Bradford-White Corp D4403S*F(BN manual

Save this manual for future reference Manual 238-48385-00A SERVICE MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qua lified servi ce providers) Models Covered by This Manual: D4403S*F(BN,SX) D4504S*F(BN,SX) (*) Denotes Warra nt y Years Gas Water Heaters Residential Flue Damper ®[...]

Page 2 Table of Contents Section Page Introduction ______________________________________________5 How to Use this Manual _____________________________________6 Tools Required for Service ___________________________________6 Specifications _____________________________________________7 Sequence of Operation ______________________________________9 P[...]

WARNING If the information in these in structions is not followed exactly, a fire or explosion may re- sult causing property damage, personal injury, or death. What to do if you smell gas: x Do not try to l ight any appli ance x Do not touch any electri cal switch; do not use any phone i n your building x Immediately call your gas supplier from a n[...]

Page 4 WARNING Water heaters are heat producing appliances. To avoid damage or injury, do not store materials against the water heater or a ny of its components. Use proper care to avoid un- necessary contact, especially by children, wi th the water heater and its components. Un- der no circumstances must flammable materials, such as gasoline or p [...]

Page 5 The Bradford White DEFENDER Safety System ® The Bradford White DEFENDER Safety System was designed to resist the ign ition of flamma- ble vapors that can occur outside of the water heater. Use an d installation are nearly identical to previous versions of atmospherically fired and vented water heaters. A number of exclusive de- sign feature[...]

Page 6 combustion chamber, the vapors are harm lessly ignited by the burner. If flammable vapors are in sufficient quantity to prevent normal combustion, the flammable vapor sensor recognizes this and shuts down the pilot and main burner. Should the flammable vapors continue to burn, the flame arrestor prevents the flames from traveling backwards a[...]

Page 7 Power Supply Dedicated 120VAC, 60 Hz, 15A Gas Supply Pipe 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. maximum for Natural Gas / Propane Approved Vent Materials Single or D[...]

Page 8 Ignition State Timing Adjust Damper Position and Verify (Open Posi- tion) 1 5 seconds Trial for Ignition 90 seconds Flame Stabilization Period 3 seconds Re-adjust Damper Position and Verify 15 seconds Flame Failure Response Time 1.5 seconds (2 second maximum; 1 second mini- m um) A djust Damper Position and Verify (Closed Po- sition) 15 seco[...]

Page 9 Power Up Sequence 1. Start-up: Upon power up, the gas control runs a safe start check with a typical de- lay 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 res[...]

Page 10 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). Da[...]

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 w[...]

Page 12 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 [...]

Page 13 L E D S t a t us C ont r o l S ta t us P r o ba bl e C a us e S e r v i ce P r o c e dur e No ne ( LE D n ot on or f la s h in g ) E le ct r ica l p o w e r n o t pr es e nt Cont r ol pow er sw i tc h i n " OF F " posi t i on. Su p p l y v ol t a g e in te rr u p t ed . Tu rn P o w e r O n One s ho rt f l ash ev er y f our se c on[...]

Page 14 L ED St at u s Con t ro l Stat us Prob ab le Cau se S ervice Proced ure Six fl a s h e s , t w o f l ashes, t h r ee s ec on d p ause ( S of t Lo c k out) D am p er test c i r c ui t no t w o rk i ng p ro p e rly d u rin g burner ope r ati on, sy stem aut o r esets a f t e r (5 ) min u t e s 1. D am pe r not i n pr ope r posi ti o n or m al[...]

Page 15 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 spa[...]

Page 16 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. Step 7. Disconnect the spark igniter/flame sensor wire from gas control. Step 8. Remo[...]

Page 17 Burner Cleaning Procedure (cont’d) Step 12. Reassemble the burner assembly and reinstall 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[...]

Page 18 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. Visually inspect the spark igniter/flame sense wire for [...]

Page 19 Pilot Inspection, Testing and Replacement (cont’d) Step 14. Visually ins pect the pilot tubing for kinks or cracks. If damage is found, replace the pilot assembly. Step 15. Inspect the pilot tubing and pilot orifice for blockages: a) Remove ferrule nut from the bottom of the pilot assembly using a 7/16" wrench. b) Remove the pilot tu[...]

