2 minutes (repeats 5 times)
Indefinite (cycle power to reset)
Indefinite (self clears if fault clears for at least 15 seconds)
Verify Resistive Delay
Simulated Resistive Load Lockout
Hardware Error Lockout
Wiring Diagram
BLOWER
BLOWER
MOTOR
BLOWER
TEMPERATURE
SWITCH
M
G
PRESSURE
BL
SWITCH
W
Y
Y
R
W
BK
G
PILOT
W
Honeywell
PLUG
BK
BK
BK
Y
G
W
R
BK
WATER TEMPERATURE
SENSOR
BL
FLAMMABLE
VAPOR SENSOR
RESETTABLE
THERMAL
11
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Sequence of Operation
Power Up Sequence
1. Start-up: Upon power up, the gas control runs a safe start check with a
typical delay of 5 seconds.
2. Flammable Vapor Verification: The gas control verifies that the Flamma-
ble Vapor Sensor is in the proper operating range prior to energizing any
components. If the sensor is within the proper range, the gas control
resumes normal operation. If the Flammable Vapor Sensor is out of
range, the gas control LED immediately flashes 7 times with a 3 second
pause.
Normal Heating Sequence
1. Thermostat Calls for Heat: Prior to energizing the blower, the gas control
checks the safety circuit to insure the circuit is open. In the safety circuit
the pressure switch is normally open and the blower temperature switch
is normally closed.
2. If the safety circuit is closed, the gas control waits 4 seconds, the gas
control LED flashes 2 times with a 3 second pause. The gas control
waits 2 minutes. Then, the blower runs for 30 seconds. This cycle re-
peats until the safety circuit opens.
3. Blower energizes.
4. Pressure switch proves blower/vent system operation: If the pressure
switch does not close within 30 seconds, the gas control LED flashes 3
times with 3 second pause. The blower runs for 30 seconds every 2 min-
utes 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. Blower pre-purge period (15 seconds).
6. Trial for Pilot Ignition (90 seconds): The gas control lights the pilot by
activating the spark igniter and gas flow to the pilot burner. If flame is
not sensed within 90 seconds, the spark igniter and gas flow are deacti-
vated. The blower will post-purge, and the gas control LED flashes 6
times with a 3 second pause.
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Sequence of Operation
Normal Heating Sequence (cont’d)
7. Main Burner Ignition: After pilot flame is sensed, the gas control acti-
vates the main valve for main burner ignition. The gas control will ig-
nore flame and pressure switch signals for 3 seconds to allow for the
main burner to stabilize.
8. Steady State Operation: During steady state operation, the gas control
monitors:
Thermostat Temperature Sensor: When the setpoint temperature is sat-
isfied, the gas control is shutdown, and the blower will post-purge for 15
seconds. The gas control LED flashes a short flash once every 4 seconds
(Idle status code).
Pressure switch/blower temperature switch: If either switch opens, the
pilot valve and the main valve are shut down. The blower continues to
run for 30 seconds attempting to close the circuit. The gas control LED
flashes 3 times with 3 second pause.
Flame Sensor: If flame is lost, the pilot and main valves are shutdown.
The blower runs for 15 seconds. The gas control attempts to re-light the
pilot 4 times. If unsuccessful, the blower is shutdown, and the gas con-
trol proceeds to a 5 minute lockout. The gas control re-attempts to light
the pilot starting at Normal Heating Sequence #2.
9. Thermostat Satisfies: Gas control LED flashes once every 4 seconds.
10.Burner Off.
11.Blower post-purge (15 seconds).
Abnormal Operation
1. Flammable Vapor Sensor Fault:
A) If the resistance is greater than 70,000 ohms: The gas control imme-
diately turns off all outputs. The gas control waits and monitors resis-
tance for 30 seconds. If the resistance is greater than 65,000 ohms af-
ter 30 seconds, the gas control proceeds to verify resistive delay for 2
minutes and flashes 7 times then 1 time with a three second pause. This
process is repeated 5 times until the control either returns to normal op-
eration or proceeds to flammable vapor lockout.
13
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Sequence of Operation
Abnormal Operation (cont’d)
B) If the resistance is below 3000 ohms: The gas control immediately
turns off all outputs and proceeds to flash 8 times then 1 time with a
three second pause. The error self clears if the resistance returns to nor-
mal range for at least 15 seconds.
2. Temperature Sensor Fault:
A) Temperature Sensor Open Circuit: The gas control immediately turns
off all outputs and proceeds to flash 8 times then 3 times with a three
second pause. The error self clears if the fault clears for at least 15 sec-
onds.
B) Thermal well 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 3 times with three second pause. The error self
clears if the fault clears for at least 15 seconds.
C) Water Temperature in excess of ECO (Energy Cut Off) Limit: The gas
control immediately turns off the pilot and main valves. The gas control
LED proceeds to flash 4 times with a 3 second pause.
To reset the gas control, rotate the setpoint knob to the minimum set-
ting for at least 6 seconds before returning to desired temperature set-
ting.
3. Pressure Switch/Blower Temperature Fault:
A) Pressure switch closed at start of call for heat: The gas control waits 4
seconds then, proceeds to flash 2 times with a 3 second pause. The
gas control waits 2 minutes and then turns on the blower for 30 sec-
onds. The blower turns off after 30 seconds and the control waits for
the pressure switch to open. Any time the pressure switch opens, the
blower turns on (or stays on) and the control proceeds to wait for the
pressure switch to close.
14
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Sequence of Operation
Abnormal Operation (cont’d)
B) Pressure switch or blower temperature switch failed to close: The gas
control runs the blower for 30 seconds waiting for the pressure switch
and/or the 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 a 3 second pause. The gas control waits 2 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 operation:
The gas control turns off the pilot and main valve, runs the blower for
15 seconds (inter-purge) waiting for the pressure switch and/or the
blower temperature switch to close. If either switch fails to close, the
gas control proceeds as described in 3b above. If the circuit closes
again by the end of the inter-purge, the recycle counter is incre-
mented, 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 a
3 second pause. The gas control waits 5 minutes before repeating ig-
nition sequence.
