Bradford White D4403S*F(BN User manual

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Manual 238-48385-00A
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
Gas Water Heaters
Residential Flue Damper
®

Page 2
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
Damper Replacement______________________________________ 19
Thermal Well Testing ______________________________________ 21
Determine Water Temperature Inside Tank_____________________ 22
Component Disassembly ___________________________________ 23
Gas Control Removal ______________________________________ 24
Gas Control Assembly _____________________________________ 25
Flammable Vapor Sensor Testing_____________________________ 27
120 VAC Circuit Trace _____________________________________ 27
Diptube Inspection ________________________________________ 28
Anode Inspection _________________________________________ 29
Damper Removal _________________________________________ 31
Inner Door Removal_______________________________________ 32
Inner Door Gasket Replacement _____________________________ 33
Inner Door Installation_____________________________________ 34
Arrestor Cleaning _________________________________________ 35
Damper Relay Installation __________________________________ 35
Common Terms __________________________________________ 38
Notes __________________________________________________ 38
Parts List _______________________________________________ 39
2

WARNING
If the information in these instructions is not followed exactly, a fire or explosion may re-
sult 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.
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 connec-
tions. 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 im-
proper and dangerous operation. Verify proper operation after servicing.
DANGER
Do not store or use gasoline or other flammable, combustible, or corrosive vapors and liq-
uids in the vicinity of this or any other appliance.
NOTICE
Before proceeding, please inspect the water heater and its components for possible dam-
age. 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 manufac-
Page 3
3

Page 4
WARNING
Water heaters are heat producing appliances. To avoid damage or injury, do not store
materials against the water heater or any of its components. Use proper care to avoid un-
necessary contact, especially by children, with the water heater and its components. Un-
der no circumstances must flammable materials, such as gasoline or paint thinner be used
orstored 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 rec-
ommend 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 wa-
ter 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 FOL-
LOWING:
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.
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

Page 5
The Bradford White DEFENDER Safety System®
The Bradford White DEFENDER Safety System was designed to resist the ignition of flamma-
ble 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 de-
sign 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 DE-
FENDER Safety System.
Introduction
The new Bradford White Residential Flue Damper water heaters are designed to provide reli-
able performance with enhanced standard features. New design features include reliable spark-
to-pilot ignition system, enhanced diagnostics, simplified servicing, significantly quiet opera-
tion, and the Bradford White Defender Safety System.
Spark-to-Pilot Ignition System - employing the spark-to-pilot ignition system promotes reli-
able 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
damper models.
How the Safety System Works
During normal operation, air for combustion is drawn into the water heater through the open-
ings 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 NOxemissions.
In the unlikely event trace amounts of flammable vapors are present in the air flowing into the
Introduction
5

Page 6
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.
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 Residential Flue Damper water heaters.
Understanding the sequence of operation section of this manual will contribute greatly to trou-
bleshooting the water heater.
The Honeywell WV4460E Electronic Gas Control will display error codes in the event of ab-
normal operation. Error 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 error
code and direct the service professional to a service procedure to properly diagnose the abnor-
mal 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: Adigital 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 elec-
tronic “pin” type multi-meter probes. These probes are available at most electronic wholesale
outlets.
Thermometer: Used to measure water temperature. An accurate thermometer is recommended.
Water Pressure Gage: Used to measure water supply pressure. Also used to determine tank
pressure by adapting to the drain valve of the heater.
Gas Control Service Tool: BWC part number 239-45991-00. A specialized tool designed to
remove the gas control from gas control thermal well. Available from your Bradford White
parts supplier.
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.
How to Use this Manual
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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
Servicing
18” from top; 24” from front; 4” from sides and rear
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
Specifications
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Page 8
Ignition State Timing
Adjust Damper Position and Verify (Open Posi-
tion) 15seconds
Trial for Ignition 90 seconds
Flame Stabilization Period 3 seconds
Re-adjust Damper Position and Verify 15 seconds
Flame Failure Response Time 1.5 seconds (2 second maximum; 1 second mini-
mum)
Adjust Damper Position and Verify (Closed Po-
sition) 15 seconds
Damper Blade Position 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)
Specifications
Wiring Diagram
Control Timings
8

