SERVICE MANUAL - Bradford White
Contents
1. BRADFORD WHITE WATER HEATERS Super High Efficiency Atmospheric Vent Gas Water Heaters SERVICE MANUAL Troubleshooting Guide and Instructions for Service To be performed ONLY by qualified service providers Models Covered by This Manual HE440S F BN SX HE450S F BN SX Denotes Warranty Years SAVASIW SYSTEM wa en k a htl Manual 238 50216 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 15 Burner Inspection Burner Cleaning Procedure Pilot Maintenance 17 Pilot Inspection Testing and Replacement Blower Replacement 19 Temperature Sensor Testing 21 Determine Water Temperature Inside Tank 23 Gas Control Removal 25 Gas Control Disassembly Assembly 26 Flammable Vapor Sensor Testing 27 120 VAC Circuit Trace 28 Diptube Inspection 28 Anode Inspection 29 Blower Removal 30 Inner Door Removal 32 Inner Door Gasket Replacement 33 Inner Door Installation 34 Pressure Switch Testing amp Replacement 35 Arrestor Cleaning 37 Common Terms 38 Notes 38 Parts List 39 2 E BRADFORD WHITE WATER HEATERS N WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage perso2. OFF position Gas control power Switch Step 2 Unplug the water heater from the wall outlet Blower water heater power cord Vent system step 3 Disconnect the vent system from the draft hood that is mounted on top of the blower Step 4 Unplug the cord sets from the blower otep 5 Remove the 3 blower mounting screws using a 1 4 nut driver and retain for later use 1 4 nut driver 30 EE BRADFORD WHITE Blower Removal Remove the Blower to Gain Access to the Flue Baffle contd Step 6 heater Step 7 Remove the flue baffle from the water heater Step 8 Inspect the baffle for deterioration and missing restrictors Clean any scale or debris build up Replace with a new baffle as necessary Step 9 Reinstall the baffle into the flue Be sure the baffle hanger tab is inserted into the notch locations at the top of the flue Step 10 Check the burner to ensure no scale has accumulated during operation see the Burner Cleaning Procedure on page 15 if accumulation has occurred Step 11 secure the blower in place using the screws from Step 5 Step 12 Reconnect the vent system to the draft hood Step 13 Reconnect the cord sets from Step 4 Step 14 Plug the water heater into the wall outlet Step 15 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 oper
3. Sequence of Operation 1 Start up Upon power up the gas control runs a safe start check with a typical delay of 5 seconds Power Up Sequence 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 blower the gas control verifies the safety circuit to see if it is in the correct state Normal switch positions in the safety circuit are as follows A Pressure switch normally open B Blower temperature switch normally closed 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 blower is energized for 30 seconds This cycle repeats until the safety circuit opens 2 Blower Energizes 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 blower runs 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 Blower Pre Purge 15 seconds 5 Trial for Pilot Ignition 90 seconds The gas control lights the p
4. three flashes three second pause Gas control electronics fault detected Eight flashes four flashes three second pause Gas control fault detected 1 Vent blockage or improper vent configuration 2 Pressure switch tubing kinked or blocked 3 Faulty pressure switch 4 Blower not spinning up to speed 5 Damper inside blower not fully opening 6 Faulty blower temperature switch 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 pressure Pilot valve stuck in open position 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 25 000 Ohms 2 Possible short in flammable vapor sensor or resettable thermal switch 1 Damage to temperature sensor wires 2 Temperature sensor resistance out of range 3 Replace temperature sensor 1 Verify control is not wet or physically damaged 2 Reset control on off switch 3 Replace gas control if 8 3 error persists 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 See Burner Inspect
5. 120 VAC Circuit Trace 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 Step 4 Using a multi meter set to the ohms setting measure the resistance of the resettable thermal switch between the left two pins of the wire harness The resistance must be between 3 000 and 48 000 ohms for both the switch and sensor If the resistance is out of this range verify that the resettable thermal switch has not been tripped If it hasn t replace the thermal switch 120 VAC Circuit Trace 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 Dip Tube Inspection and Replacement N 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 Open a nearby hot water faucet to vent the water heater for draining Open the drain valve of water heater and allow the water heater to drain to a point below the inlet connection nipple Step 4 Disconnect the
