Bradford-White Corp PE4403S*F(BN,SX) manual

Save this manual for future reference Manual 238-48494-00A SERVICE MANUAL SUPPLEMENT Troubleshooting Guide and Instructions for Service (To be performed ONLY by qua lified servi ce providers) Models Covered by This Manual: PE4403S*F(BN, SX) PE440T*F(BN,SX) PE4503*F(BN,SX) PE2XR504T*F(BN,SX) (*) Denotes Warra nt y Years Gas Water Heaters Programmabl[...]

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 thes e 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 l ight any appli ance x Do not touch any electri cal switch; do not use any p hone in your buil ding x Immediately call your gas supplier from a ne[...]

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 material s, such as ga soline or pain[...]

Page 5 The Bradford White DEFENDER Safety System ® T he Bradford White DEFENDER Safety System was designed to resist the ignition of f lammable 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 ar[...]

Page 6 How to Use this Manual T his 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 qua lified[...]

Page 7 S pecifications 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 Mater[...]

Page 8 Ignition State Timing Energize Relay and Verify (Closed Circui t) 15 seconds Trial for Ignition 90 seconds Flame Stabilization Period 3 seconds Re-energize Relay and Verify 15 seconds Flame Failure Response Time 1 .5 seconds (2 second maximum; 1 second minimum) De-energize Relay and Verify (Open Circuit) 15 secon ds Relay Fault (failed op en[...]

Page 9 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 prope[...]

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 power is removed from the relay. 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 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 wit[...]

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 Note: The Troubleshooting section replaces pages 4-6 in the Defender Atmospheric service manual, p/n 238-44943-00. L ED S ta tus C o ntr ol S ta tus P r o ba bl e C a use S e r v i c e P r oc e dur e N one ( L ED not on or fla s h in g) E le ct rica l p o w e r n o t pr e se nt Con tr ol p ow er sw i t c h i n " OF F " pos i t i o[...]

Page 14 LED S ta t u s Con t rol S t atu s Prob ab le Cau se S ervice Procedu re Six fla s h e s , t w o f l ashes, t hr ee sec on d pause ( S of t L oc k out ) Re la y n o t w o rk in g pr o perl y dur i ng burner op e r a ti o n, sy st em aut o r esets a f te r ( 5 ) m i nu te s Fa u l ty re l a y S ee R el ay R epl ac em ent on pa ge 28 Six fla [...]

Page 15 Troubleshooting 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. x 6 Pilot signal detected out of sequence. x 18 Internal gas v[...]

Page 16 Troubleshooting LED Status Accessory Module S tatus Probable Cause Green LED on continuously. Power on (no fault). n/a Red One flash and three second pause. Leak alarm fault. Inlet Shut-off valve open. Water heater tank leak. Red Two flashes and three second pause. Leak alarm fault. Inlet Shut-off valve closed. Water heater tank leak. Amber[...]

Page 17 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[...]

Page 18 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. Rem[...]

Page 19 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 Installati[...]

Page 20 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. 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 pi[...]

Page 21 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 [...]

Page 22 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. Unplug the thermal well conne[...]

Page 23 Determine Water Temperature Inside Tank (cont’d) Step 1. Move the gas control power switch to the “OFF” position. 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 t[...]

Page 24 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. Step 2. Unplug the water heater and Accessory [...]

Page 25 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. Step 2. Unplug the water heater and Accessory Module from the wall outlet. Step 3. Turn off the g[...]

Page 26 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 C[...]

Page 27 Gas Control Assembly to the Thermal Well (cont’d) Step 6. Reconnect the wire harnesses to the gas control. 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 in[...]

Page 28 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[...]

Page 29 Relay Replacement (cont’d) Step 3. Remove the (2) screws holding the Setback Control Junction Box Assembly cover on and retain for later use. Step 4. Mark the (4) wires that are attached to the relay, so their proper location is known. Step 5. Disconnect the (4) wires attached to the relay. Step 6. Remove the relay from its socket. Step 7[...]

Page 30 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 31 Parts List 1 3 4 5 6 7 8 9 10 12 13 14 15 16 15A 19 20 21 22 23 24 25 27 28 11 26 2 18 1 7 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 w el[...]

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