4. Trial for Ignition Fault:
A) Pressure switch opens during trial: The gas control turns off the ig-
niter 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 a trial for ignition starting at blower pre-purge.
B) Flame Not Sensed: The gas control energizes the spark igniter at-
tempting to light the pilot and prove flame. If flame is not sensed
within 90 seconds, the spark igniter turns off, the pilot valve is
closed. The gas control LED flashes 6 times then 1 time with 3 sec-
ond pause. The control waits 5 minutes before repeating the ignition
sequence.
15
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Sequence of Operation
Abnormal Operation (cont’d)
5. Flame Sensing Fault:
A) Flame Lost During Run: The gas control turns off the pilot and main
valves and runs the 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 LED flashes 6 times then 3 times with a 3 sec-
ond pause. The gas control waits 5 minutes before repeating the igni-
tion sequence.
B) 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 a 3 second pause. The control waits 5 minutes before repeating the
ignition sequence.
16
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Troubleshooting
Observe the green LED on the water heater gas con-
trol. Error codes are displayed with a 3 second pause
before repeating. Once the error code is known, check
and repair the water heater, as recommended in the
table below.
Green LED
LED Status
None (LED
not on or
flashing)
Control Status
Probable Cause
Control power switch in "OFF"
Service Procedure
No electrical power position.
Supply voltage interrupted.
Turn Power On
One short
flash every
four seconds satisfied (no faults)
Alternates
bright and
dim
Stand-by mode,
Thermostat is
Temperature demand is satisfied
(no call for heat)
Normal operation
Normal operation
Thermostat calling Tank temperature below
for heat (no fault) setpoint of thermostat
(heartbeat)
1. Unstable pilot
2. Pilot tube blocked or restricted 1. See Burner Inspection on
Short flash
once every
second
3. Oxidation build-up on pilot
electrode
4. Wire damage to pilot
assembly or bad connection at
gas control
page 20
Weak pilot signal
on last call for heat
2-4. See Pilot Inspection,
Testing and Replacement on
page 22
1. Pressure switch tubing kinked
Two flashes, Pressure switch not or blocked
1-3. See Pressure Switch
Testing on page 25
three second
pause
working-closed
position
2. Blocked pressure tap on
switch or blower
3. Faulty pressure switch
1. Vent blockage or improper
vent configuration
2. Pressure switch tubing kinked 1. Check vent or vent tables
or blocked
2-3. See Pressure Switch
Testing on page 25
4. See Blower Testing on
page 28
5-6. See blower Temperature
Switch Testing on page 31
Three
flashes,
Pressure switch or
blower temperature
3. Faulty pressure switch
4. Blower not spinning up to
speed
5. Blower temperature or
exhaust temperature too high
6. Faulty blower temperature
switch
three second switch not working-
pause
open position
Excessive tank
temperature,
system must be
reset
1. Test Gas Control & Thermal
Well
2. Replace gas control if
necessary
Four flashes,
three second
pause
1. Thermal well sensor out of
calibration
2. Faulty gas control
Five flashes,
three second
pause
False pilot flame
present
Pilot valve stuck in open position Replace gas control
17
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Troubleshooting
LED Status
Control Status
Probable Cause
Service Procedure
1. Unstable pilot
Six flashes,
one flash,
three second system resets after
pause (Soft
Lockout)
2. Pilot tube block or restricted 1. See Burner Inspection
Failed to light pilot,
3. Oxidation build-up on pilot
electrode
on page 20
2-4. See Pilot Inspection,
Testing and Replacement
(5) minutes
4. Wire damage to pilot
assembly or bad connection at on page 22
gas valve
1. Vent blockage or improper
vent configuration
1. Check vent or vent
2. Pressure switch tubing kinked tables
Pressure switch or or blocked
Six flashes, blower temperature 3. Faulty pressure switch
2-3. See Pressure Switch
Testing on page 25
4. Refer to venting section
of installation manual
5. See Blower Testing on
page 28
6-7. See Blower
Temperature Switch
Testing on page 31
two flashes,
three second
switch opened
during burner
4. Vent termination being
affected by wind
pause (Soft operation. System 5. Blower not spinning up to
Lockout)
resets after (5)
minutes
speed
6. Blower temperature or
exhaust temperature too high
7. Faulty blower temperature
switch
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 control
1. See Burner Inspection
on page 20
2-4. See Pilot Inspection,
Testing and Replacement
on page 22
Six flashes,
three
flashes,
three second system auto resets
pause (Soft
Lockout)
Pilot flame
extinguished,
after (5) minutes
5. Refer to Installation &
Operation Manual
5. Insufficient combustion air
6. Insufficient gas pressure
Six flashes,
four flashes,
three second
pause
Undesired false
pilot flame sensed, Pilot valve stuck in open position Replace gas control
system auto resets
1. Flammable vapor present
Flammable vapor 2. Flammable vapor sensor
Seven
flashes,
sensor or exposed to excessive moisture
resettable thermal 3. Flammable vapor sensor
See Flammable Vapor
three second
pause
switch fault
detected, see
warning label
exposed to extreme ambient
temperature
4. Resettable thermal switch
open
Sensor Testing on page 40
1. Flammable vapor sensor out
of specification; verify Flammable
Vapor Sensor (FVS) resistance is
not below 25 kŸ.