6. use the lighting instructions located in the water heater installation and operating manual Pilot Inspection Testing and Replacement Step 1 Move the gas control power switch to the OFF position Gas control power switch Step 2 Unplug the water heater from the wall outlet Blower water heater power cord Step 3 Turn off the gas supply to the water heater Step 4 Remove the outer door Step 5 Remove the 4 1 4 hex drive screws holding the right side inner door in place A Right side inner door Step 6 Disconnect the pilot tube using a ane wrench and the main burner fs control al Pilot and main feed lines BRADFORD WHITE 17 WATER HEATERS Pilot Maintenance Pilot Inspection Testing and Replacement cont d Step 7 Disconnect the spark igniter flame sensor wire from 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 Se 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 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 Step 12 Visually inspect the spark ig
7. Blower 17 Blower Wire Harness 5 Heat Trap Outlet 18 Feedline 6 Magnesium Anode Hot Water Outlet 19 Gas Control Valve 20 Wire Harness FVS RTS 21 FVS Sensor Clip 22 Flammable Vapor Sensor FVS 23 Outer Door 24 Steel Burner 25 Orifice 26 Pilot Assembly 7 Heat Trap Inlet 8 Flue Baffle Assembly 9 Dip Tube Cold Water Inlet 10 Temperature and Pressure Relief Valve 11 Glass Lined Tank 12 Combustion Chamber Assembly 13 Jacket Base Pan 14 Drain Valve BRADFORD WHITE WATER HEATERS Ambler PA For U S and Canada field service contact your professional installer or local Bradford White sales representative Sales 800 523 2931 Fax 215 641 1670 Parts Fax 215 641 2180 Technical Support 800 334 3393 Fax 269 795 1089 Warranty 800 531 2111 Fax 269 795 1089 International Telephone 215 641 9400 Telefax 215 641 9750 ts BRADFORD WHITE CANADA INC Mississauga ON Sales 866 690 0961 905 238 0100 Fax 905 238 0105 Technical Support 800 334 3393 Email parts bradfordwhite com techserv bradfordwhite com www bradfordwhite com
8. Step 1 Move the gas control power switch to the OFF position Gas control power switch Step 2 Unplug the water heater from the wall outlet Blower water heater power cord BRADFORD WHITE ee eee ee ee eee O Blower Replacement Blower Removal amp Installation cont d step 3 Disconnect the vent system from the draft hood that is mounted on top of the blower Step 4 Remove the draft hood from the blower and retain it for use on the new blower Step 5 Unplug the cord sets from the blower Step 6 Remove the three blower mounting screws using a Ie 1 4 nut driver and retain for later use 1 4 nut driver step 7 Remove the blower from the top of the water heater Top of water heater Step 8 Clean any debris from the jacket head of the water heater Step 9 set the new blower in place using the water heater tank flue and the screw holes in the jacket head Step 10 secure the blower in place using the screws from Step 6 Step 11 Re install the draft hood from Step 4 Step 12 Reconnect the vent system to the draft hood 20 BRADFORD WHITE Temperature Sensor Testing Blower Removal amp Installation cont d Step 13 Reconnect the cord sets from Step 5 Step 14 Plug the water heater into the wall outlet Step 15 To resume operation follow the instructions located on the water heater lighting instruction label Or use the lighting instructions located i
9. 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 blower is running If flame is present when the pilot valve is not open the gas control continues 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 BRADFORD WHITE Observe the green LED on the water heater gas control Error Bo codes are displayed with a 3 second pause before repeating pr Once the error code is known check and repair the water heater E as recommended in the table below aen Troubleshooting LED Status Control Status Probable Cause None LED not on or flashing One short flash every four seconds One short flash every two seconds Alternates bright and dim heartbeat Short flash once every second Two flashes three second pause Three flashes three second pause Four flashes three second pause Five flashes three second pause Six flashes one flash three second paus
10. plugged in 2 See Pressure Switch Testing and Replacement on page 35 1 Temperature sensor out of 1 Test Gas Control amp Temperature calibration Sensor 2 Faulty gas control 2 Replace gas control if necessary Fase plo te n valve stuck in open position Replace gas control present Failed to light pilot system resets after 5 minutes 1 Unstable pilot 2 Pilot tube block or restricted 1 See Burner Inspection on page 3 Oxidation build up on pilot 15 electrode 2 4 See Pilot Inspection Testing 4 Wire damage to pilot assembly or and Replacement on page 17 bad connection at gas valve BRADFORD WHITE nS Troubleshooting LED Status Control Status Probable Cause Pressure switch or Six flashes two blower temp switch flashes three opened during second pause burner operation Soft Lockout system auto resets after 5 minutes Pilot flame extinguished system auto resets after 5 minutes Six flashes three flashes three second pause Soft Lockout Undesired false pilot flame sensed system auto resets Six flashes four flashes three second Flammable vapor sensor or resettable thermal switch fault detected see warning label Seven flashes three second pause Flammable vapor sensor out of specification possible short Eight flashes one flash three second pause Eight flashes two flashes three second pause Temperature sensor fault detected Eight flashes
