Manual 238-48494-00A

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

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

Normal Heating Sequence

Troubleshooting __________________________________________ 13

Burner Maintenance _______________________________________ 17

Burner Cleaning Procedure

Pilot Maintenance _________________________________________ 19

Pilot Inspection, Testing and Replacement

Thermal Well Testing ______________________________________ 21

Determine Water Temperature Inside Tank_____________________ 22

Component Disassembly ___________________________________ 24

Gas Control Removal ______________________________________ 25

Gas Control Assembly _____________________________________ 26

Flammable Vapor Sensor Testing_____________________________ 27

120 VAC Circuit Trace _____________________________________ 28

Relay Replacement________________________________________ 28

Common Terms __________________________________________ 30

Notes __________________________________________________ 30

Parts List _______________________________________________ 31

2

Page 2

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.

Installation and service must be performed by a qualified installer, service agency, or the gas supplier.

FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED 3/4” X 3/4” TEMPERATURE AND

PRESSURE RELIEF VALVE WILL RELEASE THE MANUFACTURER FROM ANY CLAIM THAT

MIGHT RESULT FROM EXCESSIVE TEMPERATURE AND PRESSURES.

CAUTION

Incorrect operation of this water heater may create a hazard to life and property and will nullify the warranty.

If sweat fittings are to be used, DO NOT apply heat to the nipples on top of the water heater. Sweat the tubing to the adapter before fitting the adapter to the water connections. It is imperative that heat is not applied to the nipples containing a plastic liner.

Turn off or disconnect the electrical power supply to the water heater before servicing.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

NOTICE

Before proceeding, please inspect the water heater and its components for possible damage. DO NOT install any water heater with damaged components. If damage is evident, then please contact the supplier where the water heater was purchased or the manufacturer listed on the rating plate for replacement parts.

DANGER

Do not store or use gasoline or other flammable, combustible, or corrosive vapors and liquids in the vicinity of this or any other appliance.

Page 3

3

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.

Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the possibility of injury under these conditions, we recommend a hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system. If hydrogen is present, there will be an unusual sound such as air escaping through the pipes as hot water begins to flow. Do not smoke or have open flame near the faucet at the time it is open.

DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE

FOLLOWING:

Liquefied petroleum gases/propane gas and natural gas have an odorant added by the gas supplier that aids in the detection of the gas. Most people recognize this odor as a “sulfur” or “rotten egg” smell. Other conditions, such as “odorant fade” can cause the odorant to diminish in intensity, or ”fade,” and not be as readily detectable. If you have a diminished sense of smell, or are in any way unsure of the presence of gas, immediately contact your gas supplier from a neighbor's telephone. Gas detectors are available. Contact your gas supplier, or plumbing professional for more information.

Do not operate the water heater or its accessories without the Accessory Module cover in place. Do not operate the water heater or Setback Control without the Setback Control

Junction Box Assembly cover in place.

Do not operate the water heater, Accessory Module, and Setback Control with jumpered or absent controls or safety devices.

Turn off or disconnect the electrical power supply to the water heater and its accessories before servicing. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

All electrical wiring must be installed and grounded in accordance with local codes, or in the absence of local codes, the National Electrical Code, ANSI/NFPA 70 and/or CSA C22

Electrical Code.

Page 4

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. The following information will instruct service professionals on the function, proper diagnosis, and repair of water heaters employing the

Bradford White DEFENDER Safety System.

Introduction

The new Bradford White Programmable Efficiency water heaters are designed to provide reliable performance with enhanced standard features. New design features include reliable spark-to-pilot ignition system, enhanced diagnostics, simplified servicing, and the Bradford

White Defender Safety System.

Spark-to-Pilot Ignition System - employing the spark-to-pilot ignition system promotes reliable and consistent pilot and main burner ignitions to provide hot water on demand.

Integrated Immersion Thermal Well/Gas Control with LED - was developed for ease of troubleshooting by providing simple diagnostic codes to pinpoint an installation or component performance issue.

Rugged Wiring Connections - receptacle type connections promote error free wiring.