2. Possible short in flammable
vapor sensor or resettable
thermal switch wiring
Eight
flashes, one
flash, three
second
Flammable vapor
sensor out of
specification,
See Flammable Vapor
Sensor Testing on page 40
possible short
pause
18
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Troubleshooting
LED Status
Control Status
Probable Cause
Service Procedure
1. Damage to thermal well wires
2. Thermal well sensor resistance
Thermal well sensor out of range
Eight flashes,
three flashes,
three second
pause
damaged or un- 3. Replace thermal well
plugged or gas con- 4. Verify control is not wet or
trol electronics fault physically damaged
See Thermal Well Testing on
page 34
detected
5. Reset control on/off switch
6. Replace gas control if 8-3 error
persists
1. Verify control is not wet or
physically damaged
2. Reset control on/off switch
3. Replace gas control if 8-4 error
persists
Eight flashes,
four flashes,
three second
pause
1. Replace gas control if wet
or physically damaged
2. Cycle power
Gas control fault
detected
3. Replace gas control
19
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Burner Maintenance
Burner Inspection
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. The pilot flame should be stable. Some causes for an unsta-
ble pilot flame are:
a) Gas pressure is out of specification.
b) Pilot flame not fully engulfing spark/flame sensor.
The main burner should light smoothly from the pilot and burn with a blue
flame with a minimum of yellow tips. After 5 minutes of operation the
burner screen will become radiant and the flame will soften and turn or-
ange. If the burner screen does not become radiant after 5 minutes of op-
eration it must be cleaned (see burner cleaning procedure below).
Burner Cleaning Procedure
Step 1.
Move the gas control power switch to the
“OFF” position.
Gas control power
switch
Step 2.
outlet.
Unplug the water heater from the wall
TTW (water heater)
power cord
Step 3.
heater.
Turn off the gas supply to the water
Step 4.
Remove the outer door.
Outer door
20
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Burner Maintenance
Burner Cleaning Procedure (cont’d)
Step 5.
Remove the (4) 1/4” hex drive screws holding
the right side inner door in place.
(4) 1/4” hex drive
screws
Right side
inner door
Step 6.
Remove the (3) 1/4” hex drive screws holding
the left side burner door in place.
(3) 1/4” hex
drive screws
Left sid
burner do
Step 7.
Disconnect the pilot tube
using a 7/16” wrench and the main
burner feedline with a 3/4” wrench
from the gas control.
Pilot and main
feedlines
Step 8.
Disconnect the spark igniter/flame sensor
wire from gas control.
Gas control
Spark igniter/flame
sensor wire
Step 9.
Remove the burner assembly from the com-
bustion chamber.
Burner assembly
Step 10.
Remove manifold mount from burner inner door
by removing (2) 1/4” hex drive
screws.
(2) 1/4” hex drive
screws
21
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Pilot Maintenance
Burner Cleaning Procedure (cont’d)
Step 11.
Thoroughly inspect burner screen and
burner venturi and remove any loose debris accumu-
lation. Inspect burner screen for any openings larger
Burner screen
than the normal screen openings.
Step 12.
Use compressed air and/or a vacuum to
remove any scale or other debris accumulation from
the burner screen and venturi.
Burner venturi
Step 13.
Disconnect (unscrew) manifold mount from
feed line. Use a stiff brush, compressed air and/or vac-
uum to remove any debris build up from the manifold
mount.
Manifold mount
Feedline
Step 14.
Remove main burner orifice from feed line
(3/8” wrench). Inspect and clean if necessary.
Main burner orifice
Step 15.
Reassemble the burner assembly and reinstall into the water
heater. Restore gas supply and check for gas leaks.
Step 16. To resume operation, follow the instructions located on the wa-
ter heater lighting instruction label. Or, use the lighting instructions located
in the water heater installation and operating manual.
Pilot Inspection, Testing and Replacement
Step 1.
Move the gas control
Gas control power
switch
power switch to the “OFF” position
22
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Pilot Maintenance
Pilot Inspection, Testing and Replacement (cont’d)
Step 2.
from the wall outlet.
Unplug the water heater
TTW (water heater)
power cord
Step 3.
Turn off the gas supply to the water heater.
Step 4.
Step 5.
Remove the outer door.
Outer Door
Remove the (4) 1/4” hex drive screws holding
the right side inner door in place.
(4) 1/4” hex drive
screws
Right side
inner door
Step 6.
Disconnect the pilot tube
using a 7/16” wrench and the main
burner feedline with a 3/4” wrench
from the gas control.
Pilot and main
feedlines
Step 7.
Disconnect the spark igniter/flame sensor
wire from gas control.
Gas control
Spark igniter/flame
sensor wire
23
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Pilot Maintenance
Pilot Inspection, Testing and Replacement (cont’d)
Step 8.
Remove the burner assembly from the com-
bustion chamber.
Burner assembly
Step 9.
Remove the pilot assembly from the main
feedline using a 1/4" nut driver.
Pilot assembly
1/4” nut driver
Step 10.
Visually inspect the spark igniter/flame sense wire for damage.
Replace the pilot assembly, if damage is found.
Step 11.
With a multi-meter set to the ohms setting,
check continuity through the spark igniter/flame sense
wire. Replace the pilot, if there is no continuity.
Multi-meter
Step 12.
Visually inspect the spark igniter/flame sense electrode for de-
terioration. Replace the pilot assembly, if necessary. The electrode should
not be in contact with pilot hood. If it is in contact with the pilot hood,
carefully adjust electrode to a gap distance of 3/32" from the pilot hood.
Step 13.
Visually inspect the spark igniter/flame sense electrode for oxi-
dation build up. Carefully clean any oxidation using very fine emery cloth.
Step 14. Visually inspect the pilot tubing for kinks or cracks. If damage
is found, replace the pilot assembly.
24
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Pressure Switch Testing
Pilot Inspection, Testing and Replacement (cont’d)
Step 15. Inspect the pilot tubing and pilot orifice for blockages:
a) Remove ferrule nut from the bottom of
the pilot assembly using a 7/16" wrench.
b) Remove the pilot tube and pilot orifice.
c) Inspect the pilot tubing and pilot orifice
for blockages. Clean or replace, as neces-
sary.
Step 16.
Reassemble the pilot assembly and install it on the main
burner. Reinstall the burner assembly into the combustion chamber. Re-
store the gas supply and check for gas leaks.
Step 17.
To resume operation, follow the instructions located on the wa-
ter heater lighting instruction label. Or, use the lighting instructions located
in the water heater installation and operating manual.
