Bradford-White PE440T'F(BN,SX) User Manual

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P rammable Efficiency

Ga

r Heate

S ICE

MANUAL

SUPPLEMENT

T eshooting Guide a structions for Service

(To be performed ONLY by qua ce providers)

M

Covered

b

 

PE4403

SX)

PE440T

 

PE4503

 

PE2XR5

 

(*) Denotes Warra y Years

M

l 238-48494

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

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

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

Page 2

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:

xDo not try to light any appliance

xDo not touch any electrical switch; do not use any phone in your building

xImmediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

xIf 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

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

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-pilotignition system, enhanced diagnostics, simplified servicing, and the Bradford White Defender Safety System.

Spark-to-Pilot Ignition System - employing thespark-to-pilotignition 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 NOx 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

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-ampsand ohms.

Electronic Probes: In some cases, standardmulti-meterprobes will damage or simply not be effective to obtain certain voltage and ohm reading. It will be necessary to have special electronic “pin” typemulti-meterprobes. 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/n239-45991-00.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

6

Specifications

 

Specifications

 

 

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 Double Wall Metal Vent Pipe

 

 

Minimum Clearance for

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

Servicing

 

 

 

Water Supply Pressure

150 psi maximum allowable working pressure; check local

codes for supply pressure

 

 

 

ECO Limit

188°F (87°C)

 

 

Temperature Setpoint Range

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

 

 

Page 7

7

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-energizeRelay and Verify

15 seconds

 

 

Flame Failure Response Time

1.5 seconds (2 second maximum; 1 second

minimum)

 

 

 

De-energizeRelay and Verify (Open Circuit)

15 seconds

 

 

Relay Fault (failed open/close)

Retry after 2 minutes

 

 

Soft Lockout

Retry after 5 minutes

 

 

ECO Limit Lockout

Indefinite (See page 11 to reset)

 

 

Verify Resistive Delay

Retry after 2 minutes (repeats 5 times)

 

 

Simulated Resistive Load Lockout

Indefinite (cycle power to reset)

 

 

Hardware Error Lockout

Indefinite (self clears if fault clears for at least 15

seconds)

 

 

 

 

Wiring Diagram

PILOT

GAS VALVE

W

Honeywell

C

 

E

R

Y

 

 

T

V

 

 

O

 

 

 

B

 

 

 

H

 

A

 

 

 

 

 

 

 

 

 

 

 

 

 

HOT

 

 

 

 

 

 

 

L

O

W

BL BK

W

BK R

FLAMMABLE

VAPOR SENSOR

BK

R BK

 

BK

BK

G W

Y

BK

 

WATER

 

 

 

 

 

 

 

TEMPERATURE

 

 

 

 

SENSOR

BK

 

 

 

 

 

 

RE-SETTABLE

BK

 

 

 

 

 

THERMAL SWITCH

W

 

 

 

 

 

G

 

 

 

 

 

 

POWER CORD

 

 

 

 

 

 

 

 

 

 

 

ACCESSORY

 

 

 

 

 

 

MODULE

 

 

W

BK

 

 

 

W

G

W

BK

 

BK

 

 

 

RBK

 

 

 

 

 

G

 

 

 

W

W

 

 

 

 

 

W

 

 

 

PLUG-IN

 

 

 

BL

 

 

TRANSFORMER

 

R Y

 

AC AC

 

 

SETBACK CONTROL

W

BK

 

 

 

JUNCTION BOX

 

 

 

Page 8

SETBACK CONTROL

8

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-lightthe pilot 4 times. If unsuccessful, power is removed from the relay, and the gas control proceeds to a 5 minute lockout. The gas controlre-attemptsto 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.

Page 10

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-energizethe 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.

Page 12

12

Troubleshooting

Note: The Troubleshooting section replaces pages 4-6in the Defender Atmospheric service manual, p/n238-44943-00.

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

Control Status

Probable Cause

Service Procedure

None (LED

Electrical power not

Control power switch in "OFF"

Turn Power On

not on or

present

position.

flashing)

Supply voltage interrupted.