The gas control maintains water temperature, ignition sequence, and regulates gas flow. If a situation outside of normal operating parameters exists, the gas control diagnostic LED will flash a code to positively identify an operational issue.

This service manual is designed to facilitate problem diagnosis and enhance service efficiency.

To further promote quicker service times, the gas control can be removed and replaced without draining the water heater. A special tool is required and will be provided with each gas control kit shipped from your Bradford White wholesale distributor.

Please read the service manual completely before attempting service on this new series of models.

How the DEFENDER Safety System Works

During normal operation, air for combustion is drawn into the water heater through the openings in the jacket. This air travels down and around the combustion chamber and enters through holes in the very bottom of the corrosion resistant combustion chamber. The air then travels up through the flame arrestor louvers, where the velocity of the air is increased and its direction altered. The air then mixes in a normal manner with supplied gas and is efficiently combusted, producing very low NO x emissions.

In the unlikely event trace amounts of flammable vapors are present in the air flowing into the combustion chamber, the vapors are harmlessly 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 and igniting vapors outside of the combustion chamber. In addition, the resettable thermal switch will open and shut down the pilot and main burner.

Page 5

5

6

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.

Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting the water heater.

The Honeywell WV4460E Electronic Gas Control will display error codes in the event of abnormal operation. Diagnostic codes are listed in the troubleshooting chart beginning on page

13 of this service manual. The troubleshooting chart will also indicate the probable cause for the diagnostic code and direct the service professional to a service procedure to properly diagnose the abnormal operation.

Contact the Bradford White technical support group immediately if diagnosis cannot be made using the methods described in this service manual.

Tools Required for Service

Manometer: A liquid “U” tube type or a digital (magna-helic) type can be used. This device is used to measure gas and/or air pressure and vacuum.

Multi-Meter: A digital type is strongly recommended. This device is used to measure electrical values. The meter you select must have the capability to measure volts AC, volts DC, amps, micro-amps and ohms.

Electronic Probes: In some cases, standard multi-meter probes will damage or simply not be effective to obtain certain voltage and ohm reading. It will be necessary to have special electronic “pin” type multi-meter probes. These probes are available at most electronic wholesale outlets.

Thermometer: Used to measure water temperature. An accurate thermometer is recommended.

Water Pressure Gage: Used to measure water supply pressure. Also used to determine tank pressure by adapting to the drain valve of the heater.

Gas Control Service Tool: BWC p/n 239-45991-00. A specialized tool designed to remove the gas control from the thermal well. Available from your Bradford White parts supplier and is supplied with replacement gas controls.

Various Hand Tools: Pipe wrench, channel locks, open end wrenches (3/8", 7/16", 1/2"), 12" crescent wrench, Allen wrench set, screw drivers (common & Phillips), 1/4" nut driver, pliers

(common & needle nose), socket set, side cutters, wire cutters, wire strippers, wire crimpers, torpedo level, small shop vac, step ladder, flashlight, and 5 gallon pail.

Page 6

Specifications

Specifications

Power Supply

Gas Supply Pipe

Approved Gas Type

Gas Pressure

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” w.c. minimum for Natural Gas; 11” w.c. for Propane; 14” w.c. maximum for Natural Gas / Propane

Single or Double Wall Metal Vent Pipe Approved Vent Materials

Minimum Clearance for

Servicing

18” from top; 24” from front; 4” from sides and rear

Water Supply Pressure

ECO Limit

150 psi maximum allowable working pressure; check local codes for supply pressure

188°F (87°C)

Temperature Setpoint Range 60°F (16°C) to 160°F (71°C); approximate temperatures

Page 7

7

8

Specifications

Flame Failure Response Time

Control Timings

Ignition State

Energize Relay and Verify (Closed Circuit)

Trial for Ignition

Flame Stabilization Period

Re-energize Relay and Verify

Timing

15 seconds

90 seconds

3 seconds

15 seconds

1.5 seconds (2 second maximum; 1 second minimum)

De-energize Relay and Verify (Open Circuit)

Relay Fault (failed open/close)