Pressure Switch Testing
WARNING
115 volt potential exposure. Use caution making voltage checks to avoid
personal injury.
Step 1.
Step 2.
Move the gas control power switch to the “OFF” position.
Remove the three screws (Phillips screw driver) from the con-
trol access cover on the blower assembly and remove
cover (see photo 1).
Gas control power
switch
Step 3.
Carefully remove pres-
sure switch from blower housing (see photo 2).
1
2
Pressure Switch
25
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Pressure Switch Testing
Pressure Switch Testing (cont’d)
Pressure switch
wire leads
With steps 1,2 & 3
complete, discon-
nect wire leads
from pressure
switch.
Use a multi-meter
set to the ohms
setting. With
blower off, check
across the pres-
sure switch termi-
nals. Are the
Check the tubing and
pressure tap on switch
for blockage. Is there
a blockage?
N
N
Replace switch
(see page 27).
switch contacts
open (no electrical
continuity)?
Clear blockage
Y
Position the gas
control power
Y
Y
switch to the “ON”
position and adjust
the thermostat to
call for heat. This
will start the
blower. Check with
the multi-meter.
Do the pressure
switch contacts
close with the
Check the tub-
ing and pressure
tap on switch for
blockage. Is
there a block-
age?
N
Is the vent
system
blocked?
N
N
Y
Is vent system
length within the
vent table specifi-
cations listed on
pages 9 & 10?
See blower
testing (page
28). Is the
Y
blower running?
Blower OK?
Y
N
N
The switch contacts
are OK. See safety
circuit trace (page
40).
Correct the
blower prob-
lem.
Reconfigure vent
system to be
compliant with
vent tables.
26
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Pressure Switch Replacement
Pressure Switch Replacement
WARNING
115 volt potential exposure. Use caution making voltage checks to avoid
personal injury.
Step 1.
Move the gas control power switch to the
“OFF” position.
Gas control power
switch
Step 2.
Remove the three screws (Phillips screw
driver) from the control access cover on the blower as-
sembly and remove cover.
Control access
cover
Step 3.
Carefully remove pressure switch from
blower housing.
Control access
cover
Slide pressure switch
in direction of arrow
while tilting slightly
away from blower
housing
Step 4.
Disconnect tubing from the pressure switch.
Pressure switch
tubing
27
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Blower Testing
Step 5.
Disconnect yellow wires from the pres-
sure switch.
Yellow pressure
switch wires
Step 6.
Step 7.
Step 8.
Step 9.
Reconnect wires from step 5 to new pressure switch.
Reconnect tubing to new pressure switch.
Carefully position pressure switch into blower housing.
Position gas control power switch to the “ON” postion and verify
proper heater operation.
Step 10.
Replace control access cover form step 2.
Blower Testing
WARNING
115 volt potential exposure. Use caution making voltage checks to avoid
personal injury.
Step 1.
Move the gas control power switch to the
“ON” position and adjust control to call for heat.
Gas control power
switch
Step 2.
Remove the three screws (Phillips screw
driver) from the control access cover on the blower as-
sembly and remove cover.
Control access
cover
28
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Blower Testing
Blower Testing (cont’d)
Remove exhaust
Disconnect vent
system from top of
blower and remove
vent adapter (see
photo 5).
adapter
Does blower
energize within
2 minutes?
Disconnect pres-
sure switch tub-
ing from blower
(see photo 3).
Connect manome-
ter to pressure tap
of blower (see
photo 3).
Y
5
N
Pressure tap.
3
4
With blower running and
exhaust adapter removed
from top of blower, is there
a negative pressure of –
2.15” to –2.30” W.C.
Y
Blower OK.
Pressure
switch tubing
N
Does blower
energize after
2 minutes, run
for 30 seconds
and shut
N
Y
Determine volt-
age problem and
correct.
Y
Is there 115VAC across blue
and green wires (see photo 8).
See pressure
switch testing
on page 25.
Replace blower.
down?
6
7
N
Disconnect
cord set in
photo 9. Is
Is there
115VAC
Y
Y
across termi-
nals shown
in photo 7?
there 115VAC
across termi-
nals shown in
photo 11?
Reconnect cord set
shown in photo 4.
Is there 115VAC
between blue wire
and ground wire
(see photo 8).
Y
Replace blower.
N
N
Incorrect supply
voltage polarity.
Blue wire
Green ground
wire
N
Determine
power source
problem and
correct.
N
Does cord set
have electrical
continuity?
N
Replace cord
set.
Is there
115VAC at
wall outlet?
Y
8
Y
Shown with pressure
switch removed
Replace gas
control.
Y
Check power cord
for damage.
Repair or replace
power cord.
N
Replace blower.
29
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Blower Replacement
Blower Removal
Step 1.
Move the gas control power switch to the
“OFF” position.
Gas control power
switch
Step 2.
let.
Unplug the water heater from the wall out-
TTW (water heater)
power cord
Step 3.
Disconnect vent system
Remove exhaust
from exhaust adapter on top of blower.
adapter and retain
for use on new
blower
Blower mount-
ing screws
Step 4.
Remove exhaust adapter
from blower (blade screw driver) and retain for
use on new blower.
Step 5.
Remove dilution air clip from air in-
take boot and retain for use on new blower.
Step 6.
Step 7.
Unplug cord sets from blower.
Remove the three blower
Blower cord
sets
Remove dilution air
clip and retain for
use on new blower
mounting screws (1/4” nut driver).
Step 8. Remove blower with gasket from water heater.
Blower Installation
Step 9.
Clean any debris from jacket head of
water heater
Locating pins on
blower flange
Step 10. 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.
Pin location holes
in jacket head
30
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Blower Temperature Switch Testing
Blower Installation (cont’d)
Step 11.
Step 12.
Step 13.
Step 14.
Step 15.
Step 16.
Step 17.
Secure blower in place using mounting screws from step 7.
Reinstall exhaust adapter from step 4.
Reinstall dilution air clip from step 5.
Reconnect vent system to exhaust adapter.