11. 1 4 hex drive screws removed in Step 5 of the Inner Door Removal Procedure on page 32 secure the left side inner door in place Do not over tighten the screws Step 3 Position the pilot tube and spark igniter wire against the left side inner door flange gasket Do not route these through the concave channel with the feedline Step 4 Firmly place the right side inner door flange against the left side inner door flange Step 5 Using the 1 4 hex drive screws removed in Step 4 of the Inner Door Removal Procedure on page 32 secure the two flanges together Do not over tighten the screws Step 6 Align the right side inner door to the combustion chamber and verify the fastener holes of the combustion chamber are aligned with the right side inner door slotted openings Verify seal integrity around the combustion chamber opening Step 7 Using the 1 4 hex drive screws removed in Step 4 of the Inner Door Removal Procedure on page 32 secure the right side inner door Do not over tighten the screws Verify that both the left and right side inner doors are properly positioned and sealed against the combustion chamber Step 8 Re install the outer door Step 9 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 34 E BRADFORD WHITE Pressure Switch Testing Step 1 Move the gas cont
12. 43 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 999 190 982 965 949 933 917 901 886 871 857 842 200 828 814 801 788 775 762 749 737 125 713 24 BRADFORD WHITE Gas Control Removal Gas Control Removal Step 1 Move the gas control power switch to the OFF position Gas control power Step 2 Unplug the water heater from the wall outlet Blower water heater power cord 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 E WY j Step 4 Disconnect the pilot tube using a 7 16 wrench and the main burner f feedline with a 3 4 wrench from the gas 4 gt control a Pilot and main feed Step 5 Disconnect the wire harnesses and spark igniter flame sense wire from the gas control Spark igniter flame sensor wire Wire harnesses Step 6 Spin the gas control out of the water heater tank BRADFORD WHITE ee ee ee ee ee ee eee eee O Gas Control Assembly Gas Control Disassembly Assembly Following the steps below allows for the removal of the gas control from the temperature sensor well without removing the temperature se
13. ater heater Connect a hose to the drain valve of the water heater and route to an open drain Open a nearby hot water faucet to vent the water heater for draining Open the drain valve of water heater and allow the water heater to drain to a point below the outlet connection nipple Step 4 Disconnect the outlet nipple from the plumbing system Step 5 With an appropriate tool such as a pipe wrench remove the outlet nipple anode from the water heater Use caution not to damage the pipe threads Step 6 Visually inspect the outlet nipple anode The outlet nipple anode should show signs of depletion which is normal If depletion is one half the original anode diameter approximately 3 4 diameter replacement is recommended If any of the steel core of the anode is exposed replacement is recommended Step 7 Upon completion of the inspection or subsequent replacement reinstall the outlet nipple anode into the water heater Connect the nipple to the plumbing system resume water supply to the water heater refill the water heater and check for 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 operating manual BRADFORD WHITE Ge ee ee ee ee eee O Blower Removal Remove the Blower to Gain Access to the Flue Baffle Step 1 Move the gas control power switch to the
14. ating manual BRADFORD WHITE eC Inner Door Removal Inner Door Removal Procedure Step 1 Move the gas control power switch to the OFF position Gas control power switch Step 2 Unplug the water heater from the wall outlet Blower water heater power cord Step 3 Remove the outer door Step 4 Remove 4 1 4 hex drive screws from the right f side inner door a p 4 1 4 hex arive ORS A screws _ E Right side inner door Left side inner door Step 5 Remove 2 1 4 drive screws from the left side inner door 1 4 hex drive screws Step 6 Remove the connectors attached to the resettable thermal switch on the right side inner door Connectors attached to reset table thermal switch 32 M BRADFORD WHITE 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 If not replacement of the inner door gaskets is not necessary Inner Door Gasket Replacement Procedure N WARNING If the information in these instructions is not follo
