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Bradford White ICON System™

Standard Equipment On Residential and Light Duty Commercial Atmospheric Vent and Direct Vent models* Atmospheric Vent Examples: •M-I-40T6FBN, M-I-5036FSX, M-I-75S6BN •M-4-5036FBN, M-4-60T6FSX •M-2-XR504T6FSX, M-2-XR75S6BN Direct Vent Examples: •DS1-40S6FSX, DS1-50S6FBN •DH1-504T6FBN, DH1-75S6FSX *(Not currently utilized on High Performance, Eco-Defender and Mobile Home Models).

Features • Advanced Temperature Control System- Microprocessor constantly monitors and controls burner operation to maintain consistent and accurate water temperature levels. • Exclusive Performance Software- Propriety algorithms provide enhanced First Hour Delivery ratings and tighter temperature differentials. •Intelligent Diagnostics- An exclusive green LED light prompts the installer during start-up and provides ten different diagnostic codes to assist in troubleshooting. • Pilot-On-Indication- Flashing green LED provides positive indication that pilot is on. •Millivolt Powered- An off-the-shelf thermopile converts heat energy from the pilot flame into electrical energy to operate the gas valve and electronics. No external electricity required.

Features • Separate Immersed Thermowell- High strength advanced polymer composite thermowell provides isolation between electronic temperature sensor and surrounding water. No need to drain the tank when removing, or replacing the gas valve. •Integrated Piezo Igniter- Built into the control itself, the igniter eliminates the need to open the combustion chamber to light the pilot. • Universal Replacement- The Bradford White ICON System™ service kits are available for direct replacement, or for the replacement of Robertshaw or WhiteRodgers gas valves on most older Bradford White models. •Proven Technology- Over 100,000 units installed over the past 3 years have proven the durability, reliability and simplicity of this technology.

Gas Valve Type Black backing is Natural Gas

Residential is Silver

Red backing is Propane Gas

Commercial is Grey

Approx. Residential Temperature Settings Very Hot = 160°F C = 150°F B = 140°F A = 130°F Hot = 120°F Low = 55°F

Approx. Commercial Temperature Settings Very Hot = 180°F C = 170°F B = 160°F A = 150°F Hot = 140°F Low = 75°F

How it generates power

Pilot Flame

Thermopile (bundle of thermocouples)

An off-the-shelf thermopile converts heat energy from the pilot flame into electrical energy to operate the gas valve and electronics. No external electricity is required.

Thermocouple vs Thermopile • A standard thermocouple generates 20-30 Millivolts.

• A standard thermopile generates over 350 Millivots.

• We incorporated this type of Millivolt technology because of the electrical requirements of the intelligent gas valve.

Thermowell • High strength advanced polymer composite thermowell provides isolation between electronic Temperature Sensor and surrounding water. •No need to drain the tank when removing or replacing the gas valve. Thermowell Temperature Sensor Thermowell gets placed inside tank

How To Light The Pilot Step 1. First, turn the red control knob to PILOT position. Step 2. Then, press and hold in the red control knob. Step 3. Immediately depress the igniter button until you hear a “click� sound (may take a couple of tries). Step 4. Keep holding in the red control knob until the green LED display starts blinking. Once is starts blinking, the pilot is lit. (Note: To energize the control and hold the pilot flame, it takes approximately 90 seconds, compared to 45 seconds on a standard gas valve)

Trouble Shooting

LED Diagnostic Codes •A diagnostic code label is placed on the front of the water heater to provide the contractor with an easy to read tutorial on the association between the LED Status Indicator and Control Status Procedure. •This greatly reduces installation and service time, allowing more time to be spent on other jobs.

Gas Valve Disassembly Step 1. Rotate red knob of the gas control to the “OFF� position and turn off gas supply to the water heater. Step 2. Disconnect gas supply line from gas control and disconnect piezo igniter wire. Step 3. Remove inner door, outer door and burner assembly and remove (1) screw to take off the face plate. Gas control cover torx slotted screw removed by a T-15 torx driver, or a regular (flat blade) screw driver

Feedline removed

Gas Valve Disassembly Step 4. Depress both tabs on the top of the gas control cover and pull to remove.

Do not damage or bend the (3) valve body pins

Gas Valve Disassembly Step 5. Disconnect temperature sensor from circuit board and remove wire from the temperature sensor wire routing clip.

Wiring routing clip Circuit board Disconnect temperature sensor

Gas Valve Disassembly Step 6. Remove the piezo igniter by releasing the lock tab on the control cover.

Release lock tab

Gas Valve Disassembly Step 7. Remove valve body by removing torx slotted head screw (removed by a T-15 torx driver, or a regular flat blade screw driver) located at the lower left corner clip. Then, using a flat head screwdriver, unclip the lower right side and then the lower left side from the backplate. Unclip lower right side first

Unclip lower left side second

Torx slotted head screw

Gas Valve Disassembly Step 8. Unclip the temperature sensor clips and remove the temperature sensor and insertion stick from the back plate (can only be re-installed in one way).

Temperature sensor clips Insertion stick fully inserted into back plate (approx. 2 o’clock)

Gas Valve Disassembly Step 9. Remove temperature sensor from insertion stick by pulling apart as illustrated. Temperature sensor Insertion stick

Gas Valve Disassembly Step 10. To reassemble gas control, follow the previous steps in reverse order. Once gas control is reassembled, burner assembly is reinstalled, and the gas supply line is reconnected. Be sure tank is full of water before lighting. Step 11. To resume operation, follow the lighting instructions located on the lighting instruction label or the lighting instructions located in the I&O Manual.