Reconnect cords from step 6.
Position gas control power switch to the “ON” position.
Verify proper blower operation.
Blower Temperature Switch Testing
WARNING
115 volt potential exposure. Use caution making voltage checks to avoid
personal injury.
Step 1.
Move the gas control power switch to the
“OFF” position.
Gas control power
switch
Step 2.
Remove the three screws (Phillips screw
driver) from control access cover on blower and remove
cover.
Control access
cover
Blower temperature
switch location
Step 3.
Locate the blower temperature switch.
Air mixing
inlet
31
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Blower Temperature Switch Testing
Blower Temperature Switch Testing (cont’d)
Switch Setting
Opens on rise @ approximately 165oF
Auto resets on fall @ approximately 160oF
Cool switch to
below 160oF
Disconnect wire leads to
switch. Using multi-meter set
to the ohms setting. Is there
continuity between the switch
terminals?
N
Replace switch
(see page 33).
Common causes for high
exhaust temperature
Y
1. Vent length is below mini-
mum allowable
N
Reconnect wire leads and ob-
serve heater operation. Do
exhaust gas temperatures
rise to or above 170oF with
vent connected?
2. Vent diameter not to speci-
fication
Y
Do switch
contacts
open?
Exhaust
temperature
is too hot.
Y
3. Restricted dilution air inlet
4. Missing or deteriorated flue
baffle
N
5. Gas pressure is out of
specification
Y
Do switch con-
tacts open?
Replace switch
(see page 33).
N
Switch OK
32
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Blower Temperature Switch Replacement
Blower Temperature Switch Replacement
WARNING
115 volt potential exposure. Use caution making voltage checks to avoid
personal injury.
Step 1.
Move the gas control power switch to the
“OFF” position.
Gas control power
switch
Step 2.
Remove the three screws (Phillips screw
driver) from the control access cover on the blower as-
sembly and remove cover.
Control access
cover
Step 3.
Locate blower temperature switch.
Blower temperature
switch location
Step 4.
Disconnect red and yellow wire leads from
the switch.
Step 5.
With an appropriate tool such as side cut-
ters, snip the retaining lug from the
blower housing to allow removal of
temperature switch.
Snip retaining lug from
blower housing
Step 6.
Remove switch from blower housing.
Step 7.
Install new switch. Be sure switch is prop-
erly seated in mounting area.
Step 8. Reconnect red and yellow wires to new switch. Wires are inter-
changeable with either terminal.
Step 9.
Position the gas control power switch to the “ON” position and
verify proper heater operation.
Step 10.
Replace control access cover from step 2.
33
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Thermal Well Testing
Thermal Well Testing
CAUTION
Do not use standard multi-meter probes for this testing. Doing so will damage the connector. Use special pin type
electronic probes or small diameter wire pins inserted into connector.
Follow the procedure, below, if the water heater gas control has gone into a ECO lock-
out (4 flash, 3 second pause). Reset the gas control by rotating the setpoint knob to
the minimum setting for at least 6 seconds before returning to the desired water tem-
perature setting.
Step 1.
control.
Unplug the thermal well connector from the gas
Thermal well connector
Step 2.
With a multi-meter set to the ohms setting, meas-
ure the resistance between the middle and right side wires.
Step 3.
With a multi-meter set to the ohms setting, meas-
ure the resistance between the middle and left side wires.
34
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Determine Tank Temperature
Thermal Well Testing (cont’d)
Determine the correct resistance values using the Determine the Water Temperature
Inside the Tank procedure on page 23. If the values are correct, replace the gas con-
trol, otherwise replace the thermal well.
Determine Water Temperature Inside Tank
WARNING
Stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to pre-
vent personal injury.
Note: It is important to understand once the resistance for the thermal well is deter-
mined using the Thermal Well Testing Procedure on page 21, water flow through the
water 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 affect-
ing the resistance value of thermal well.
Step 1.
Move the gas control power switch to the “OFF”
position.
Gas control power
switch
Step 2.
Draw approximately 4 gallons of water from the drain valve into a con-
tainer and discard. Draw an additional gallon and immediately measure the water tem-
perature using an accurate thermometer. It may be necessary to open a hot water fau-
cet to allow heater to drain.
Step 3.
Using the chart on page 23, determine the 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 tem-
perature falls.
35
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Component Disassembly
Sensor Resistance at Various Temperatures
In Degrees F
°F
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
0
1
2
3
4
5
6
7
8
9
26109
19906
15314
11884
9299
7333
5827
4663
3758
3048
2488
2043
1688
1402
1170
982
25400
19383
14925
11592
9078
7165
5697
4562
3679
2986
2439
2004
1656
1376
1150
965
24712
18876
14548
11308
8862
7000
5570
4464
3602
2925
2391
1966
1625
1351
1129
949
24045
18383
14180
11032
8653
6839
5446
4368
3527
2866
2344
1928
1595
1327
1110
933
23399
17905
13823
10763
8449
6683
5326
4274
3453
2808
2298
1891
1566
1303
1090
917
22771
17440
13477
10502
8250
6531
5208
4183
3382
2752
2253
1856
1537
1280
1071
901
22163
16990
13140
10248
8057
6383
5094
4094
3312
2697
2209
1820
1509
1257
1053
886
21573
16553
12812
10000
7869
6238
4982
4006
3244
2643
2166
1786
1481
1235
1035
871
21000
16128
12494
9760
7685
6098
4873
3922
3177
2590
2124
1753
1454
1213
1017
857
20445
15715
12185
9526
7507
5961
4767
3839
3112
2538
2083
1720
1427
1191
999
842
713
828
814
801
788
775
762
749
737
725
Gas Control & Thermal Well Removal From Water Heater
Step 1.
sition.
Move the gas control power switch to the “OFF” po-
Gas control power
switch
Step 2.
Unplug the water heater from the wall outlet.
TTW (water heater)
power cord
Step 3.
Drain the water heater to a point below the gas
control level.
Step 4.
Turn off the gas supply to the water heater and disconnect the gas piping
from the gas control.