15. e Soft Lockout Electrical power not present Stand by mode Thermostat is satisfied no faults Control power switch in OFF position Turn Power On Supply voltage interrupted Temperature demand is satisfied higmaalbeneration no call for heat P Stand by mode Temperature on Setback Control is Sabbath mode no jadjusted down to prevent burner Normal operation faults operation Tank temperature below setpoint of Nomaaleweration thermostat P Thermostat calling for heat no fault Weak pilot signal on last call for heat Pressure switch not working closed position Pressure switch or temperature switch not working open position Excessive tank temperature system must be reset False pilot flame 1 Unstable pilot 2 Pilot tube blocked or restricted 1 See Burner Inspection on page 3 Oxidation build up on pilot 15 electrode 2 4 See Pilot Inspection Testing 4 Wire damage to pilot assembly or and Replacement on page 17 bad connection at gas control 1 Pressure switch tubing kinked or blocked 2 Blocked pressure tap on switch or blower 3 Faulty pressure switch See Pressure Switch Testing and Replacement on page 35 1 Vent blockage or improper vent configuration 2 Pressure switch tubing kinked or blocked 3 Faulty pressure switch 4 Blower not spinning up to speed 5 Damper inside blower not fully opening 6 Faulty blower temperature switch 1 Verify cord sets are fully
16. e very bottom of the corrosion resistant combustion chamber bottom The air then travels up through the flame arrestor louvers where the velocity of the air 1s increased and its direction altered The air then mixes in a normal manner with supplied gas and is efficiently combusted producing very low NO 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 BRADFORD WHITE E 5 How to Use this Manual 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 How to Use this Manual 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 Super High Efficiency atmospheric gas water heaters Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting the water heater The Honeywell WV4462 Electronic Gas Control will display error codes in the event of abnormal operation Error codes are listed in the troubleshooting chart beginning on pa
17. emperature 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 Pressure Switch Blower Temperature Switch Safety Circuit Fault A Pressure Switch Closed at Start of Call for Heat The gas control proceeds to flash 2 times with a 3 second pause The gas control waits 2 minutes and then turns the blower on for 60 seconds The blower turns off after 60 seconds and the control waits for the pressure switch to open B Pressure Switch Failed to Close The gas control runs the blower for 60 seconds waiting for the pressure switch to close If the switch does not close in 60 seconds the blower turns off and the control flashes 3 times with a 3 second pause The gas control waits two minutes before turning on the blower for another 60 seconds to see the circuit close This cycle repeats as long as there is a call for heat or until the circuit closes C N Pressure Switch Blower Temperature Switch Opens During Burner Operation The gas control turns off the pilot and main valve and runs the blower for 15 seconds inter purge waiting for the pressure switch and or blower temperature switch to close If either switch fails to close the control proceeds as described i
18. ers common amp needle nose socket set side cutters wire cutters wire strippers wire crimpers torpedo level small shop vac step ladder flashlight and 5 gallon pail 6 BE BRADFORD WHITE Specifications Power Supply Dedicated 120VAC 60 Hz 15A Minimum 1 2 Schedule 40 black iron pipe Gas Supply Pipe recommended Approved Gas Type Natural or Propane unit must match gas type supplied 5 w c minimum for Natural Gas 11 w c for Propane Gas Pressure 14 w c maximum for Natural Gas Propane Approved Vent Materials Single or Double Wall Metal Vent Pipe Recommended Minimum _ 18 from top 24 from front 4 from sides and rear Clearance for Servicing 150 psi maximum allowable working pressure check local Water Supply Pressure codes for supply pressure ECO Limit 188 F 87 C P itch Setti ressure mi ch Setting 020 wee normal altitude Temperature Setpoint Range 60 F 16 C to 160 F 71 C approximate temperatures BRADFORD WHITE E T Specifications Control Timings Flame Stabilization Period 3 seconds 1 5 seconds 2 second maximum 1 second mini Flame Failure Response Time mum Indefinite self clears if fault clears for at least 15 Hardware Error Lockout seconds Wiring Diagram TEMPERATURE BLOWER SWITCH BLOWER MOTOR PRESSURE SWITCH FLAMMABLE RE SETTABLE VAPOR SENSOR THERMAL SWITCH BRADFORD WHITE WATER HEATERS
19. essure switch Verify the switch setting of the replacement switch matches the original switch s setting Step 12 Remove both terminals from the pressure switch Step 13 Connect both terminals to the new pressure switch Step 14 Place the pressure switch into the blower junction box Step 15 Align the pressure switch and install the 2 screws removed in Step 7 Step 16 Re install the blower junction box cover Step 17 Re install the 3 screws removed in Step 4 Step 18 Re install the pressure switch tubing Step 19 Reconnect the cord sets from Step 3 Step 20 Plug the water heater into the wall outlet 36 EE BRADFORD WHITE Arrestor Cleaning Step 21 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 Pressure Switch Testing amp Replacement cont d 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 Remove the burner a
