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Programmable Efficiency
Manual 238-48494-00A
Gas Water Heaters
SERVICE
MANUAL
SUPPLEMENT
and Instructions for Service
Troubleshooting Guide
(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
Save this manual for future reference
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Table of Contents
Related Manuals for Bradford White PE4403S Series
Summary of Contents for Bradford White PE4403S Series
- Page 1 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...
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Page 2: Table Of Contents
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 _______________________________________ 17 Burner Inspection Burner Cleaning Procedure Pilot Maintenance _________________________________________ 19 Pilot Inspection, Testing and Replacement... - Page 3 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: Do not try to light any appliance Do not touch any electrical switch; do not use any phone in your building Immediately call your gas supplier from a neighbor’s phone.
- Page 4 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.
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Page 5: Introduction
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. -
Page 6: How To Use This Manual
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. -
Page 7: Specifications
Specifications Specifications Dedicated 120VAC, 60 Hz, 15A Power Supply Minimum 1/2” NPT (Schedule 40 black iron pipe Gas Supply Pipe recommended) Natural or Propane; unit must match gas type supplied Approved Gas Type 5” w.c. minimum for Natural Gas; 11” w.c. for Propane; 14” Gas Pressure w.c. -
Page 8: Control Timings
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 1.5 seconds (2 second maximum; 1 second Flame Failure Response Time minimum) De-energize Relay and Verify (Open Circuit) 15 seconds... -
Page 9: Sequence Of Operation
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. -
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 power is removed from the relay. The gas control LED flashes a short flash once every 4 seconds (Idle status code). - Page 11 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.
- 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
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 Green LED code is known, check and repair the water heater, as recommended in the table below. - Page 14 Troubleshooting LED Status Control Status Probable Cause Service Procedure Six flashes, Relay not working two flashes, properly during See Relay Replacement on three second burner operation, Faulty relay page 28 pause (Soft system auto resets Lockout) after (5) minutes 1. Unstable pilot 2.
- Page 15 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 WV4460E Diagnostic Accessory (intermittent pilot Description Code # Module gas control)
- Page 16 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. Accessory Module LED Status Probable Cause Status Green LED on continuously. Power on (no fault). n/a Leak alarm fault.
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Page 17: Burner Maintenance
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. - Page 18 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”...
- Page 19 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.
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Page 20: Pilot Maintenance
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. -
Page 21: Pilot Inspection, Testing And Replacement
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"... -
Page 22: Determine Water Temperature Inside Tank
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. - Page 23 Determine Tank Temperature Determine Water Temperature Inside Tank (cont’d) 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 container and discard. Draw an additional gallon and immediately measure the water temperature using an accurate thermometer.
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Page 24: Component Disassembly
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. Move the gas control power switch to the “OFF” position. -
Page 25: Gas Control Removal
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. Move the gas control power switch to the “OFF” position. -
Page 26: Gas Control Assembly
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. -
Page 27: Flammable Vapor Sensor Testing
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. -
Page 28: 120 Vac Circuit Trace
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. - Page 29 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 Screw (other not Box Assembly Cover shown) White Wire Step 4. Mark the (4) wires that are attached to the relay, so their proper location is known.
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Page 30: 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 31: Parts List
Parts List 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. - Page 32 Email parts@bradfordwhite.com techserv@bradfordwhite.com www.bradfordwhite.com...
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