36
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Gas Control Removal
Gas Control & Thermal Well Removal From Water Heater (cont’d)
Step 4. Disconnect the pilot tube
using a 7/16” wrench and the main burner
feedline with a 3/4” wrench from the gas
control.
Pilot and main
feedlines
Step 5.
Disconnect the wire harnesses and spark igniter/
flame sense wire from the gas control.
Gas control
Spark igniter/flame
sensor wire
Step 6.
Remove the gas control & thermal well by rotating
the flats of the Thermal Well counter clockwise using a 1-5/16”
wrench.
Flats of thermal
well
Gas Control Removal From Thermal Well
Following the steps below allows for the removal of the gas control from the thermal
well without removing the thermal well from the tank.
Step 1.
Move the gas control power switch to the “OFF”
position.
Gas control power
switch
Step 2.
Unplug the water heater from the wall outlet.
TTW (water heater)
power cord
37
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Gas Control Assembly
Gas Control Removal From Thermal Well (cont’d)
Step 3.
Turn off the gas supply to the water heater and disconnect the gas piping
from the gas control.
Step 4.
Disconnect the pilot tube
using a 7/16” wrench and the main burner
feedline with a 3/4” wrench from the gas
control.
Pilot and main
feedlines
Step 5.
Disconnect the wire harnesses and spark igniter/
flame sense wire from the gas control.
Gas control
Spark igniter/flame
sensor wire
Step 6.
Using the gas control service tool, p/n 239-45991-
00, available from your BWC parts supplier, insert the tool into
the back of the gas control.
Gas control service
tool
Step 7.
Pivot the tool towards the water heater, as far as possible. Lift straight up
on the gas control. The gas control should move about 1/8". Hold the gas control in
position and remove the tool. Lift straight up on the gas control to remove it completely
from the thermal well.
Gas Control Assembly to the Thermal Well
Step 1.
Install the threaded end of the thermal well into the tank. Be sure the
thermal well flange is positioned properly to allow for proper gas control installation.
Tighten the thermal well using a 1-5/16” wrench.
38
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Gas Control Assembly
Gas Control Assembly to the Thermal Well (cont’d)
Step 2.
Route the wire leads back into relief opening.
Wire leads on
thermal well
Slots in thermal well
Relief opening
Step 3.
Align the slots located on the thermal well flange
with the tabs located on the back of the gas control.
Tabs on back of gas
control
Step 4.
Carefully push the gas control back onto the thermal well flange as far as
possible towards the water heater. Then, slide the gas control down to lock into posi-
tion.
Step 5.
Install the burner assembly
and connect the pilot and main feedlines
to the gas control using a 7/16” and 3/4”
wrench, respectively.
Pilot and main
feedlines
Step 6.
Step 7.
Reconnect the wire harnesses to the gas control.
Wire harnesses
Reconnect the gas piping to the gas control. Re-
store the gas supply and check for gas leaks.
39
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Flammable Vapor Sensor Testing
Gas Control Assembly to the Thermal Well (cont’d)
Step 8.
To resume operation, follow the instructions located on the water heater
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.
Flammable Vapor Sensor Testing
CAUTION
Do not use standard multi-meter probes for this testing. Doing so will damage the connector. Use special pin type
electronic probes or small diameter wire pins inserted into connector.
Step 1.
Move the gas control power switch to the “OFF”
position.
Gas control power
switch
Step 2.
Disconnect the flammable vapor sensor harness
from the gas control.
Flammable vapor
sensor harness
Step 3.
Using a multi-meter set to the ohms setting, measure
the resistance of the flammable vapor sensor and resettable ther-
mal switch. The resistance must be between 3,000 and 48,000
ohms. If the resistance is out of this range, verify that the re-
settable thermal switch has not been tripped. If it hasn’t, replace
the thermal switch.
Flammable vapor
sensor harness
115 VAC Circuit Trace
Step 1.
Verify 115VAC and proper polarity are at the wall outlet.
Step 2.
With the water heater plugged in and the gas control power switch in the
“ON” position verify LED status.
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115 VAC Circuit Trace
WARNING
115 volt potential exposure. Use caution making voltage checks to avoid
personal injury.
LED status:
None, control
LED not on or
flashing.
LED status:
Short flash
once every four
seconds.
LED status:
“Heartbeat”,
alternates
LED status:
Various flash-
ing error codes.
bright/dim.
Verify error
code as listed
on page 17.
Waiting for call
for heat.
Thermostat call-
ing for heat.
Disconnect cord
set as shown in
photo 9.
9
10
11
Using a volt meter
set to volts AC, is
there 115VAC across
terminals shown in
photo 10?
N
N
Y
Check for damage
Y
Repair damage.
to AC supply
power cord.
Is there 115VAC
across terminals
shown in photo 11?
Reconnect cord set
shown in photo 9.
N
12
Replace blower.
N
Disconnect wire har-
ness from gas control
(see photo 12).
Incorrect supply
voltage polarity.
Wire harness
Locate black & white wires at connector, it
may be necessary to pull back wire sheath to
identify wire colors (see photo 13).
13
Wire sheath pulled back to
identify wire colors
Y
Is there 115VAC across
Replace gas control.
black & white wire as
shown in photo 13?
Check for 115VAC between black and white wires.
-NOTE-
N
Electronic meter probes required. Use car not to
damage connector during this check.
Call for technical support.
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Safety Circuit Voltage Trace
WARNING
115 volt potential exposure. Use caution making voltage checks to avoid
personal injury.
Safety Circuit Voltage Trace
14
Note: This procedure assumes a cold tank.
Step 1.
Remove three screws (Phillips screw driver) from
control access cover on blower and remove
cover.
Control access
cover
Position gas control switch to the “ON”
position and adjust the thermostat dial
N
Is LED on gas valve flash-
ing the “heartbeat” code
(alternating bright/dim)?
Y
to call for heat. Is there 10 to 13VAC
between the red wire leading to the
blower temperature switch and the
green ground wire? Blower must be
running during this voltage check (see
photo 15).
