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Manual 238-48385-00A
Residential Flue Damper
Gas Water Heaters
SERVICE
MANUAL
Troubleshooting Guide
and Instructions for Service
(To be performed ONLY by
qualified service providers)
Models Covered
by This Manual:
D4403S*F(BN,SX)
D4504S*F(BN,SX)
(*) Denotes Warranty Years
Save this manual for future reference
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Table of Contents
Related Manuals for Bradford White D4403S*F(BN
Summary of Contents for Bradford White D4403S*F(BN
- Page 1 Residential Flue Damper Manual 238-48385-00A Gas Water Heaters SERVICE MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qualified service providers) Models Covered by This Manual: D4403S*F(BN,SX) D4504S*F(BN,SX) (*) Denotes Warranty Years Save this manual for future reference...
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Page 2: Table Of Contents
Section 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 _______________________________________ 15 Burner Inspection Burner Cleaning Procedure Pilot Maintenance _________________________________________ 17 Pilot Inspection, Testing and Replacement Damper Replacement______________________________________ 19 Thermal Well Testing ______________________________________ 21... - Page 3 Do not store or use gasoline or other flammable, combustible, or corrosive vapors and liq- uids in the vicinity of this or any other appliance. Incorrect operation of this water heater may create a hazard to life and property and will nullify the warranty.
- Page 4 Un- der 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.
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Page 5: Introduction
The Bradford White DEFENDER Safety System was designed to resist the ignition of flamma- ble 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 de- sign features are incorporated in the system that will require additional knowledge on the part of the qualified service provider. -
Page 6: How To Use This Manual
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. -
Page 7: Specifications
Power Supply Gas Supply Pipe Approved Gas Type Gas Pressure Approved Vent Materials Minimum Clearance for Servicing Water Supply Pressure ECO Limit Temperature Setpoint Range Dedicated 120VAC, 60 Hz, 15A Minimum 1/2” NPT (Schedule 40 black iron pipe recommended) Natural or Propane; unit must match gas type supplied 5”... -
Page 8: Control Timings
Specifications Ignition State Adjust Damper Position and Verify (Open Posi- tion) Trial for Ignition Flame Stabilization Period Re-adjust Damper Position and Verify Flame Failure Response Time Adjust Damper Position and Verify (Closed Po- sition) Damper Blade Position Fault (failed open/close) Soft Lockout ECO Limit Lockout Verify Resistive Delay... -
Page 9: Sequence Of Operation
“Damper Circuit Open,” as this means that the damper blade is in the horizontal posi- tion. “Damper Circuit Closed” means that the damper blade is in the vertical position, and the water heater can proceed to an ignition trial. 1. Thermostat Calls for Heat: Prior to energizing the damper, the gas control verifies the damper safety circuit to see if it is in the correct state. -
Page 10: Abnormal 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 the damper is powered closed. The gas control LED flashes a short flash once every 4 seconds (Idle status code). - Page 11 Abnormal Operation (cont’d) 2. Temperature Sensor Fault: A) Temperature Sensor Open Circuit: The gas control immediately turns off all out- puts 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.
- Page 12 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.
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Page 13: Troubleshooting
Observe the green LED on the water heater gas control. 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. LED Status... - Page 14 Troubleshooting LED Status Control Status Damper test circuit Six flashes, not w orking two flashes, properly during three second burner operation, pause (Soft system auto resets Lockout) after (5) minutes Six flashes, three Pilot flame flashes, extinguished, three second system auto resets pause (Soft after (5) minutes Lockout)
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Page 15: Burner Maintenance
Move the gas control power switch to the “OFF” position. Step 2. Unplug the water heater from the wall outlet. Step 3. Turn off the gas supply to the water heater. Step 4. Remove the outer door. Burner Maintenance Gas control power... - Page 16 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. 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.