Soft Lockout

ECO Limit Lockout

Verify Resistive Delay

Simulated Resistive Load Lockout

Hardware Error Lockout

15 seconds

Retry after 2 minutes

Retry after 5 minutes

Indefinite (See page 11 to reset)

Retry after 2 minutes (repeats 5 times)

Indefinite (cycle power to reset)

Indefinite (self clears if fault clears for at least 15 seconds)

PILOT

W

Wiring Diagram

GAS VALVE

Honeywell

HOT

A

B

C

VE

RY

HO

T

LO

W

W

BK

R

FLAMMABLE

VAPOR SENSOR

G

BK

W

BL

R

Y

BK

BK

BK

BK

BK

WATER

TEMPERATURE

SENSOR

BK

RE-SETTABLE

THERMAL SWITCH

BK W

POWER CORD

ACCESSORY

MODULE

W BK

W

W

G

G

W

BL

R

Y

SETBACK CONTROL

JUNCTION BOX

BK

PLUG-IN

TRANSFORMER

BK

W

AC AC

W

BK

R

BK

W

Page 8

SETBACK CONTROL

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. If the

Flammable Vapor Sensor is out of range, the gas control LED immediately flashes

7 times with a 3 second pause.

Normal Heating Sequence

1.

Thermostat Calls for Heat: Prior to energizing the relay, the gas control verifies the safety circuit to see if it is in the correct state. If the safety circuit is closed, the gas control LED flashes 2 times with a 3 second pause. The gas control waits 2 minutes. Then, the control cuts power to the relay. This cycle repeats until the safety circuit opens.

2.

Relay Energized

3.

Safety Circuit Check: If the safety circuit does not close within 30 seconds, the gas control LED flashes 3 times with a 3 second pause. The relay is powered for a maximum of 30 seconds every 2 minutes trying to close the safety circuit. This cycle repeats as long as there is a call for heat.

4.

Hold Period (15 seconds)

5.

Trial for Pilot Ignition (90 seconds): The gas control lights the pilot by activating the spark igniter and gas flow to the pilot burner. If flame is not sensed within 90 seconds, the spark igniter and gas flow are deactivated. The relay will remain powered, and the gas control LED flashes 6 times with a 3 second pause.

6.

Main Burner Ignition: After pilot flame is sensed, the gas control activates the main valve for main burner ignition. The gas control will ignore flame signals for 3 seconds to allow for the main burner to stabilize.

Page 9

9

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. The relay is powered attempting to close the safety circuit. The gas control LED flashes 3 times with a 3 second pause.

Flame Sensor: If flame is lost, the pilot and main valves are shutdown. The relay is powered. The gas control attempts to re-light the pilot 4 times. If unsuccessful, power is removed from the relay, and the gas control proceeds to a 5 minute lockout. The gas control re-attempts to light the pilot starting at Normal Heating

Sequence #2.

8.

Thermostat Satisfies: Gas control LED flashes once every 4 seconds.

9.

Burner Off

10.

Relay De-energized (15 seconds)

Abnormal Operation

1.

Flammable Vapor Sensor Fault:

A) If the resistance is greater than 70,000 ohms: The gas control immediately turns off all outputs. The gas control waits and monitors resistance for 30 seconds. If the resistance is greater than 65,000 ohms after 30 seconds, the gas control proceeds to verify resistive delay for 2 minutes and flashes 7 times then 1 time with a three second pause. This process is repeated 5 times until the control either returns to normal operation or proceeds to flammable vapor lockout.

B) If the resistance is below 3000 ohms: The gas control immediately turns off all outputs and proceeds to flash 8 times then 1 time with a three second pause. The error self clears if the resistance returns to normal range for at least 15 seconds.

10

Page 10

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. The error self clears if the fault clears for at least 15 seconds.

C) Water Temperature in excess of ECO (Energy Cut Off) Limit: The gas control immediately turns off the pilot and main valves. The gas control LED proceeds to flash 4 times with a 3 second pause.

To reset the gas control, rotate the setpoint knob to the minimum setting for at least

6 seconds before returning to desired temperature setting.

3.