No voltage from gas control.
Call for technical support.
N
Determine cause of blower
temperature switch activa-
tion and correct.
Verify 115VAC to gas con-
trol (see page 41).
Y
N
Is there 10 to 13VAC between
Is there continuity through
the blower temperature
switch (see page 31)?
Check for loose or broken
wire connection at switch
terminals.
Y
N
the yellow wire leading from the
pressure switch and the green
ground wire (see photo 27)?
Y
N
Y
Do you hear or can you
see the igniter sparking?
Check igniter/sensor (see page
22). Is igniter/sensor OK?
Faulty cord set
or gas control
Y
Correct igniter/
sensor problem
15
Safety circuit
voltage is OK.
Green ground wire
Red sire leading to
blower temp. switch
If burner does not light, ob-
serve LED flash code on gas
control and refer to trouble-
shooting section on page 17.
Yellow wire leading
from pressure switch
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Blower Removal
Remove the Blower to Gain Access to the Flue Baffle
Gas control power
Step 1.
switch to the “OFF” position.
Move the gas control
power
switch
TTW (water heater)
power cord
Step 2.
Unplug the water
heater
from the wall outlet.
Exhaust adapter
Blower mounting
screws
Step 3.
Disconnect the vent system from
the exhaust adapter on top of blower.
Step 4.
blower.
Unplug the cord sets from the
Blower cord sets
Step 5.
Remove the three blower mounting screws (1/4” nut driver).
Remove the blower with gasket from the
Step 6.
top of the water heater.
Flue baffle
Step 7.
Remove the flue baffle from the
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Dip Tube Inspection
water heater.
Remove the Blower to Gain Access to the Flue Baffle (cont’d)
Step 8.
Inspect the baffle for deterioration and missing restrictors. Clean any
scale or debris build-up. Replace with a new baffle, as necessary.
Step 9. Reinstall the baffle into the flue. Be sure the baffle hanger tab is inserted
into the notch locations at the top of the flue.
Step 10.
Check the burner to ensure no scale has accumulated during operation.
See the Burner Cleaning Procedure on page 20, if accumulation has occurred.
Step 11.
Step 12.
Step 13.
Step 14.
Step 15.
Secure the blower in place using the screws from Step 5.
Reconnect the vent system to the exhaust adapter.
Reconnect the cord sets from Step 4.
Plug the water heater into the wall outlet.
To resume operation, follow the instructions located on the water heater
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.
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.
Dip Tube Inspection and Replacement
Step 1.
Step 2.
Step 3.
Move the gas control power switch to the “OFF” position
Unplug the water heater from the wall outlet.
Turn off the cold water supply to the water heater. Connect a hose to the
drain valve of the water heater and route to an open drain. Open a nearby hot water
faucet to vent the water heater for draining. Open the drain valve of water heater and
allow the water heater to drain to a point below the inlet connection nipple.
Step 4.
Disconnect the inlet nipple from the plumbing system.
Step 5.
With an appropriate tool, such as a pipe wrench, remove the inlet nipple/
diptube from the water heater. Use caution not to damage pipe threads.
Step 6.
Visually inspect the inlet nipple/diptube. The inlet nipple/diptube should
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Anode Inspection
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 uninten-
tional holes are not field repairable and the inlet nipple/diptube must be replaced.
Step 7.
the inlet nipple/diptube into the water
system, resume water supply to the water heater, and refill the water heater.
Upon completion of the inspection or subsequent replacement, reinstall
heater. Connect the nipple to the plumbing
Step 8.
To resume operation, follow the instructions located on the water heater
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.
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.
Anode Inspection and Replacement
Step 1.
Step 2.
Step 3.
Move the gas control power switch to the “OFF” position
Unplug the water heater from the wall outlet.
Turn off the cold water supply to the water heater. Connect a hose to the
drain valve of the water heater and route to an open drain. Open a nearby hot water
faucet to vent the water heater for draining. Open the drain valve of water heater and
allow the water heater to drain to a point below the outlet connection nipple.
Step 4.
Disconnect the outlet nipple from the plumbing system.
Step 5.
With an appropriate tool, such as a pipe wrench, remove the outlet nip-
ple/anode from the water heater. Use caution not to damage the pipe threads.
Step 6. Visually inspect the outlet nipple/anode. The outlet nipple/anode should
show signs of depletion, which is normal. If depletion is one-half the original anode
diameter (approximately 3/4” diameter), replacement is recommended. If any of the
steel core of the anode is exposed, replacement is recommended.
Step 7.
Upon completion of the inspection or subsequent replacement, reinstall
heater. Connect the nipple to the plumbing
the outlet nipple/anode into the water
system, resume water supply to the water heater, and refill the water heater.
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Inner Door Removal
Step 8.
To resume operation, follow the instructions located on the water heater
lighting instruction label. Or, use the lighting instructions located
in the water heater installation and operating manual.
Gas control power
Inner Door Removal Procedure
switch
Step 1.
sition.
Move the gas control power switch to the “OFF” po-
Blower (water
heater) power cord
Step 2.
Unplug the water heater from the wall outlet.
Outer door
Step 3.
Remove the outer door.
(4) 1/4” hex drive
screws
Right side
inner door
Step 4.
Remove (4) 1/4” hex drive screws from the right side
inner door.
(3) 1/4” hex
drive screws
Step 5.
Remove (3) 1/4” drive screws from the left side
burner door.
Connectors attached to
resettable thermal switch
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Inner Door Gasket Replacement
Step 6.
Remove the connectors attached to the re-
settable thermal switch on the manifold mount.
Flammable vapor
sensor clip
Inner Door Removal Procedure (cont’d)
Flammable vapor
Remove the flammable vapor sensor from the clip by
sensor
Step 7.
pushing down on the tab to open the clip.
Step 8.
Inspect both inner doors for any of the following imperfections: tears,
missing material, cracks, dirt or debris, lack of adhesion to the inner door, material left
WARNING
If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage,
personal injury, or death.
on combustion chamber, or any other imperfections that will inhibit a proper seal.
