Programmable Efficiency Gas Water Heaters SERVICE MANUAL SUPPLEMENT Troubleshooting Guide and Instructions for Service (To be performed ONLY by qualified service providers) Models Covered by This Manual: PE4403S*F(BN,SX) PE440T*F(BN,SX) PE4503*F(BN,SX) PE2XR504T*F(BN,SX) (*) Denotes Warranty Years Manual 238-48494-00A Save this manual for future reference
Table of Contents Section Page Introduction ______________________________________________5 How to Use this Manual _____________________________________6 Tools Required for Service ___________________________________6 Specifications _____________________________________________7 Sequence of Operation______________________________________9 Power Up Sequence Normal Heating Sequence Abnormal Operation Troubleshooting __________________________________________ 13 Burner Maintenance ___________________________
WARNING If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury, or death. What to do if you smell gas: x Do not try to light any appliance x Do not touch any electrical switch; do not use any phone in your building 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.
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 flammable 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.
Introduction The Bradford White DEFENDER Safety System® The Bradford White DEFENDER Safety System was designed to resist the ignition of flammable vapors that can occur outside of the water heater. Use and installation are nearly identical 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 provider.
How to Use this Manual How to Use this Manual This manual serves as a supplement to the Defender Atmospheric service manual, p/n 238-44943-00. Please refer to the Defender Atmospheric service manual for all features on this water heater that are consistent with a Defender (standard) Atmospheric water heater. 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 Programmable Efficiency water heaters.
Specifications Specifications Power Supply Gas Supply Pipe Dedicated 120VAC, 60 Hz, 15A Minimum 1/2” NPT (Schedule 40 black iron pipe recommended) Approved Gas Type Natural or Propane; unit must match gas type supplied Gas Pressure 5” w.c. minimum for Natural Gas; 11” w.c. for Propane; 14” w.c.
Specifications Control Timings Ignition State Timing Energize Relay and Verify (Closed Circuit) 15 seconds Trial for Ignition 90 seconds Flame Stabilization Period 3 seconds Re-energize Relay and Verify 15 seconds Flame Failure Response Time 1.
Sequence of Operation Note: The Sequence of Operation section is in addition to the Defender Atmospheric Service Manual, p/n 238-44943-00. 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 Flammable 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.
Sequence of Operation Normal Heating Sequence (cont’d) 7. Steady State Operation: During steady state operation, the gas control monitors: Thermostat Temperature Sensor: When the setpoint temperature is satisfied, the gas control is shutdown, and power is removed from the relay. The gas control LED flashes a short flash once every 4 seconds (Idle status code). Relay Status: If the relay is altered during a call for heat, the pilot and main valves are shutdown.
Sequence of Operation Abnormal Operation (cont’d) 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 seconds. 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.
Sequence of Operation Abnormal Operation (cont’d) 5. Flame Sensing Fault: A) Flame Lost During Run: The gas control turns off pilot and main valves. 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 second pause. The gas control waits 5 minutes before repeating the ignition sequence.
Troubleshooting Note: The Troubleshooting section replaces pages 4-6 in the Defender Atmospheric service manual, p/n 238-44943-00. Observe the green LED on the water heater gas control. Diagnostic codes are displayed with a 3 second pause before repeating. Once the diagnostic code is known, check and repair the water heater, as recommended in the table below. Green LED LED Status Control Status Probable Cause Service Procedure Control pow er sw itch in "OFF" None (LED Electrical pow er not position.
Troubleshooting LED Status Control Status Probable Cause Service Procedure Six flashes, Relay not working two flashes, properly during three second burner operation, Faulty relay pause (Soft system auto resets Lockout) after (5) minutes See Relay Replacement on page 28 1. Unstable pilot 2. Pilot tube block or restricted Six flashes, 3. Oxidation build-up on pilot Pilot flame three electrode extinguished, flashes, 4.
Troubleshooting The table, below, details the diagnostic codes that can be seen on the Setback Control. Reference the Setback Control manual, p/n 238-47808-00, for more details on this control. Gas Valve / Control Model Diagnostic Code # Description Accessory Module WV4460E (intermittent pilot gas control) Conn Setback Control not connected to gas valve / control or improperly wired together. x x 2 Relay remains energized x 4 Weak pilot signal detected.
Troubleshooting The table, below, details the diagnostic codes that can be seen on the Accessory Module. Reference the Accessory Module manual, p/n 238-47878-00, for more details on this control. LED Status Green LED on continuously. Power on (no fault). n/a Water heater tank leak. Leak alarm fault. Two flashes and three Inlet Shut-off valve second pause. closed. Water heater tank leak. Amber Four flashes and three Leak sensor second pause. malfunction. 1. Leak Sensor resistor removed. 2.