 

 

 

One short

Stand-bymode,

Temperature demand is satisfied

 

flash every

Thermostat is

Normal operation

four seconds

satisfied (no faults)

(no call for heat)

 

Alternates

 

 

 

bright and

Thermostat calling

Tank temperature below

Normal operation

dim

for heat (no fault)

setpoint of thermostat

 

(heartbeat)

 

 

 

 

 

1. Unstable pilot

 

 

 

2. Pilot tube blocked or restricted

1. See Burner Inspection on

Short flash

Weak pilot signal

3. Oxidation build-upon pilot

page 17

once every

electrode

2-4.See Pilot Inspection,

second

on last call for heat

4. Wire damage to pilot

Testing and Replacement on

 

 

assembly or bad connection at

page 19

 

 

gas control

 

 

 

 

 

Two flashes,

 

 

1. Verify cord sets are fully

 

 

plugged in

three second

Relay not working

Faulty relay

2. See Relay Replacement on

pause

 

 

 

 

page 28

 

 

 

Three

 

 

1. Verify cord sets are fully

flashes,

Relay not working

Faulty relay

plugged in

three second

2. See Relay Replacement on

pause

 

 

page 28

 

 

 

 

Four flashes,

Excessive tank

1. Thermal well sensor out of

1. Test Gas Control & Thermal

temperature,

Well

three second

calibration

system must be

2. Replace gas control if

pause

2. Faulty gas control

reset

necessary

 

 

Five flashes,

False pilot flame

 

 

three second

Pilot valve stuck in open position

Replace gas control

present

pause

 

 

 

 

 

 

 

 

 

 

 

1. Unstable pilot

 

Six flashes,

 

2. Pilot tube block or restricted

1. See Burner Inspection on

one flash,

Failed to light pilot,

3. Oxidation build-upon pilot

page 17

three second

system resets after

electrode

2-4.See Pilot Inspection,

pause (Soft

(5) minutes

4. Wire damage to pilot

Testing and Replacement on

Lockout)

 

assembly or bad connection at

page 19

 

 

gas valve

 

 

 

 

Page 13

13

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

 

Six flashes,

 

2.

Pilot tube block or restricted

1. See Burner Inspection

 

3.

Oxidation build-upon pilot

on page 17

three

Pilot flame

electrode

2-4.See Pilot Inspection,

flashes,

extinguished,

4.

Wire damage to pilot

Testing and Replacement

three second

system auto resets

pause (Soft

after (5) minutes

assembly or bad connection at

on page 19

gas control

5. Refer to Installation &

Lockout)

 

 

5.

Insufficient combustion air

Operation Manual

 

 

 

 

6.

Insufficient gas pressure

 

Six flashes,

Undesired false

 

 

 

four flashes,

 

 

 

pilot flame sensed,

Pilot valve stuck in open position

Replace gas control

three second

pause

system auto resets

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.

Flammable vapor present

 

 

Flammable vapor

2.

Flammable vapor sensor

 

Seven

sensor or

exposed to excessive moisture

 

flashes,

resettable thermal

3.

Flammable vapor sensor

See Flammable Vapor

three second

switch fault

exposed to extreme ambient

Sensor Testing on page 27

pause

detected, see

temperature

 

 

warning label

4.

Resettable thermal switch

 

 

 

open

 

 

 

1.

Flammable vapor sensor out

 

Eight

Flammable vapor

of specification; verify Flammable

 

flashes, one

Vapor Sensor (FVS) resistance is

 

sensor out of

See Flammable Vapor

flash, three

specification,

not below 25 k .

Sensor Testing on page 27

second

2.

Possible short in flammable

possible short

 

pause

vapor sensor or resettable

 

 

 

 

 

thermal switch wiring

 

 

 

1.

Damage to thermal well wires

 

Eight

 

2.

Thermal well sensor

 

Thermal well sensor

resistance out of range

 

flashes,

 

damaged or

3.

Replace thermal well

 

three

See Thermal Well Testing

unplugged or gas

4.

Verify control is not wet or

flashes,

on page 21

control electronics

physically damaged

three second

 

pause

fault detected

5.

Reset control on/off switch

 

 

6.

Replace gas control if 8-3error

 

 

 

 

 

 

persists

 

 

 

 

 

 

Eight

 

1.

Verify control is not wet or

1. Replace gas control if

flashes, four

 

physically damaged

Gas control fault

wet or physically damaged

flashes,

2.

Reset control on/off switch

detected

2. Cycle power

three second

3.

Replace gas control if 8-4error

pause

 

persists

3. Replace gas control

 

 

 

 

 

 

 

Page 14

14

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

 

 

 

 

Diagnostic

 

Accessory

WV4460E

Description

(intermittent pilot

Code #

Module

 

gas control)

 

 

 

 

 

 

 

Conn

Setback Control not connected to gas valve / control or

x

x

improperly wired together.