If any of the imperfections above are present,
door gasket following the Inner Door Gasket
Replacement Procedure. If not, replacement
of the inner door gaskets is not necessary.
replace the inner
Gasket overlap must be
as shown 1/32
Enlarged
view of
flange
area
Inner Door Gasket Replacement Procedure
Step 1.
Completely remove all gasket and adhesive
residue from the right and left side inner doors, as needed.
Recommended pattern for RTV sealant
Step 2.
U s i n g
RTV sealant,
apply a 1/8”
bead to secure
Gasket overlap must be
t h e
Slice gasket here to slide over burner venturi
Expanded view
as shown
1/32
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Inner Door Installation
inner door gasket to the inner door sections. Refer to the illustration for proper applica-
WARNING
Stripped fastener connections may allow for an inner door seal breach. A seal breach may result in a fire or explosion,
causing property damage, personal injury, or death. Do not over tighten screws. If a fastener connection is stripped,
contact the manufacturer listed on the water heater rating plate.
tion. Note the overlap configuration in the flange area of the inner door. Set the flange
section first, and this will help to achieve the proper overlap position.
Inner Door Installation with Gasket
Step 1.
Clean any residual gasket residue or other debris from the combustion
chamber surface before installing the inner door/gasket assembly.
Step 2. Place the left side inner door into position first, being sure to firmly posi-
tion the concave channel of the inner door around the feedline.
Step 3. Using the 1/4” hex drive screws removed in Step 5 of the Inner Door Re-
moval Procedure on page 32, secure the left side inner door in place. Do not over-
tighten the screws.
Step 3.
Position the pilot tube and spark igniter wire against the left side inner
door flange gasket. Do not route these through the concave channel with the feedline.
Step 4.
Firmly place the right side inner door flange against the left side inner
door flange.
Step 5.
Using the 1/4” hex drive screws removed in Step 4 of the Inner Door Re-
moval Procedure on page 32, secure the two flanges together. Do not over-tighten the
screws.
Step 6.
Align the right side inner door to the combustion chamber and verify the
fastener holes of the combustion chamber are aligned with the right side inner door
slotted openings. Verify seal integrity around the combustion chamber opening.
Step 7.
Using the 1/4” hex drive screws removed in Step 3 of the Inner Door Re-
moval Procedure on page 32, secure the right side inner door. Do not over-tighten the
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Arrestor Cleaning
screws. Verify that both the left and right side inner doors are properly positioned and
sealed against the combustion chamber.
Step 8.
Re-install the outer door.
Step 9.
To resume operation, follow the instructions located on the water heater
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.
ScreenLok® Flame Arrestor Cleaning Procedure
Step 1.
Move the gas control power switch to the “OFF” position and unplug the
water heater from the wall outlet.
Step 2.
Remove the outer door.
Step 3.
Remove the right side inner door per the Inner Door Removal Procedure
on page 32.
Step 4.
Disconnect the pilot tube using a 7/16” wrench and the main burner
feedline with a 3/4” wrench from the gas control.
Step 5.
Step 6.
Step 7.
Disconnect the spark igniter/flame sensor wire from gas control.
Remove the burner assembly from the combustion chamber.
Clean the ScreenLok® flame arrestor using a stiff brush, compressed air,
and/or a shop vacuum to remove any scale or other debris accumulation. Using a soft
brush, clear jacket openings from any dirt, dust, restrictions, or other obstructions.
Step 8.
Remove any debris from the burner assembly following the Burner
Cleaning Procedure on page 15.
Step 9.
Re-install the burner assembly.
Step 10.
control.
Reconnect the main and pilot tubing and spark igniter wire to the gas
Step 11.
Re-install the inner door per the Inner Door Installation with Gasket Pro-
cedure on page 34.
Step 12.
To resume operation, follow the instructions located on the water heater
lighting instruction label. Or, use the lighting instructions located in the water heater
installation and operating manual.
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Common Terms
Common Terms
BTU
ECO
GPM
Hz
British Thermal Units
Energy Cut Off
Gallons per Minute
Hertz
KWh
LED
NPT
Ohms
PSI
Kilowatts per hour
Light Emitting Diode
National Pipe Thread
Ohms of resistance
Pounds per Square Inch
Revolutions per Minute
Volts Alternating Current
Inches of Water Column
Degrees Centigrade
Degrees Fahrenheit
RPM
VAC
W.C.
°C
°F
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
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Parts List
2
3
40
9
12
13
10
1
4
5
11
14
7
6
28
27
15
33
26
32
34
35
23
31
25
20
21
36
30
24
37
19
22
18
38
18
16
39
17
18
18
29
18
29
Part Name and Description
15. T&P Valve
1. Blower Complete
2. Air Mixing Inlet
3. Pressure Switch
29. Burner Assembly
30. Flexible Gas Feedline
31. Thermal Switch
32. Screw #8-18 x 1/2”
33. Burner
16. Outer Door
17. Right Side Inner Door
18. Screw #10-12 x 3/4”
19. Brass Drain Valve
4. Blower Temperature Switch
5. Blower Gasket
6. Blower Power Cord
20. Flammable Vapor Sensor Clip
21. Flammable Vapor Sensor
34. Pilot Assembly
7. Vent Adapter w/ Vent Term.
35. Screw #8-18 x 1/2”
8. Condensate Hose Kit
9. Heat Trap Outlet
10. Hot Water Outlet Anode
11. Flue Baffle
22. Flammable Vapor Sensor Harness 36. Pilot Orifice
23. Thermowell
37. Manifold Mount
38. FVIR Sensor Plate
39. Orifice
24. Gas Control
25. Gas Control Service Tool
26. 3/4” NPT Pipe Plug
27. ASSE Approved Mixing Valve
28. Kit—Heat Trap Insert
12. Heat Trap Inlet
13. Inlet Dip Tube
14. Wire Harness
40. Dilution Air Clip
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