Open Circuit Thermopile Testing The following test should be performed while the pilot flame is on.

Step 1. Turn red control knob to “PILOT� position and depress. Step 2. Continue pressing red control knob and remove red (+) wire from resettable thermal door switch. Step 3. Using a Multimeter capable of measuring Millivolts, connect the positive side of the Multimeter to the terminal of the resettable thermal switch. Connect the negative side of the Multimeter to any earth ground Resettable thermal location (jacket base, screw, etc.). switch terminal (+)

Jacket base screw (-)

Open Circuit Thermopile Testing Normal thermopile reading is between 350 Millivolts – 850 Millivolts. If reading is less than 350 Millivolts, replace pilot assembly or thermopile.

Step 4. If the thermopile is reading between 350 Millivolts – 850 Millivolts, remove Multimeter and reconnect red wire to positive (+) terminal of gas control. Step 6. Release gas control knob and turn to desired setting to resume normal operation.

Igniter Testing Step 1. Make sure the gas control is in the “OFF� position. Step 2. Remove outer jacket door. Step 3. Slide open or remove the inner combustion door.

Repeatedly depress igniter

Step 4. Depress the igniter button repeatedly while viewing the spark through the sight glass window. If there is no spark, proceed to Step 5. If there is a spark, the igniter is OK. View spark through sight glass

Igniter Testing cont. Step 5. Remove white wire from piezo igniter and install a jumper wire in its place. Hold the other end of the jumper by the wire insulation or using an insulated tool, next to an unpainted surface such as the feedline and depress the piezo igniter. Step 6. If there is a spark, the igniter is ok and the pilot assembly is not functioning and must be replaced. Step 7. If no spark is present, the piezo igniter is not functioning and must be replaced.

Removed white wire from piezo igniter

Temperature Sensor Testing Step 1. If control has gone into lockout mode due to excessive tank temperature (four flashes and a three second pause) turn the gas control to the “OFF� position and wait a minimum of (5) minutes. Then follow lighting instructions and return control knob to desired set point. Step 2. Observe green LED indicator. Does error code 4 continue? If so, proceed to Step 3. Step 3. Temperature Sensor Testing (follow Gas Control Disassembly section to access temperature sensor). Step 4. With the temperature sensor still in the thermowell, use a Multimeter set to the Ohms (Ί) setting, determine the resistance of temperature sensor (see next page). DO NOT use standard Multimeter probes for this test. Doing so will damage the connector. Use special pin type electronic probes or small diameter wire pins inserted into connector.

Temperature Sensor Testing (cont.) Step 5. Using a Multimeter set to the Ohms (立) setting, insert one meter probe (black) into center wire position of thermowell connector, then insert the second probe (red) into left thermowell connection. Record value. Step 6. insert one meter probe (black) into center wire position of thermowell connector, then insert the second probe (red) into right thermowell connection. Record value. Step 7. Once the temperature sensor resistance values are known, the water temperature must also be known to determine if the resistance values are correct.

Temperature Sensor Testing (cont.) It is important to understand that once the resistance for the temperature sensor is determined from the previous page, water flow through the water heater should not occur. Prior to drawing water from the drain valve, turn off cold water supply to the water heater. This will prevent cold water flow into the tank affecting the resistance value of the temperature sensor.

Step 8. Set the gas control knob to the “OFF� position and turn off the inlet water supply to the water heater. Step 9. 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 water heater to drain. Step 10. Using the chart on the following page, determine correct resistance value for the water temperature from Step 5. Step 11. If the temperature sensor resistance values are correct, replace the gas valve. If the temperature sensor resistance values are incorrect, replace the temperature sensor.

Temperature Sensor Testing (cont.) 째F 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

0 26109 19906 15314 11884 9299 7333 5827 4663 3758 3048 2488 2043 1688 1702 1170 982 828

Sensor Resistance at Various Temperatures In degrees F 1 2 3 4 5 6 7 8 9 25400 24712 24045 23399 22771 22163 21573 21000 20445 19383 18876 18383 17905 17440 16990 16553 16128 15715 14925 14548 14180 13823 13477 13140 12812 12494 12185 11592 11308 11032 10763 10502 10248 10000 9760 9526 9078 8862 8653 8449 8250 8057 7869 7685 7507 7165 7000 6839 6683 6531 6383 6238 6098 5961 5697 5570 5446 5326 5208 5094 4982 4873 4767 4562 4464 4368 4274 4183 4094 4006 3922 3839 3679 3602 3527 3453 3382 3312 3244 3177 31412 2986 2925 2866 2808 2752 2697 2643 2590 2538 2439 2391 2344 2298 2253 2209 2166 2124 2083 2004 1966 1928 1891 1856 1820 1786 1753 1720 1656 1625 1595 1566 1537 1509 1481 1454 1427 1376 1351 1327 1303 1280 1257 1253 1213 1191 1150 1129 111 1090 1071 1953 1035 1017 999 965 949 9333 917 901 886 871 857 842 814 801 788 775 762 749 737 725 716

Example: If the temperature of the water is 84째F, then the resistance through the sensor would be 8449

Summary Check List Make sure the Green LED Display is blinking when determining if the Pilot is lit. For Thermopile testing, make sure a reading over 350 Millivolts is indicated. For Igniter testing, make sure you see a spark in the combustion chamber, if not seen, check for a spark in the igniter lead itself. For Temperature Sensor testing, make sure you read a correct resistance value in drawn out water. Tech Support Phone Number 1-800-334-3393.

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Bradford White ICON