Residential Flue Damper Gas Water Heaters SERVICE MANUAL Troubleshooting Guide and Instructions for Service (To be performed ONLY by qualified service providers) Models Covered by This Manual: D4403S*F(BN,SX) D4504S*F(BN,SX) (*) Denotes Warranty Years Manual 238-48385-00A 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 ___________________________
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.
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.
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.
How to Use this Manual 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. And, the resettable thermal switch will open and shut down the pilot and main burner.
Specifications Power Supply Gas Supply Pipe Dedicated 120VAC, 60 Hz, 15A 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.
Specifications Control Timings Ignition State Timing Adjust Damper Position and Verify (Open Position) 15 seconds Trial for Ignition 90 seconds Flame Stabilization Period 3 seconds Re-adjust Damper Position and Verify 15 seconds 1.
Sequence of Operation 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.
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 the damper is powered closed. The gas control LED flashes a short flash once every 4 seconds (Idle status code). Damper Position: If the damper position is altered during a call for heat, the pilot and main valves are shutdown.
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.
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.
Troubleshooting Observe the green LED on the water heater gas control. Error codes are displayed with a 3 second pause before repeating. Once the error 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 Control power switch in "OFF" None (LED Electrical power not position. not on or Turn Power On present Supply voltage interrupted.
Troubleshooting LED Status Control Status Damper test circuit Six flashes, not w orking two flashes, properly during three second burner operation, pause (Soft system auto resets Lockout) after (5) minutes Six flashes, three Pilot flame flashes, extinguished, three second system auto resets after (5) minutes pause (Soft Lockout) Probable Cause 1. Damper not in proper position or malfunctioning - damper moved from full open position during run cycle 2. Obstructed venting 3. Faulty damper 4.
Burner Maintenance 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.
Burner Maintenance Burner Cleaning Procedure (cont’d) Step 5. Remove the (4) 1/4” hex drive screws holding the right side inner door in place. (4) 1/4” hex drive screws Right side inner door Step 6. Disconnect the pilot tube using a 7/16” wrench and the main burner feedline with a 3/4” 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. chamber.
Pilot Maintenance Burner Cleaning Procedure (cont’d) Step 12. Reassemble the burner assembly and reinstall into the water heater. Restore gas supply and check for gas leaks. Step 13. To resume operation, follow the instructions located on the water heater lighting instruction label. Or, use the lighting instructions located in the water heater installation and operating manual. Pilot Inspection, Testing and Replacement Step 1.
Pilot Maintenance Pilot Inspection, Testing and Replacement (cont’d) Step 7. Disconnect the spark igniter/flame sensor wire from gas control. 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.
Damper Replacement Pilot Inspection, Testing and Replacement (cont’d) 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.
Damper Replacement Damper Removal & Installation (cont’d) Step 3. Disconnect the vent system from the draft hood that is mounted on top of the damper. Vent system Step 4. Remove the draft hood from the damper and retain it for use on the new damper. Draft hood Damper Step 5. Unplug the cord sets from the damper. Cord sets Step 6. Remove the two damper mounting screws using a 1/4” nut driver and retain for later use. 1/4” nut driver Step 7. heater.
Thermal Well Testing Damper Removal & Installation (cont’d) Step 13. Reconnect the cord sets from Step 5. Step 14. Plug the water heater into the wall outlet. Step 15. Move the gas control power switch to the “ON” position. Step 16. Verify proper damper operation. Thermal Well Testing 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.
Determine Tank Temperature Thermal Well Testing (cont’d) Determine the correct resistance values using the Determine the Water Temperature Inside the Tank procedure on page 23. If the values are correct, replace the gas control, otherwise replace the thermal well. Determine Water Temperature Inside Tank WARNING Stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury.
Component Disassembly Sensor Resistance at Various Temperatures °F 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 0 26109 19906 15314 11884 9299 7333 5827 4663 3758 3048 2488 2043 1688 1402 1170 982 828 1 25400 19383 14925 11592 9078 7165 5697 4562 3679 2986 2439 2004 1656 1376 1150 965 814 2 24712 18876 14548 11308 8862 7000 5570 4464 3602 2925 2391 1966 1625 1351 1129 949 801 3 24045 18383 14180 11032 8653 6839 5446 4368 3527 2866 2344 1928 1595 1327 1110 933 788 In Degrees 4 23399 179
Gas Control Removal Gas Control & Thermal Well Removal From Water Heater (cont’d) Step 4. Disconnect the pilot tube using a 7/16” wrench and the main burner feedline with a 3/4” wrench from the gas control. 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.
Gas Control Assembly Gas Control Removal From Thermal Well (cont’d) Step 3. Turn off the gas supply to the water heater and disconnect the gas piping from the gas control. Step 4. Disconnect the pilot tube using a 7/16” wrench and the main burner feedline with a 3/4” wrench from the gas control. 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.
Gas Control Assembly Gas Control Assembly to the Thermal Well (cont’d) 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.