20. formance 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 Ifa 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 Please read the service manual completely before attempting service on this new series of super high efficiency gas models How the 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 th
21. ge 13 of this service manual The troubleshooting chart will also indicate the probable cause for the error 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 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 amp Phillips torx bits 1 4 nut driver pli
22. hermostat Satisfies Gas control LED flashes once every 4 seconds 9 Burner Off 10 Blower Postpurge 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 with a 3 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 240 ohms The gas control immediately turns off all outputs and proceeds to flash 8 times then 1 time with a 3 second pause The error self clears if the resistance returns to normal range for at least 15 seconds aa BRADFORD WHITE 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 2 times with a 3 second pause The error self clears if the fault clears for at least 15 seconds B Temperature sensors not reading the same temperature within 5 F The gas control immediately turns off all outputs and proceeds to flash 8 times then 2 times with 3 second pause The error self clears if the fault clears for at least 15 seconds C Water T
23. his 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 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 4 E BRADFORD WHITE 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 Super High Efficiency atmospheric vent gas water heaters are designed to provide reliable per
24. ilot 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 blower will postpurge and the gas control LED flashes 6 times then 1 time 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 BRADFORD WHITE e 9 Sequence of Operation Normal Heating Sequence cont d 7 Steady State Operation During steady state operation the gas control monitors Temperature Sensor When the setpoint temperature is satisfied the gas control is shutdown and the blower will postpurge for 15 seconds The gas control LED flashes a short flash once every 4 seconds Idle status code Pressure Switch Blower Temperature Switch If either switch opens the pilot and main valves are shutdown The blower continues to run for 30 seconds attempting to close the 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 blower runs for 15 seconds The gas control attempts to re light the pilot 4 times If unsuccessful the blower is shutdown 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 T
25. ing the resistance value of temperature sensor BRADFORD WHITE EK 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 heater to drain Step 3 Using the chart below determine the correct resistance value for the water temperature from Step 2 Example lf temperature of water 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 5 6 7 8 9 40 26109 25400 24712 24045 22771 22163 21573 21000 20445 50 19906 19383 18876 18383 17440 16990 16553 16128 15715 60 15314 14925 14548 14180 13477 13140 12812 12494 12185 70 11884 11592 11308 11032 10502 10248 10000 9760 9526 80 9299 9078 8862 8653 8250 8057 7869 7685 7507 90 1339 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 26
26. inlet nipple from the plumbing system Step 5 With an appropriate tool such as a pipe wrench remove the inlet nipple diptube from the water heater Use caution not to damage pipe threads Step 6 Visually inspect the inlet nipple diptube The inlet nipple diptube should be free of cracks and any blockage Hydro jet slots should be open and free of any blockage Any damage such as cracks restriction due to deformation or unintentional holes are not field repairable and the inlet nipple diptube must be replaced 28 E BRADFORD WHITE Anode Inspection Step 7 Upon completion of the inspection or subsequent replacement reinstall the inlet nipple diptube into the water heater Connect the nipple to the plumbing system resume water supply to the water heater refill the water heater and check for leaks Dip Tube Inspection and Replacement 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 Anode Inspection and Replacement N 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 w
27. ion on page 15 2 4 See Pressure Switch Testing and Replacement on page 35 1 See Burner Inspection on page 15 2 4 See Pilot Inspection Testing and Replacement on page 17 5 Refer to Installation amp Operation Manual Replace gas control See Flammable Vapor Sensor Testing on page 27 See Flammable Vapor Sensor Testing on page 27 See Temperature Sensor Testing on page 21 See Gas Control Removal on page 25 1 Replace gas control if wet or physically damaged 2 Cycle power 3 Replace gas control 14 BRADFORD WHITE HEATERS Burner Maintenance 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 Burner Inspection 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 below Burner Cleaning Procedure Step 1 Move the gas control power switch to the OFF position Gas control power switch Step 2 Unplug the water heater fro