Page 9
Power Up Sequence
1. Start-up: Upon power up, the gas control runs a safe start check with a typical de-
lay 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
7times with a 3 second pause.
Normal Heating Sequence
When the phrase “Damper Open” is used, this means that the damper blade is in the
vertical position (open). Alternatively, “Damper Closed” means that the damper blade
is in the horizontal position (closed). This must not be confused with the phrase
“Damper Circuit Open,” as this means that the damper blade is in the horizontal posi-
tion. “Damper Circuit Closed” means that the damper blade is in the vertical position,
and the water heater can proceed to an ignition trial.
1. Thermostat Calls for Heat: Prior to energizing the damper, the gas control verifies
the damper 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 con-
trol waits 2 minutes. Then, the damper is powered closed. This cycle repeats until
the safety circuit opens.
2. Damper Powered Open
3. Damper Safety Circuit Check: If the damper safety circuit does not close within 30
seconds, the gas control LED flashes 3 times with a 3 second pause. The damper
is powered open for a maximum of 30 seconds every 2 minutes trying to close the
damper safety circuit. This cycle repeats as long as there is a call for heat.
4. Damper 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 damper will remain
open, 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.
Sequence of Operation
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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. The damper is powered open attempting to close
the damper 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 damper
is powered open. The gas control attempts to re-light the pilot 4 times. If unsuc-
cessful, the damper is closed, and the gas control proceeds to a 5 minute lockout.
The gas control re-attempts to light the pilot starting at Normal Heating Sequence
#2.
8. Thermostat Satisfies: Gas control LED flashes once every 4 seconds.
9. Burner Off
10.Damper Powered Closed (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.
Sequence of Operation
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Abnormal Operation (cont’d)
2. Temperature Sensor Fault:
A) Temperature Sensor Open Circuit: The gas control immediately turns off all out-
puts 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 sec-
onds.
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
6seconds before returning to desired temperature setting.
3. Damper Safety Circuit Fault:
A) Damper Failed to Open: The gas control proceeds to flash 3 times with a three
second pause. The gas control waits 5 minutes, and then tries to open the
damper again.
B) Damper Failed to Close: The gas control proceeds to flash 2 times with a three
second pause. The gas control waits 5 minutes, and then tries to open the
damper again.
4. Trial for Ignition Fault:
A) Damper Jostled During Trial: The gas control stops the trial for ignition. The gas
control proceeds to flash 3 times with a three second pause. The gas control
waits 5 minutes, and then tries to open the damper 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 re-
peating the ignition sequence.
Sequence of Operation
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Page 12
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 damper is in the open position. 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.
Sequence of Operation
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LED Status Control Status Probable Cause Service Procedure
None (LED
not on or
flashin
g)
Ele ctrical pow er not
present
Control power switch in "OFF"
position.
Su
pp
l
y
volta
g
einte rru
p
ted.
Turn P ow er On
One short
flash every
four seconds
Stand-by mode,
Thermostat is
satisfied
(
no faults
)
Temperature demand is satisfied
(no call for heat) Normal operation
Alternates
bright and
dim
(
heartbeat
)
Thermostat calling
for heat (no fault)
Tank temperature below
setpoint of thermostat Normal operation
Short flash
once every
second
Weak pilot signal
on last call for heat
1. Unstable pilot
2. Pilot tube blocked or restricted
3. Oxidation build-up on pilot
electrode
4. W ire damage to pilot
assembly or bad connection at
gas control
1. See Burner Inspection on
page 15
2-4. See Pilot Inspection,
Testing and Replacement on
page 17
Tw o fla she s,
three second
pause
Damper test circuit
not working
1. Damper not in proper position
or malfunctioning - stuck in open
position
2. Obstructed venting
3. Faulty damper
1. Verify cord sets are fully
plugged in
2. Verify switch on damper is
in "Automatic" position
3. Verify that damper and
ventin
g
is not obstructed
Three
flashes,
three second
pause
Damper test circuit
not working
1. Damper not in proper position
or malfunctioning - not reaching
full open position
2. Obstructed venting
3. Faulty damper
1. Verify cord sets are fully
plugged in
2. Verify switch on damper is
in "Automatic" position
3. Verify that damper and
ventin
g
is not obstructed
Four flashes,
three second
pause
Excessive tank
temperature,
system must be
reset
1. Thermal well sensor out of
calibration
2. Faulty gas control
1. Test Gas Control & Thermal
Well
2. Replace gas control if
necessar
y
Five flashes,
three second
pause
False pilot flame
present Pilot valve stuck in open position Replace gas control
Six flashes,
one flash,
three second
pause (Soft
Lockout)
Failed to light pilot,
system resets after
(5) minutes
1. Unstable pilot
2. Pilot tube block or re stricted
3. Oxidation build-up on pilot
electrode
4. W ire damage to pilot
assembly or bad connection at
g
as valve
1. See Burner Inspection on
page 15
2-4. See Pilot Inspection,
Testing and Replacement on
page 17
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.
Troubleshooting
Green LED
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Page 14
LED Status Control Status Probable Cause Service Procedure
Six flashes,
two flashes,
three second
pause (Soft
Lockout)
Damper test circuit
not working
properly during
burner operation,
system auto resets
afte r (5) minutes
1. Damper not in proper position
or malfunctioning - damper
moved from full open position
during run cycle
2. Obstructed venting
3. Faulty damper
4. Damper jostled during run
c
y
cle
1. See Burner Inspection
on page 15
2-4. See Pilot Inspection,
Testing and Replacement
on pate 17
Six flashe s,
three
flashes,
three second
pause (Soft
Lockout)
Pilot flame
extinguished,
system auto resets
afte r (5) minutes
1. Unstable pilot
2. Pilot tube block or restricted
3. Oxidation build-up on pilot
electrode
4.Wire damage to pilot
assembly or bad connection at
gas control
5. Insufficient combustion air
6. Insufficient
g
as
p
ressure
1. See Burner Inspection
on page 15
2-4. See Pilot Inspection,
Testing and Replacement
on page 17
5. Refer to Installation &
Operation Manual
Six flashes,
four flashes,
three second
pause
Undesired false
pilot flame sensed,
system auto resets
Pilot valve stuck in open position Replace gas control
Seven
flashes,
three second
pause
Flammable vapor
sensor or
resettable thermal
switch fault
detected, see
warning label
1. Fla mmable va por present
2. Flammable vapor sensor
exposed to excessive moisture
3. Flammable vapor sensor
exposed to extreme ambient
temperature
4. Resettable thermal switch
o
p
en
See Flammable Vapor
Sensor Testing on page 27
Eight
flashes, one
flash, three
second
pause
Flammable vapor
sensor out of
specification,
possible short
1. Flammable vapor sensor out
of specification; verify Flammable
Vapor Sensor (FVS) resistance is
not below 25 k.
2. Possible short in flammable
vapor sensor or resettable
thermal s w itch w irin
g
See Flammable Vapor
Sensor Testing on page 27
Eight
flashes,
three
flashes,
three second
pause
Thermal well sensor
damaged or
unplugged or gas
control electronics
fault detected
1. Damage to thermal well wires
2. Thermal we ll sensor
resistance out of range
3. Re pla ce the rmal w ell
4. Ve rify control is not w et o r
physically da maged
5. Reset control on/off switch
6. Replace gas control if 8-3 error
persists
See Thermal Well Testing
on page 21
Eight
flashes, four
flashes,
three second
pause
Gas control fault
detected
1. Ve rify control is not w et o r
physically da maged
2. Reset control on/off switch
3. Replace gas control if 8-4 error
persists
1. Replace gas control if
wet or physically damaged
2. Cycle power
3. Replace gas control
Troubleshooting
14