Safety Circuit Fault:

A) Safety Circuit Failed to Close: The gas control proceeds to flash 3 times with a 3 second pause. The gas control waits 5 minutes, and then tries to energize the relay again.

B) Safety Circuit Failed to Open: The gas control proceeds to flash 2 times with a 3 second pause. The gas control waits 5 minutes, and then tries to de-energize the relay.

4.

Trial for Ignition Fault:

A) Relay Fault During Trial: The gas control stops the trial for ignition. The gas control proceeds to flash 3 times with a 3 second pause. The gas control waits

5 minutes, and then tries to energize the relay again.

B) Flame Not Sensed: The gas control energizes the spark igniter attempting to light the pilot and prove flame. If flame is not sensed within 90 seconds, the spark igniter turns off, the pilot valve is closed. The gas control LED flashes 6 times then 1 time with 3 second pause. The control waits 5 minutes before repeating the ignition sequence.

Page 11

11

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.

B) Flame Sensed Out of Sequence: The gas control only looks for pilot flame when the relay is energized. If flame is present when the pilot valve is not open, the gas control proceeds to wait for flame loss and flashes 5 times with 3 second pause.

This continues until flame is lost. Once the flame signal is lost, the control flashes 6 times then 4 times with a 3 second pause. The control waits 5 minutes before repeating the ignition sequence.

12

Page 12

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

None (LED not on or flashing)

One short flash every four seconds

Alternates bright and dim

(heartbeat)

Control Status

Electrical power not present

Probable Cause

Control power switch in "OFF" position.

Supply voltage interrupted.

Stand-by mode,

Thermostat is satisfied (no faults)

Temperature demand is satisfied

(no call for heat)

Service Procedure

Turn Power On

Normal operation

Thermostat calling for heat (no fault)

Tank temperature below setpoint of thermostat

Normal operation

Short flash once every second

Weak pilot signal on last call for heat

1. Unstable pilot

2. Pilot tube blocked or restricted

3. Oxidation build-up on pilot electrode

4. Wire damage to pilot assembly or bad connection at gas control

1. See Burner Inspection on page 17

2-4. See Pilot Inspection,

Testing and Replacement on page 19

Two flashes, three second pause

Three flashes, three second pause

Four flashes, three second pause

Relay not working Faulty relay

Relay not working Faulty relay

Excessive tank temperature, system must be reset

1. Thermal well sensor out of calibration

2. Faulty gas control

1. Verify cord sets are fully plugged in

2. See Relay Replacement on page 28

1. Verify cord sets are fully plugged in

2. See Relay Replacement on page 28

1. Test Gas Control & Thermal

Well

2. Replace gas control if necessary

Five flashes, three second pause

False pilot flame present

Pilot valve stuck in open position Replace gas control

Six flashes, one flash, three second pause (Soft

Lockout)

Failed to light pilot, system resets after

(5) minutes

1. Unstable pilot

2. Pilot tube block or restricted

3. Oxidation build-up on pilot electrode

4. Wire damage to pilot assembly or bad connection at gas valve

1. See Burner Inspection on page 17

2-4. See Pilot Inspection,

Testing and Replacement on page 19

Page 13

13

14

Troubleshooting

LED Status Control Status Probable Cause

Six flashes, two flashes, three second pause (Soft

Lockout)

Relay not working properly during burner operation, system auto resets after (5) minutes

Faulty relay

Service Procedure

See Relay Replacement on page 28

Six flashes, three flashes, three second pause (Soft

Lockout)

Pilot flame extinguished, system auto resets after (5) minutes

1. Unstable pilot

2. Pilot tube block or restricted

3. Oxidation build-up on pilot electrode

4. Wire damage to pilot assembly or bad connection at gas control

5. Insufficient combustion air

6. Insufficient gas pressure

1. See Burner Inspection on page 17

2-4. See Pilot Inspection,

Testing and Replacement on page 19

5. Refer to Installation &

Operation Manual

Six flashes, four flashes, three second pause

Undesired false pilot flame sensed, system auto resets

Pilot valve stuck in open position Replace gas control

Seven flashes, three second pause

Eight flashes, one flash, three second pause

Flammable vapor sensor or resettable thermal switch fault detected, see warning label

Flammable vapor sensor out of specification, possible short

1. Flammable vapor present

2. Flammable vapor sensor exposed to excessive moisture

3. Flammable vapor sensor exposed to extreme ambient temperature

4. Resettable thermal switch open

1. Flammable vapor sensor out of specification; verify Flammable

Vapor Sensor (FVS) resistance is not below 25 kŸ.