28. m the wall outlet Blower water heater power cord Step 3 Turn off the gas supply to the water heater Step 4 Remove the outer door BRADFORD WHITE eee eee eee eee 16 Burner Maintenance Burner Cleaning Procedure cont d Step 5 Remove the 4 1 4 hex drive screws holding the f 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 Step 7 Disconnect the spark igniter flame sensor wire from gas control Step 8 Remove the burner assembly from the combustion M chamber 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 Main burner orifice 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 wrenc BRADFORD WHITE WATER HEATERS Pilot Maintenance Step 12 Reassemble the burner assembly and reinstall into the water heater Restore gas supply and check for gas leaks Burner Cleaning Procedure cont d Step 13 To resume operation follow the instructions located on the water heater lighting instruction label Or
29. n 3B above If the circuit closes again by the end of the inter purge the recycle counter is incremented 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 turns off the blower and flashes 6 times then 2 times with a 3 second pause The gas control waits 5 minutes before repeating the ignition sequence BRADFORD WHITE ee eee eee ee eee ee ee ee eee Sequence of Operation Abnormal Operation cont d 4 Trial for Ignition Fault A Pressure Switch Blower Temperature Switch Opens During Trial The gas control stops the trial for ignition The gas control monitors the pressure switch until it closes If the pressure switch closes within 30 seconds the gas control will continue with the trial for ignition starting at blower pre purge B N 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 and the gas control runs the blower through postpurge The gas control LED flashes 6 times then 1 time with 3 second pause The control waits 5 minutes before repeating the ignition sequence 5 Flame Sensing Fault A Flame Lost During Run The gas control turns off pilot and main valves and runs the blower for 15 seconds inter purge The gas control increments the recycle count if the recycle
30. n the water heater installation and operating manual Temperature Sensor Testing N CAUTION Do not use standard multi meter probes for this testing Doing so will damage the con nector Use special pin type electronic probes or small diameter wire pins inserted into connector 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 Move the gas control power switch to the OFF position Gas control power switch Step 2 Unplug the water heater from the wall outlet Blower water heater power cord BRADFORD WHITE ee es Temperature Sensor Testing Temperature Sensor Testing cont d Step 3 Disconnect the spark igniter from the gas control Gas control Spark igniter flame sensor wire Step 4 Disconnect the gas control power harness from the bottom of the control Gas control power harness Step 5 Disconnect the flammable vapor sensor resettable thermal switch FVS RTS harness from the bottom of the control FVS RTS harness Step 6 Using a slotted screwdriver remove the screw holding the cover on at the bottom of the gas control Slotted screwdriver Step 7 Depress both tabs on the top of the gas control cover and pull to rem
31. nal injury or death What to do if you smell gas e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e 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 N 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 N 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
32. niter 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 _ I axx Ey BRADFORD WHITE Blower 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 a a assembly using a 7 16 wrench il orifice hood b Remove the pilot tube and pilot orifice y J bi gt c Inspect the pilot tubing and pilot orifice for owe blockages Clean or replace as necessary Igniter flame igniter flame sense wire sense electrode Step 16 Reassemble 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 operating manual Blower Removal amp Installation
33. nsor 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 from the wall outlet Blower water heater power cord 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 fs feedline with a 3 4 wrench from the gas f gt control Aa Pilot and main feed lines Step 5 Disconnect the wire harnesses and spark igniter flame sense wire from the gas control Gas control 26 E BRADFORD WHITE Flammable Vapor Sensor Testing Gas Control Disassembly Assembly cont d otep 6 Using a slotted screwdriver or a T 15 torx i remove the screw holding the cover on at the bottom of the gas ijl control Slotted screwdriver Step 7 Depress both tabs on the top of the gas control cover and pull to remove Step 8 Disconnect the temperature sensor wire harness from the gas control board Temperature sensor wire harness Flammable Vapor Sensor Testing step 1 Move the gas control power switch to the OFF pai position Gas control power switch Step 2 Disconnect the flammable vapor sensor resettable thermal switch FVS RTS harness from the gas control FVS RTS harness BRADFORD WHITE Se ee ee ee eee ee eee eee WATER HEATERS