Page 15
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 15).
Burner Cleaning Procedure
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 gas supply to the water heater.
Step 4. Remove the outer door.
Burner Maintenance
Gas control power
switch
Damper (water
heater) power cord
Outer door
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Page 16
Burner Cleaning Procedure (cont’d)
Step 5. Remove the (4) 1/4” hex drive screws holding the
right side inner door in place.
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
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 the main burner orifice from the main
feedline using a 1/2” wrench. Inspect the orifice and clean or
replace, if necessary.
Burner Maintenance
(4) 1/4” hex drive
screws Right side
inner door
Pilot and main
feedlines
Spark igniter/flame
sensor wire
Gas control
Burner assembly
Burner surface area
and burner ports
1/2” wrench
Main burner
orifice
Main feedline
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Page 17
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. 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 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.
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 Maintenance
Gas control power
switch
Outer door
(4) 1/4” hex drive
screws Right side
inner door
Pilot and main
feedlines
Damper (water
heater) power cord
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Page 18
Pilot Inspection, Testing and Replacement (cont’d)
Step 7. Disconnect the spark igniter/flame sensor wire from
gas control.
Step 8. Remove the burner assembly from the combustion
chamber.
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 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 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.
Pilot Maintenance
Spark igniter/flame
sensor wire
Gas control
Burner assembly
Pilot assembly
1/4” nut driver
Multi-meter
18

Page 19
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. 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.
Damper Removal & Installation
Step 1. Move the gas control power switch to the “OFF”
position.
Step 2. Unplug the water heater from the wall outlet.
Damper Replacement
Gas control power
switch
Damper (water
heater) power cord
19

Page 20
Damper Removal & Installation (cont’d)
Step 3. Disconnect the vent system from the draft hood
that is mounted on top of the damper.
Step 4. Remove the draft hood from the damper and retain
it for use on the new damper.
Step 5. Unplug the cord sets from the damper.
Step 6. Remove the two damper mounting screws using a
1/4” nut driver and retain for later use.
Step 7. Remove the damper from the top of the water
heater.
Step 8. Clean any debris from the jacket head of the water heater.
Step 9. Set the new damper with in place using the water heater tank flue and
the screw holes in the jacket head.
Step 10 Secure the damper 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.
Damper Replacement
Vent system
Draft hood
Damper
Cord sets
1/4” nut driver
Damper
Top of water
heater
Water heater tank flue
20