Flammable Vapor Sensor Testing Gas Control Assembly to the Thermal Well (cont’d) Step 8. To resume operation, follow the instructions located on the water heater lighting instruction label. Or, use the lighting instructions located in the water heater installation and operating manual. Flammable Vapor Sensor Testing 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.
Dip Tube Inspection Dip Tube Inspection and Replacement WARNING Water heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Step 1. Move the gas control power switch to the “OFF” position Step 2. Unplug the water heater from the wall outlet. Step 3. Turn off the cold water supply to the water heater. Connect a hose to the drain valve of the water heater and route to an open drain.
Anode Inspection Anode Inspection and Replacement WARNING Water heater components and stored water may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Step 1. Move the gas control power switch to the “OFF” position Step 2. Unplug the water heater from the wall outlet. Step 3. Turn off the cold water supply to the water heater. Connect a hose to the drain valve of the water heater and route to an open drain.
Damper Removal Remove the Damper to Gain Access to the Flue Baffle Step 1. position. Move the gas control power switch to the “OFF” Gas control power switch Step 2. Unplug the water heater from the wall outlet. Damper (water heater) power cord Step 3. Disconnect the vent system from the draft hood that is mounted on top of the damper. Vent system Draft hood Damper Step 4. Unplug the cord sets from the damper. Cord sets Step 5.
Damper Removal Remove the Damper to Gain Access to the Flue Baffle (cont’d) Step 6. heater. Remove the damper from the top of the water Damper Top of water heater Water heater tank flue Step 7. Remove the flue baffle from the water heater. Step 8. Inspect the baffle for deterioration and missing restrictors. Clean any scale or debris build-up. Replace with a new baffle, as necessary. Step 9. Reinstall the baffle into the flue.
Inner Door Removal Inner Door Removal Procedure Step 1. position. Move the gas control power switch to the “OFF” Gas control power switch Step 2. Unplug the water heater from the wall outlet. Damper (water heater) power cord Step 3. Remove the outer door. Outer door Step 4. Remove (4) 1/4” hex drive screws from the right side inner door. (4) 1/4” hex drive screws Step 5. Remove (2) 1/4” drive screws from the left side inner door. Step 6.
Inner Door Gasket Replacement Inner Door Removal Procedure (cont’d) Step 7. Inspect both inner doors for any of the following imperfections: tears, missing material, cracks, dirt or debris, lack of adhesion to the inner door, material left on combustion chamber, or any other imperfections that will inhibit a proper seal. If any of the imperfections above are present, replace the inner door gasket following the Inner Door Gasket Replacement Procedure.
Inner Door Installation Inner Door Installation with Gasket WARNING Stripped fastener connections may allow for an inner door seal breach. A seal breach may result in a fire or explosion, causing property damage, personal injury, or death. Do not over tighten screws. If a fastener connection is stripped, contact the manufacturer listed Step 1. Clean any residual gasket residue or other debris from the combustion chamber surface before installing the inner door/gasket assembly. Step 2.
Arrestor Cleaning ScreenLok® Flame Arrestor Cleaning Procedure Step 1. Move the gas control power switch to the “OFF” position and unplug the water heater from the wall outlet. Step 2. Remove the outer door. Step 3. Remove the right side inner door per the Inner Door Removal Procedure on page 32. Step 4. Disconnect the pilot tube using a 7/16” wrench and the main burner feedline with a 3/4” wrench from the gas control. Step 5. Disconnect the spark igniter/flame sensor wire from gas control. Step 6.
Damper Relay Installation Damper Relay Installation (cont’d) Step 2. Unplug the water heater from the wall outlet. Damper (water heater) power cord Step 3. Disconnect the vent system from the draft hood that is mounted on top of the damper. Vent system Draft hood Damper Step 4. damper. Remove the draft hood from the damper and retain it for use on the new Step 5. Unplug the cord sets from the damper. Cord sets Step 6.
Damper Relay Installation Damper Relay Installation (cont’d) Step 9. Turn the damper on its side and lay it on top of the water heater. Step 10. Remove the Red wire in the damper housing from its location. Connect the 1/4” Red female connector on the relay harness in its place. Step 11. Remove the Yellow wire in the damper housing from its location. Connect the 1/4” Yellow female connector on the relay harness in its place. White Wire Blue Wire Yellow Wire Red Wire Step 12.
Common Terms Common Terms BTU ECO GPM Hz KWh LED NPT Ohms PSI RPM VAC W.C.
Parts List 1 2 5 3 6 7 8 9 4 10 11 18 17 19 14 20 16 21 23 22 27 26 12 15 24 13 25 15A PART NAME AND DESCRIPTION 1. Draft Hood 15. Inner Door (Right) 2. Damper 15A. Resettable Thermal Switch 3. Jacket Head Pan 16. Inner Door (Left) 4. Jacket 17. Damper Wire Harness 5. Heat Trap—Cold Water Inlet 18. Thermal Well 6. Magnesium Anode–Hot Water Outlet 19. Gas Control Valve 7. Heat Trap—Cold Water 20. Wire Harness (FVS / RTS) 8. Flue Baffle Assembly 21. FVS Sensor Clip 9.
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