2. Possible short in flammable vapor sensor or resettable thermal switch wiring

See Flammable Vapor

Sensor Testing on page 27

See Flammable Vapor

Sensor Testing on page 27

Eight flashes, three flashes, three second pause

Thermal well sensor damaged or unplugged or gas control electronics fault detected

1. Damage to thermal well wires

2. Thermal well sensor resistance out of range

3. Replace thermal well

4. Verify control is not wet or physically damaged

5. Reset control on/off switch

6. Replace gas control if 8-3 error persists

See Thermal Well Testing on page 21

Eight flashes, four flashes, three second pause

Gas control fault detected

1. Verify control is not wet or physically damaged

2. Reset control on/off switch

3. Replace gas control if 8-4 error persists

1. Replace gas control if wet or physically damaged

2. Cycle power

3. Replace gas control

Page 14

Troubleshooting

24

29

31

32

63

64

4

6

18

20

23

85

96

143

145

87

89

93

95

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.

Diagnostic

Code #

Description

Gas Valve / Control Model

Accessory

Module

WV4460E

(intermittent pilot gas control)

Conn

Setback Control not connected to gas valve / control or improperly wired together.

Weak pilot signal detected.

Pilot signal detected out of sequence.

Internal gas valve fault detected.

Failed to light pilot.

Pilot signal detected out of sequence (before it should).

Pilot signal detected out of sequence (after it should).

Relay failed to energize

Upper tank sensor out of specification.

Lower tank sensor out of specification.

Ignition successful, but flame lost during run cycle.

Soft lockout.

Internal gas valve fault detected.

Soft Lockout due to maximum number of recycles exceeded, last recycle was from pressure switch open

A manual reset is required due to Rollout Limit

Equipment missing or improperly wired together.

Internal gas valve fault detected.

Flammable vapor sensor fault detected, see warning label.

Flammable vapor sensor out of specification, possible short.

Water heater tank leak detected.

Leak sensor improperly installed or leak sensor resistor missing. x x x x x x x x x x x x x x x x x x x x x

Page 15

15

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.

Green

Red

Red

Amber

Amber

Red

LED Status

Accessory Module

Status

Probable Cause

LED on continuously. Power on (no fault). n/a

One flash and three second pause.

Leak alarm fault.

Inlet Shut-off valve open.

Water heater tank leak.

Two flashes and three second pause.

Leak alarm fault.

Inlet Shut-off valve closed.

Water heater tank leak.

Four flashes and three second pause.

Five flashes and three second pause.

LED strobe (quick flashes).

Leak sensor malfunction.

Gas control missing / not connected.

Hardware error.

1. Leak Sensor resistor removed.

2. Leak Sensor improperly connected to Accessory

Module.

1. Wrong gas control wire harness was used.

2. Accessory Module was not connected to gas valve.

Internal electronics failure, replace Accessory Module.

16

Page 16

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.

The main burner should light smoothly from the pilot and burn with a blue flame with a minimum of yellow tips.

Steel burner models self adjust air to gas ratio mixture and do not have an adjustable air shutter. The main burner must be free from any debris accumulation that may effect burner operation (See Burner Cleaning Procedure on page 17).

Burner Cleaning Procedure

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. Turn off the gas supply to the water heater.

Step 4. Remove the outer door.

Outer door

Page 17

17

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

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. gas control.

Disconnect the spark igniter/flame sensor wire from

Gas control

Spark igniter/flame sensor wire

Step 8. chamber.

Remove the burner assembly from the combustion

Burner assembly

Burner surface area and burner ports

Step 9. Thoroughly inspect the burner surface area and burner port area and remove any loose debris.