34. ove Step 8 Disconnect the temperature sensor wire harness from the gas control board Temperature sensor wire harness 22 BRADFORD WHITE Determine Tank Temperature Temperature Sensor Testing cont d CAUTION Do not use standard multi meter probes for this testing Doing so will damage the con nector Use special pin type electronic probes or small diameter wire pins inserted into connector Step 9 With a multi meter set to the ohms setting measure the resistance between the middle and right side wires Multi meter leads Step 10 With a multi meter set to the ohms setting measure the resistance between the middle and left side wires Multi meter leads Determine the correct resistance values using the Determine the Water Temperature Inside the Tank procedure below If the values are correct replace the gas control otherwise replace the temperature sensor Determine Water Temperature Inside Tank N 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 temperature sensor is determined using the Temperature Sensor Testing Procedure on page 21 water flow through the water heater should not occur Prior to performing the steps below turn off the cold water supply to the water heater This will prevent cold water flow into the tank affect
35. rol power switch to the OFF position Gas control power switch Step 2 Unplug the water heater from the wall outlet Blower water heater power cord Pressure Switch Testing amp Replacement Step 3 Unplug the cord sets from the blower Slotted screwdriver Step 4 Using a slotted screwdriver remove the 3 ae screws one on the backside of the junction box is not shown Se holding the end of the blower junction box on Retain the screws for later use Bioneriuncion bos K a Step 5 Remove the pressure switch tubing from the hoas pressure switch cS Pressure switch tubing gt ay Step 6 Carefully pull out and lower the blower junction box cover Junction box cover BRADFORD WHITE Seer eee Pressure Switch Testing Pressure Switch Testing amp Replacement cont d Step 7 Using a slotted screwdriver remove the 2 screws holding the pressure to the blower junction box Retain the screws for later use Step 8 Pull the pressure switch out of the junction box Pressure switch Step 9 Using a multi meter check the resistance across the pressure switch terminals There should be no electrical continuity meaning the switch is open Multi meter leads Step 10 If the switch is open check the pressure switch jas tubing and pressure tap on the switch for a blockage Clear the blockage if one is present Step 11 If there is not a blockage replace the pr
36. ssembly from the combustion chamber step 7 Clean the ScreenLok flame arrestor using a stiff brush compressed air and or a shop vacuum to remove any scale or other debris accumulation Using a soft brush clear jacket openings from any dirt dust restrictions or other obstructions Step 8 Remove any debris from the burner assembly following the Burner Cleaning Procedure on page 15 Step 9 Re install the burner assembly Step 10 Reconnect the main and pilot tubing and spark igniter wire to the gas control Step 11 Re install the inner door per the Inner Door Installation with Gasket Procedure on page 34 Step 12 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 BRADFORD WHITE Seer eee ee eee ee eee ee 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 ge Degrees Centigrade aF Degrees Fahrenheit NOTES 38 me BRADFORD WHITE Parts List PART NAME AND DESCRIPTION 1 Draft Hood 15 Inner Door Right 2 Jacket Head Pan 15A Resettable Thermal Switch 3 Jacket 16 Inner Door Left 4
37. the water heater was purchased or the manufacturer listed on the rating plate for replacement parts BRADFORD WHITE E 3 N 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 t
38. wed exactly a fire or explosion may re Sult causing property damage personal injury or death Step 1 Completely remove all gasket and adhesive residue from the right and left side inner doors as needed Gasket Overlap must be as shown 1 32 Enlarged Step 2 Using RTV sealant apply a 1 8 bead to secure view of the inner door gasket to the inner door sections Refer to the flange area illustration for proper application Note the overlap configuration in the flange area of the inner door Set the flange section first and this will help to achieve the proper overlap position Recommended pattern for RTV sealant aie Gasket Overlap must be as Expanded view shown 1 32 BRADFORD WHITE WATER HEATERS 33 Inner Door Installation Inner Door Installation with Gasket N 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 on the water heater rating plate Step 1 Clean any residual gasket residue or other debris from the combustion chamber surface before installing the inner door gasket assembly otep 2 Place the left side inner door into position first being sure to firmly position the concave channel of the inner door around the feedline Step 3 Using the
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