 

 

 

 

 

 

 

2

Relay remains energized

 

x

 

 

 

 

4

Weak pilot signal detected.

 

x

 

 

 

 

6

Pilot signal detected out of sequence.

 

x

18

Internal gas valve fault detected.

x

 

 

 

 

 

20

Failed to light pilot.

 

x

 

 

 

 

23

Pilot signal detected out of sequence (before it

 

x

should).

 

 

 

 

24

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

 

x

 

 

 

 

29

Relay failed to energize

 

x

31

Upper tank sensor out of specification.

 

 

 

 

 

 

32

Lower tank sensor out of specification.

 

x

 

 

 

 

63

Ignition successful, but flame lost during run cycle.

 

x

Soft lockout.

 

 

 

 

 

 

 

 

64

Internal gas valve fault detected.

 

x

 

 

 

 

85

Soft Lockout due to maximum number of recycles

 

x

exceeded, last recycle was from pressure switch open

 

 

 

 

 

 

 

 

87

A manual reset is required due to Rollout Limit

 

x

 

 

 

 

89

Equipment missing or improperly wired together.

x

 

 

 

 

 

93

Internal gas valve fault detected.

 

x

 

 

 

 

95

Flammable vapor sensor fault detected, see warning

 

x

label.

 

 

 

 

96

Flammable vapor sensor out of specification, possible

 

x

short.

 

 

 

 

143

Water heater tank leak detected.

x

 

 

 

 

 

145

Leak sensor improperly installed or leak sensor

x

 

resistor missing.

 

 

 

 

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.

 

LED Status

Accessory Module

Probable Cause

 

Status

 

 

 

 

Green

 

LED on continuously.

Power on (no fault).

n/a

 

 

 

 

 

 

 

One flash and three

Leak alarm fault.

 

Red

 

Inlet Shut-offvalve

Water heater tank leak.

 

second pause.

 

 

open.

 

 

 

 

 

Red

 

Two flashes and three

Leak alarm fault.

Water heater tank leak.

 

second pause.

Inlet Shut-offvalve

 

 

closed.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1. Leak Sensor resistor

 

 

Four flashes and three

Leak sensor

removed.

Amber

 

2. Leak Sensor improperly

 

second pause.

malfunction.

 

 

connected to Accessory

 

 

 

 

 

 

 

 

Module.

 

 

 

 

 

 

 

 

 

1. Wrong gas control wire

 

 

Five flashes and three

Gas control

harness was used.

Amber

 

missing / not

2. Accessory Module was

 

 

second pause.

connected.

not connected to gas

 

 

 

 

 

 

 

valve.

Red

 

LED strobe (quick

Hardware error.

Internal electronics failure,

 

flashes).

replace Accessory Module.

 

 

 

 

 

 

 

 

Page 16

16

Burner Maintenance

Note: The Burner Maintenance section replaces pages 31-33in the Defender Atmospheric service manual, p/n238-44943-00.

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. Move the gas control power switch to the

position. Gas control power switch

Step 2. Unplug the water heater and Accessory Module wall outlet.

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

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
Burner assembly
Burner surface area and burner ports
Step 9. Thoroughly inspect the burner surface area burner port area and remove any loose debris.
Remove the burner assembly from the combustion
Step 8. chamber.
Disconnect the spark igniter/flame sensor wire from
Gas control
Spark igniter/flame sensor wire
Step 7. gas control.
Burner Maintenance
Burner Cleaning Procedure (cont’d)
Step 5. Remove the (4) 1/4” hex drive screws holding 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

Right side inner door

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

Main burner orifice

18

Burner Maintenance

Burner Cleaning Procedure (cont’d)

Step 12. Re-assemblethe burner assembly andre-installinto 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. Move the gas control power switch to the “OFF” position

Gas control power switch

Step 2. Unplug the water heater and Accessory Module from the wall outlet.

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

Step 5. Remove the (4) 1/4” hex drive screws holding

right side inner door in place.

(4) 1/4” hex drive screws

Right side inner door

Page 19

19

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.

Gas control

Spark igniter/flame sensor wire

Step 8. Remove the burner assembly from the combustion chamber.

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-meterset to the ohms setting, check continuity through the spark igniter/flame sense wire. Replace the pilot, if there is no continuity.

Page 20

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-assemblethe 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-meterprobes 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

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. Unplug the thermal well connector from the gas control.

Thermal well connector

Step 2. With a multi-meterset to the ohms setting, measure the resistance between the middle and right side wires.

