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Manual 238-48494-00A

SERVICE

MANUAL

SUPPLEMENT

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Models Covered

by This Manual:

PE4403S*F(BN,SX)

PE440T*F(BN,SX)

PE4503*F(BN,SX)

PE2XR504T*F(BN,SX)

(*) Denotes Warranty Years

Gas Water Heaters

Programmable Efficiency

Summary of Contents for PE2XR504T Series

Page 1: ...SUPPLEMENT Troubleshooting Guide and Instructions for Service To be performed ONLY by qualified service providers Models Covered by This Manual PE4403S F BN SX PE440T F BN SX PE4503 F BN SX PE2XR504T...

Page 2: ...t Maintenance _________________________________________ 19 Pilot Inspection Testing and Replacement Thermal Well Testing ______________________________________ 21 Determine Water Temperature Inside Ta...

Page 3: ...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 adapt...

Page 4: ...uefied 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...

Page 5: ...rmal 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 enhanc...

Page 6: ...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...

Page 7: ...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 Servicing 18 from top 24 from front 4 from...

Page 8: ...out 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...

Page 9: ...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 circu...

Page 10: ...out The gas control re attempts to light the pilot starting at Normal Heating Sequence 2 8 Thermostat Satisfies Gas control LED flashes once every 4 seconds 9 Burner Off 10 Relay De energized 15 secon...

Page 11: ...ds 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 minut...

Page 12: ...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...

Page 13: ...rking Faulty relay 1 Verify cord sets are fully plugged in 2 See Relay Replacement on page 28 Three flashes three second pause Relay not working Faulty relay 1 Verify cord sets are fully plugged in 2...

Page 14: ...ammable vapor sensor exposed to excessive moisture 3 Flammable vapor sensor exposed to extreme ambient temperature 4 Resettable thermal switch open See Flammable Vapor Sensor Testing on page 27 Eight...

Page 15: ...ensor out of specification x 63 Ignition successful but flame lost during run cycle Soft lockout x 64 Internal gas valve fault detected x 85 Soft Lockout due to maximum number of recycles exceeded las...

Page 16: ...cond pause Leak sensor malfunction 1 Leak Sensor resistor removed 2 Leak Sensor improperly connected to Accessory Module Amber Five flashes and three second pause Gas control missing not connected 1 W...

Page 17: ...rner 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 Th...

Page 18: ...from the combustion chamber Step 9 Thoroughly inspect the burner surface area and burner port area and remove any loose debris Step 10 Unscrew the burner from the main burner orifice Step 11 Remove th...

Page 19: ...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 Step 2 Unp...

Page 20: ...amber Step 9 Remove the pilot assembly from the main feedline using a 1 4 nut driver Step 10 Visually inspect the spark igniter flame sense wire for damage Replace the pilot assembly if damage is foun...

Page 21: ...of the pilot assembly using a 7 16 wrench b Remove the pilot tube and pilot orifice c Inspect the pilot tubing and pilot orifice for blockages Clean or replace as necessary Step 16 Re assemble the pil...

Page 22: ...ter 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 Temperatu...

Page 23: ...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 1024...

Page 24: ...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...

Page 25: ...s 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 Step 5 Disconnect the wire harnesses and spark ig...

Page 26: ...ow 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 Step 3 Align the slots located on the thermal well flange wit...

Page 27: ...nstallation 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 Step 1 Move t...

Page 28: ...ddition 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 sw...

Page 29: ...nect the 4 wires attached to the relay Step 6 Remove the relay from its socket Step 7 Install the new relay p n 233 47642 00 Step 8 Re connect the wires removed in Step 5 to their proper locations Ste...

Page 30: ..._______________________________________________________ ____________________________________________________________ ____________________________________________________________ ______________________...

Page 31: ...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 B...

Page 32: ...Email parts bradfordwhite com techserv bradfordwhite com www bradfordwhite com...

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