Step 10. Unscrew the burner from the main burner orifice.

Main feedline

Step 11. Remove the main burner orifice from the main feedline using a 1/2” wrench. Inspect the orifice and clean or replace, if necessary.

1/2” wrench

Page 18

Right side inner door

Main burner orifice

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 Inspection, Testing, and Replacement

Note: The Pilot Maintenance section replaces page 13 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.

Step 4.

Water heater power cord and

Accessory Module transformer

Turn off the gas supply to the water heater.

Remove the outer door.

Outer door

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

Page 19

19

20

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. gas control.

Disconnect the spark igniter/flame sensor wire from

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 assembly

1/4” nut driver

Step 10. Visually inspect the spark igniter/flame sense wire for damage. Replace the pilot assembly, if damage is found.

Multi-meter

Step 11. With a multi-meter set to the ohms setting, check continuity through the spark igniter/flame sense wire. Replace the pilot, if there is no continuity.

Page 20

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. Carefully clean any oxidation using very fine emery cloth.

Step 14. Visually inspect 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 tube and pilot orifice. c) Inspect the pilot tubing and pilot orifice for blockages. Clean or replace, as necessary.

Step 16. Re-assemble the pilot assembly and install it on the main feedline. Reinstall the burner assembly into the combustion chamber. Restore the gas supply and check for gas leaks.

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 Operation manual.

Thermal Well Testing

Note: The Thermal Well Testing section replaces page 22 in the Defender Atmospheric

Service Manual, p/n 238-44943-00.

CAUTION

Do not use standard multi-meter probes for this testing. Doing so will damage the connector. Use special pin type electronic probes or small diameter wire pins inserted into connector.

Page 21

21

22

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. With a multi-meter set to the ohms setting, measure the resistance between the middle and right side wires.

Step 3. With a multi-meter set to the ohms setting, measure the resistance between the middle and left side wires.

Determine the correct resistance values using the Determine the Water Temperature

Inside the Tank procedure. If the values are correct, replace the gas control, otherwise replace the thermal well.

Determine Water Temperature Inside Tank

Note: The Determine Tank Temperature section replaces page 23 in the Defender

Atmospheric Service Manual, p/n 238-44943-00.

WARNING

Stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.

Note: It is important to understand once the resistance for the thermal well is determined using the Thermal Well Testing Procedure on page 21, water flow through the water heater should not occur. Prior to performing the following steps, 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 22

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

90

100

110

120

130

140

150

160

170

180

190

200

°F

40

50

60

70

80

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. Using the chart below, determine the correct resistance value for the water temperature from Step 2.

Example: If the water temperature is 84°F, then the resistance through the sensor would be 8449 (see shaded area). NOTE: Sensor resistance increases as the temperature falls.

Sensor Resistance at Various Temperatures

In Degrees F

7333

5827

4663

3758

3048

2488

2043

1688

1402

1170

982

828

0 1 2 3 4 5 6 7 8 9

26109 25400 24712 24045 23399 22771 22163 21573 21000 20445

19906 19383 18876 18383 17905 17440 16990 16553 16128 15715

15314 14925 14548 14180 13823 13477 13140 12812 12494 12185

11884

9299

11592

9078

11308

8862

11032

8653

10763

8449

10502

8250

10248

8057

10000

7869

9760

7685

9526

7507

7165

5697

4562

3679

2986

2439

2004

1656

1376

1150

965

814

7000

5570

4464

3602

2925

2391

1966

1625

1351

1129

949

801

6839

5446

4368

3527

2866

2344

1928

1595

1327

1110

933

788

6683

5326

4274

3453

2808

2298

1891

1566

1303

1090

917

775

6531

5208

4183

3382

2752

2253

1856

1537

1280

1071

901

762

6383

5094

4094

3312

2697

2209

1820

1509

1257

1053

886

749

6238

4982

4006

3244

2643

2166

1786

1481

1235

1035

871

737

6098

4873

3922

3177

2590

2124

1753

1454

1213

1017

857

725

5961

4767

3839

3112

2538

2083

1720

1427

1191

999

842

713

Page 23

23

24

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

Water heater power cord and

Accessory Module transformer

Step 3. level.