Page 20 Damper Removal & Installation (cont’d) Step 3. Disconnect the vent system from the draft hood that is mounted on top of the damper. Step 4. Remove the draft hood from the damper and retain it for use on the new damper. Step 5. Unplug the cord sets from the damper. Step 6. Remove the two damper mounting screws using a 1/4” nut driver[...]

Page 21 Damper Removal & Installation (cont’d) Step 13. Reconnect the cord sets from Step 5. Step 14. Plug the water heater into the wall outlet. Step 15. Move the gas control power switch to the “ON” position. Step 16. Verify proper damper operation. Thermal Well Testing Follow the procedure, below, if the water heater gas control has go[...]

Page 22 Thermal Well Testing (cont’d) Determine the correct resistance values using the Determine the Water Temperature Inside the Tank procedure on page 23. If the values are correct, replace the gas control, otherwise replace the thermal well. Determine Water Temperature Inside Tank Note: It is important to understand once the resistance for th[...]

Page 23 Sensor Resistance at Various Temperatures Gas Control & Thermal Well Removal From Water Heater Step 1. Move the gas control power switch to the “OFF” position. Step 2. 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 heat[...]

Page 24 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. Step 6. Remove the gas control & thermal well[...]

Page 25 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” wrench from the gas control. Step 5. Disconnect the wire harnesses and spark igniter/ fla[...]

Page 26 Gas Control Assembly to the Thermal Well (cont’d) Step 2. Route the wire leads back into relief opening. Step 3. Align the slots located on the thermal well flange with the tabs located on the back of the gas control. Step 4. Carefully push the gas control back onto the thermal well flange as far as possible towards the water heater. Then[...]

Page 27 Gas Control Assembly to the Thermal Well (cont’d) 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 operating manual. Flammable Vapor Sensor Testing Step 1. Move the gas control power switch to the “O[...]

Page 28 Dip Tube Inspection and Replacement Step 1. 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 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[...]

Page 29 Anode Inspection and Replacement Step 1. 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 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 wa[...]

Page 30 Remove the Damper to Gain Access to the Flue Baffle 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. Step 4. Unplug the cord sets from the damper. Step 5. Remove the two dampe[...]

Page 31 Remove the Damper to Gain Access to the Flue Baffle (cont’d) Step 6. Remove the damper from the top of the water heater. Step 7. Remove the flue baffle from the water heater. Step 8. Inspect the baffle for deterioration and missing restrictors. Clean any scale or debris build-up. Replace with a new baffle, as necessary. Step 9. Reinstall [...]

Page 32 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. Step 5. Remove (2) 1/4” drive screws from the left side inner door. Step 6. Remove[...]

Page 33 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, [...]

Page 34 Inner Door Installation with Gasket Step 1. Clean any residual gasket residue or other debris from the combustion chamber surface before installing the inner door/gasket assembly. Step 2. Place the left side inner door into position first, being sure to firmly position the concave channel of the inner door around the feedline. Step 3. Using[...]

Page 35 ScreenLok ® Flame Arrestor Cleaning Procedure Step 1. Move the gas control power switch to the “OFF” position and unplug the water heater from the wall outlet. Step 2. Remove the outer door. Step 3. Remove the right side inner door per the Inner Door Removal Procedure on page 32. Step 4. Disconnect the pilot tube using a 7/16” wrench[...]

Page 36 Damper Relay Installation (cont’d) 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. Step 4. Remove the draft hood from the damper and retain it for use on the new damper. Step 5. Unplug the cord sets from the damper. Step 6. Remove the two da[...]

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 1 0. 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. Step 11. Remove the Yellow wire in the damper housing from its location. Connect the[...]

Page 38 Common Terms BTU British Thermal Units ECO Energy Cut Off GPM Gallons per Minute Hz Hertz KWh Kilowatts per hour LED Light Emitting Diode NPT National Pipe Thread Ohms Ohms of resistance PSI Pounds per Square Inch RPM Revolutions per Minute VAC Volts Alternating Current W.C. Inches of Water Column °C Degrees C entigrade °F Degrees F ahren[...]

Page 39 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 15A 17 18 19 20 21 22 23 24 26 27 11 25 PART NAME AND DESCRIPTION 1. Draft Hood 15. Inner Door (Right) 2. Damper 15A. Resettable Thermal Switch 3. Jacket Head Pan 16. Inner Door (Left) 4. Jacket 17. Damper Wire Harness 5. Heat Trap—Cold Water Inlet 18. Thermal Well 6. Magnesium Anode–Hot Water Outlet [...]

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