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Page 17: Pilot Maintenance
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 operating manual. Pilot Inspection, Testing and Replacement Step 1. - Page 18 Pilot Maintenance Pilot Inspection, Testing and Replacement (cont’d) Step 7. Disconnect the spark igniter/flame sensor wire from gas control. Step 8. Remove the burner assembly from the combustion chamber. Step 9. Remove the pilot assembly from the main feedline using a 1/4" nut driver. Step 10.
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Page 19: Damper Replacement
Step 17. 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. Damper Removal & Installation Step 1. - Page 20 Step 8. Clean any debris from the jacket head of the water heater. Step 9. Set the new damper with in place using the water heater tank flue and the screw holes in the jacket head. Step 10 Secure the damper in place using the screws from Step 6.
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Page 21: Thermal Well Testing
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 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. -
Page 22: Determine Water Temperature Inside Tank
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 affecting the resistance value of thermal well. -
Page 23: Component Disassembly
Unplug the water heater from the wall outlet. 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. Component Disassembly In Degrees F... -
Page 24: Gas Control Removal
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. Step 5. Disconnect the wire harnesses and spark igniter/ flame sense wire from the gas control. -
Page 25: 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”... - Page 26 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 position. Step 5.
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Page 27: Flammable Vapor Sensor Testing
120 VAC Circuit Trace Step 1. Verify 120VAC 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. Flammable Vapor Sensor Testing CAUTION... -
Page 28: Diptube Inspection
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. -
Page 29: Anode Inspection
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. -
Page 30: Damper Removal
Step 1. Move the gas control power switch to the “OFF” position. Step 2. Unplug the water heater from the wall outlet. Step 3. Disconnect the vent system from the draft hood that is mounted on top of the damper. -
Page 31: Damper Removal
Plug the water heater into the wall outlet. Step 15. 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. Damper Removal... -
Page 32: Inner Door Removal
Inner Door Removal Procedure Step 1. Move the gas control power switch to the “OFF” position. Step 2. Unplug the water heater from the wall outlet. Step 3. Remove the outer door. Step 4. Remove (4) 1/4” hex drive screws from the right side inner door. -
Page 33: Inner Door Gasket Replacement
Inner Door Removal Procedure (cont’d) Step 7. 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 on combustion chamber, or any other imperfections that will inhibit a proper seal. If any of the imperfections above are present, replace the inner door gasket following the Inner Door Gasket Replacement Procedure. -
Page 34: Inner Door Installation
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. Page 34 WARNING... -
Page 35: Arrestor Cleaning
Or, use the lighting instructions located in the water heater installation and operating manual. Damper Relay Installation If the damper fails and water heater operation is necessary temporarily, a relay, p/n 233-47642-00, and harness, p/n 239-48471-00, can be ordered from the Bradford White Service Parts Department. - Page 36 Step 7. Move the damper blade to the vertical position. Step 8. Move the switch on the back to the damper to the “Service” position (towards the front of the water heater). Page 36 Damper (water heater) power cord Vent system...
- Page 37 Damper Relay Installation (cont’d) Step 9. Turn the damper on its side and lay it on top of the water heater. Step 10. Remove the Red wire in the damper housing from its location. Connect the 1/4” Red female connector on the relay harness in its place.
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Page 38: Common Terms
Common Terms Common Terms British Thermal Units Energy Cut Off Gallons per Minute Hertz Kilowatts per hour Light Emitting Diode National Pipe Thread Ohms Ohms of resistance Pounds per Square Inch Revolutions per Minute Volts Alternating Current W.C. Inches of Water Column °C Degrees Centigrade °F... -
Page 39: Parts List
PART NAME AND DESCRIPTION 1. Draft Hood 2. Damper 3. Jacket Head Pan 4. Jacket 5. Heat Trap—Cold Water Inlet 6. Magnesium Anode–Hot Water Outlet 7. Heat Trap—Cold Water 8. Flue Baffle Assembly 9. Dip Tube–Cold Water Inlet 10. Temperature and Pressure Relief Valve 11. - Page 40 Email parts@bradfordwhite.com techserv@bradfordwhite.com www.bradfordwhite.com...