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COMMERCIAL 24 VOLT FLUE DAMPER
SERIES WATER HEATER
ATMOSPHERIC GAS WATER HEATERS
Manual 47324A
Energy Saver
Troubleshooting Guide and
SERVICE
MANUAL
Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
For the Bock Water Heaters
"W" Series Models:
38W-155
75W-(125, 160, 300)
66W-(370, 399)
80W-(180, 199, 250)
80W-(425, 450, 505)
100W-(199, 250, 270, 300)
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Table of Contents
Related Manuals for Bock Water heaters 38W-155
Summary of Contents for Bock Water heaters 38W-155
- Page 1 MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qualified service providers) Models Covered by This Manual: For the Bock Water Heaters “W” Series Models: 38W-155 75W-(125, 160, 300) 66W-(370, 399) 80W-(180, 199, 250) 80W-(425, 450, 505)
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Page 2: Table Of Contents
W-Series Atmospheric Gas Table of Contents Service Page Procedure Introduction - - - Tools Required for Service - - - Sequence of Operation - - - Troubleshooting - - - Thermostat Circuit Testing 24-I Pilot Operation Testing 24-II Main Burner Operation Testing 24-III Main Burner and Pilot Removal and Inspection 24-IV... -
Page 3: Introduction
W-Series Introduction It is intended for this manual to be used by qualified service personal for the primary purpose of troubleshooting, analysis, and repair of the Bock 24 Volt Flue Damper W-Series Water Heater. Understanding the “Sequence of Operation” section of this manual will contribute greatly to troubleshooting this product. -
Page 4: Sequence Of Operation
W-Series Sequence of Operation Thermostat calls for heat. The relay closes on the thermostat board, sending 24 volts from the “COM” terminal of the thermostat board to the flue damper. Flue damper begins to rotate open. Once damper is full open, 24 volts is allowed to continue through damper to the “TH”... -
Page 5: Troubleshooting
W-Series Troubleshooting CAUTION Use Caution Not to Damage Connectors When Making Voltage Measurements or Jumping Terminals. DANGER 120 Volt Exposure. Use Caution Rear Terminals to Avoid Personal Injury primary (120 VAC) Verify primary and secondary voltage at the transformer. (see photo 1) Ignition Module LED Status OFF = No power to module ON = Module has power... -
Page 6: Thermostat Circuit Testing
Service Procedure 24-I W-Series Thermostat Circuit Testing CAUTION DANGER Be careful when making voltage 120 Volt Exposure. To avoid personal injury, measurements or jumping terminals use caution while performing this procedure. not to damage or deform connectors or connector pins. This procedure assumes the flue damper is in working order. - Page 7 Service Procedure 24-I W-Series Thermostat Circuit Testing Thermister Resistance Testing Upper Thermister: Upper thermister location 1. Determine resistance value of upper thermister. Test across (applicable models) grey wires. (see photo 9) 2. Draw quart of water off T&P valve. Using a thermometer determine water temperature 3.
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Page 8: Pilot Operation Testing
Service Procedure 24- II W-Series Pilot Operation Testing CAUTION DANGER Be careful when making voltage 120 Volt Exposure. To avoid personal injury, measurements or jumping terminals use caution while performing this procedure. not to damage or deform connectors or connector pins. Condition Pilot will not light. - Page 9 Service Procedure 24-II W-Series Pilot Operation Testing CAUTION DANGER Be careful when making voltage 120 Volt Exposure. To avoid personal injury, measurements or jumping terminals use caution while performing this procedure. not to damage or deform connectors or connector pins. Condition: Pilot lights, no flame signal.
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Page 10: Main Burner Operation Testing
Service Procedure 24-III W-Series Main Burner Operation Testing CAUTION DANGER Be careful when making voltage 120 Volt Exposure. To avoid personal injury, measurements or jumping terminals use caution while performing this procedure. not to damage or deform connectors or connector pins. Condition : Main burner will not light. - Page 11 Service Procedure 24-III W-Series Main Burner Operation Testing CAUTION DANGER Be careful when making voltage 120 Volt Exposure. To avoid personal injury, measurements or jumping terminals use caution while performing this procedure. not to damage or deform connectors or connector pins. Condition : Main burner short cycle.
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Page 12: Main Burner And Pilot Removal And Inspection
Service Procedure 24-IV W-Series Main Burner & Pilot Removal and Inspection WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent injury. Gas Valve Burner Rack Wire Leads Main Burner Removal Mounting Gas Valve Screw... - Page 13 Service Procedure 24-IV W-Series Main Burner & Pilot Removal and Inspection Pilot Burner Removal Pilot Shield Step 1. With burner rack removed from heater, disconnect pilot tube connection from gas valve. Step 2. Remove the two pilot burner mounting screws securing the pilot and pilot shield in place.
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Page 14: Flue Baffle Removal And Inspection
W-Series Service Procedure V Flue Baffle Removal & Inspection WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent injury. Step 1. Disconnect (unplug) water heater from electrical supply. Step 2. Disconnect venting from draft diverter and remove draft diverter from top of water heater. -
Page 15: Anode Removal And Inspection
W-Series Service Procedure 24-VI Anode Removal & Inspection WARNING Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent injury. Step 1. Disconnect (unplug) water heater from electrical supply. Step 2. Turn “OFF” water supply to water heater. Step 3. -
Page 16: Generic Parts List
W-Series Generic Parts List 16/16A 17/17A Draft Diverter w/Leg Kit 12. 1” x ¾” Reducer Bushing 20. Burner Assembly (Complete) Draft Diverter 13. Nipple T&P Valve 21. Brass Drain Valve Draft Diverter Leg 14. T&P Valve 22. Cold Water Inlet Nipple (Side) Damper Outlet Reducer 15. - Page 17 W-Series Generic Parts List 1A. Draft Panel 11A. Pilot Mounting Screw 21A. 1” Close Nipple Black 2A. Burner Rack 12A. Burner Tube Support 22A. Pilot Regulator 3A. Burner Tube 13A. Manifold Bracket 23A. Pilot Solenoid 4A. Gas Valve 14A. C-Cane Manifold 24A 1/8”...
- Page 18 W-Series Generic Parts List 1C. Temperature Control Knob 9C. Power Cord Train Relief Bushing 2C. Potentiometer Gasket 10C. Power Cord 3C. Potentiometer (Temperature Control) 11C. Pilot Wire Strain Relief Bushing 4C. 7/8” Snap Bushing 12C. 7/8” Snap Bushing 5C. Temperature Scale Plate 13C.
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Page 19: Glossary Of Terms/Notes
W-Series Glossary of Terms Alternating Current BTU/H British Thermal Units Carbon Monoxide Carbon Dioxide Direct Current Energy Cut Off Ground Fault Interrupt Gallons per Minute Hertz Light Emitting Diode Oxides of Nitrogen National Pipe Thread Pounds per Square Inch Volt Amps Volts Alternating Current W.C. - Page 20 Madison, Wisconsin For U.S. and Canada field service, contact your professional installer or local Bock Water Heaters sales representative Sales/608-227-3311 Fax/608-327-3311 Application & Sizing/608-227-3311 Fax/608-327-3311 Technical Support/888-784-8322 Fax/610-683-9208 Warranty/608-227-3319 Fax/608-327-3300 Email sales@bockwaterheaters.com www.bockwaterheaters.com...
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