Burner Maintenance Note: The Burner Maintenance section replaces pages 31-33 in the Defender Atmospheric service manual, p/n 238-44943-00. 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 unstable pilot flame are: a) Gas pressure is out of specification. b) Pilot flame not fully engulfing spark/flame sensor.
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. 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 Step 8. chamber.
Burner Maintenance Burner Cleaning Procedure (cont’d) Step 12. Re-assemble the burner assembly and re-install into the water heater. Restore gas supply and check for gas leaks. Step 13. 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 Operation manual.
Pilot Maintenance Pilot Inspection, Testing, and Replacement (cont’d) 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 Step 8. chamber. Remove the burner assembly from the combustion Burner assembly Step 9. Remove the pilot assembly from the main feedline using a 1/4" nut driver.
Pilot Maintenance Pilot Inspection, Testing, and Replacement (cont’d) Step 12. Visually inspect the spark igniter/flame sense electrode for deterioration. 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 oxidation build-up.
Thermal Well Testing Thermal Well Testing (cont’d) Follow the procedure, below, if the water heater gas control has gone into a ECO lockout (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 temperature setting. Step 1. control. Unplug the thermal well connector from the gas Thermal well connector Step 2.
Determine Tank Temperature Determine Water Temperature Inside Tank (cont’d) Step 1. position. Move the gas control power switch to the “OFF” Gas control power switch Step 2. Draw approximately 4 gallons of water from the drain valve into a container and discard. Draw an additional gallon and immediately measure the water temperature using an accurate thermometer. It may be necessary to open a hot water faucet to allow the water heater to drain. Step 3.
Component Disassembly Gas Control & Thermal Well Removal From Water Heater Note: The Component Disassembly, Gas Control Removal, and Gas Control Assembly sections replace pages 24-30 in the Defender Atmospheric service manual, p/n 238-44943-00. Step 1. position. Move the gas control power switch to the “OFF” Gas control power switch Step 2. wall outlet. Unplug the water heater and Accessory Module from the Step 3. level.
Gas Control Removal Gas Control Removal From Thermal Well Following the steps below allow for the removal of the gas control from the thermal well without removing the thermal well from the tank. Step 1. position. Move the gas control power switch to the “OFF” Gas control power switch Step 2. wall outlet. Unplug the water heater and Accessory Module from the Water heater power cord and Accessory Module transformer Step 3.
Gas Control Removal Gas Control Removal From Thermal Well (cont’d) 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.
Gas Control Assembly Gas Control Assembly to the Thermal Well (cont’d) Step 6. Reconnect the wire harnesses to the gas control. Wire harnesses Step 7. Reconnect the gas piping to the gas control. Restore the gas supply and check for gas leaks. 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 Operation manual.
Flammable Vapor Sensor Testing Flammable Vapor Sensor Testing (cont’d) Step 3. Using a multi-meter set to the ohms setting, measure the resistance of the flammable vapor sensor and resettable thermal switch. The resistance must be between 3,000 and 48,000 ohms. If the resistance is out of this range, verify that the resettable thermal switch has not been tripped. If it hasn’t, replace the flammable vapor sensor.
Relay Replacement Relay Replacement (cont’d) Step 3. Remove the (2) screws holding the Setback Control Junction Box Assembly cover on and retain for later use. Setback Control Junction Box Assembly Cover Screw (other not shown) White Wire Step 4. Mark the (4) wires that are attached to the relay, so their proper location is known. Blue Wire Step 5. Disconnect the (4) wires attached to the relay. Red Wire Yellow Wire Relay Step 6. Remove the relay from its socket. Relay Step 7.
Common Terms Common Terms BTU ECO GPM Hz KWh LED NPT Ohms PSI RPM VAC W.C.
Parts List 1 2 5 3 6 7 8 9 4 17 10 11 19 18 20 14 21 16 22 24 28 23 27 12 15 25 13 26 15A PART NAME AND DESCRIPTION 1. Draft hood 15A. Resettable Thermal Switch 2. Setback Control Junction Box Assembly 16. Left side inner door 3. Jacket head 17. Accessory Module 4. Jacket 18. Junction box wire harness 5. Heat trap (outlet) 19. Thermal well 6. Anode Outlet Device 20. Gas control 7. Heat trap (inlet) 21. FV sensor / RTS wire harness 8. Baffle 22. FV sensor clip 9.
Email parts@bradfordwhite.com techserv@bradfordwhite.com www.bradfordwhite.