Step 3. With a multi-meterset 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

22

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. 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

°F

0

1

2

3

4

5

6

7

8

9

40

26109

25400

24712

24045

23399

22771

22163

21573

21000

20445

50

19906

19383

18876

18383

17905

17440

16990

16553

16128

15715

60

15314

14925

14548

14180

13823

13477

13140

12812

12494

12185

70

11884

11592

11308

11032

10763

10502

10248

10000

9760

9526

80

9299

9078

8862

8653

8449

8250

8057

7869

7685

7507

90

7333

7165

7000

6839

6683

6531

6383

6238

6098

5961

100

5827

5697

5570

5446

5326

5208

5094

4982

4873

4767

110

4663

4562

4464

4368

4274

4183

4094

4006

3922

3839

120

3758

3679

3602

3527

3453

3382

3312

3244

3177

3112

130

3048

2986

2925

2866

2808

2752

2697

2643

2590

2538

140

2488

2439

2391

2344

2298

2253

2209

2166

2124

2083

150

2043

2004

1966

1928

1891

1856

1820

1786

1753

1720

160

1688

1656

1625

1595

1566

1537

1509

1481

1454

1427

170

1402

1376

1351

1327

1303

1280

1257

1235

1213

1191

180

1170

1150

1129

1110

1090

1071

1053

1035

1017

999

190

982

965

949

933

917

901

886

871

857

842

200

828

814

801

788

775

762

749

737

725

713

Page 23

23

Component Disassembly

Gas Control & Thermal Well Removal From Water Heater

Note: The Component Disassembly, Gas Control Removal, and Gas Control Assembly sections replace pages 24-30in the Defender Atmospheric service manual, p/n238-44943-00.

Step 1. position.

Step 2. wall outlet.

Move the gas control power switch to the “OFF”

Gas control power switch

Unplug the water heater and Accessory Module from the

Water heater power cord and

Accessory Module transformer

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.

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-

wrench.

Flats of thermal well

Page 24

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. Move the gas control power switch to the “OFF” position.

Gas control power switch

Step 2. Unplug the water heater and Accessory Module from

wall outlet.

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

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

26

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. 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-meterprobes 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. Move the gas control power switch to the “OFF” position.

Gas control power switch

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

Page 27

27

Flammable Vapor Sensor Testing

Flammable Vapor Sensor Testing (cont’d)

Step 3. Using a multi-meterset 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. Move the gas control power switch to the “OFF” position.

Gas control power switch

Step 2. Unplug the water heater and Accessory Module wall outlet.

Water heater power cord and

Accessory Module transformer

Page 28

28

Relay Replacement

Relay Replacement (cont’d)

Step 3. Remove the (2) screws holding the Junction Box Assembly cover on and retain for

Setback Control Junction

Box Assembly Cover

White Wire

Step 4. Mark the (4) wires that are attached to the their proper location is known.

Blue Wire

Screw (other not shown)

Step 5. Disconnect the (4) wires attached to the relay

Red Wire

Yellow Wire

Relay

Step 6. Remove the relay from its socket.

Relay

Step 7. Install the new relay, p/n 233-47642-00.

Socket

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

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

Page 29

29

Common Terms

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 Centigrade

°F

Degrees Fahrenheit

NOTES

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

Page 30

30

Parts List

 

 

1

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

3

 

 

 

 

7

 

 

 

 

 

 

6

 

 

 

 

 

 

 

8

 

 

 

 

 

 

 

9

 

17

4

 

 

 

 

10

 

 

 

 

 

 

 

11

 

 

18

 

 

 

 

 

 

19

 

 

 

 

 

 

20

 

 

 

 

14

12

21

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

22

16

 

15

 

 

 

 

 

 

 

 

 

 

23

25

 

 

 

13

 

 

24

26

 

 

 

 

 

 

28 27

 

 

 

 

 

 

 

 

 

15A

 

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 well

 

6.

Anode Outlet Device

 

 

20.

Gas control

 

7.

Heat trap (inlet)

 

 

21.

FV sensor / RTS wire harness

 

8.

Baffle

 

 

 

22.

FV sensor clip

 

9.

Diptube

 

 

 

23.

FV sensor

 

10. T&P valve

 

 

24.

Outer door

 

11. Tank

 

 

 

25.

Burner

 

12. Combustion chamber

 

 

26.

Orifice

 

13. Pedestal base

 

 

27.

Pilot assembly

 

14. Drain valve

 

 

28.

Main burner feedline

 

15. Right side inner door

 

 

 

 

 

Page 31

31

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