Drain the water heater to a point below the gas control

Step 4. 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.

Pilot and main feedlines

Step 5. Disconnect the wire harnesses and spark igniter/ flame sense wire from the gas control.

Gas control

Spark igniter/flame sensor wire

Step 6. Remove the gas control & thermal well by rotating the flats of the Thermal Well counter clockwise using a 1-5/16” wrench.

Flats of thermal well

Page 24

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. 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.

Pilot and main feedlines

Step 5. Disconnect the wire harnesses and spark igniter/ flame sense wire from the gas control.

Gas control

Spark igniter/flame sensor wire

Step 6. Using the gas control service tool, p/n

239-45991-00, available from your BWC parts supplier, insert the tool into the back of the gas control.

Gas control service tool

Page 25

25

26

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. Be sure the thermal well flange is positioned properly to allow for proper gas control installation.

Tighten the thermal well using a 1-5/16” wrench.

Step 2. Route the wire leads back into relief opening.

Wire leads on thermal well

Slots in thermal well

Relief opening

Step 3. Align the slots located on the thermal well flange with the tabs located on the back of the gas control.

Tabs on back of gas control

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. Install the burner assembly and connect the pilot and main feedlines to the gas control using a 7/16” and 3/4” wrench, respectively.

Pilot and main feedlines

Page 26

Gas Control Assembly to the Thermal Well (cont’d)

Gas Control Assembly

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

Note: The Flammable Vapor Sensor Testing section is in addition to the Defender

Atmospheric service manual, p/n 238-44943-00.

CAUTION

Do not use standard multi-meter probes for this testing. Doing so will damage the connector. Use special pin type electronic probes or small diameter wire pins inserted into connector.

Step 1. position.

Move the gas control power switch to the “OFF”

Gas control power switch

Step 2. Disconnect the flammable vapor sensor harness from the gas control.

Page 27

27

28

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.

Flammable vapor sensor harness

120 VAC Circuit Trace

Note: The 120 VAC Circuit Trace section is in addition to the Defender Atmospheric service manual, p/n 238-44943-00.

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.

Relay Replacement

Note: The Relay Replacement section is in addition to 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

Water heater power cord and

Accessory Module transformer

Page 28

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.

Step 7.

Remove the relay from its socket.

Relay

Install the new relay, p/n 233-47642-00.

Socket

Step 8. Re-connect the wires removed in Step 5 to their proper locations.

Step 9. Re-install the Setback Control Junction Box Assembly cover and the (2) screws removed in Step 3.

Page 29

29

30

Common Terms

Common Terms

BTU

ECO

British Thermal Units

Energy Cut Off

GPM Gallons per Minute

Hz Hertz

KWh

LED

NPT

Ohms

PSI

RPM

VAC

W.C.

Kilowatts per hour

Light Emitting Diode

National Pipe Thread

Ohms of resistance

Pounds per Square Inch

Revolutions per Minute

Volts Alternating Current

Inches of Water Column

°C Degrees

NOTES

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____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

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Page 30

Parts List

1

2

3

5

6 7

8

9

17

4 10

11

21

20

19

18

23

24

28

27

26

22

25

14

16 15

15A

PART NAME AND DESCRIPTION

1. Draft hood

2. Setback Control Junction Box Assembly

3. Jacket head

4. Jacket

5. Heat trap (outlet)

6. Anode Outlet Device

7. Heat trap (inlet)

8. Baffle

9. Diptube

10. T&P valve

11. Tank

12. Combustion chamber

13. Pedestal base

14. Drain valve

15. Right side inner door

15A. Resettable Thermal Switch

16. Left side inner door

17. Accessory Module

18. Junction box wire harness

19. Thermal well

20. Gas control

21. FV sensor / RTS wire harness

22. FV sensor clip

23. FV sensor

24. Outer door

25. Burner

26. Orifice

27. Pilot assembly

28. Main burner feedline

12

13

Page 31

31

Email [email protected]

[email protected]

www.bradfordwhite.com