SERVICE MANUAL - Bradford White
Contents
1. Does water heater display Is 24VAC present between Check wires for proper operate Increase thermostat N RED and BLACK wire pin termination to control display connections on the back of Are wire terminations connected control display properly to control display Y N Y Check wire Display operates See next page Display operates See next page harness for proper N Replace control board Replace setting if tank is warm control board continuity N Make proper wire terminations BRADFORD WHITE A WATER HEATERS Troubleshooting N CAUTION WARNING Use caution not to damage connectors when 120 volt potential exposure Use caution making making voltage measurements or jumping terminals voltage checks to avoid personal injury From previous page Does combustion blower operate Error code 67 on display Measure voltage between black and white wires of the 3 wire harness at the blower make sure the control display shows heating in the status mode if not increase the setpoint Is there 110 120 VAC Replace power cord blower harness if N display shows heating and no voltage is present to the blower Replace Blower Measure voltage between yellow and green wires Is there 17 30 VDC Check that the 5 wire blower modulation harness is plugged in to the blower Plug in the wire harness Note If this harness is unplugged blower will2. Error code 80 will be shown in the water heater display The control can only be reset in the Service Mode which is detailed in the Troubleshooting section of this Service Manual 3 ERROR CODE 67 a Ifthe exhaust terminal becomes blocked or the condensate elbow fails to drain condensate the normally closed exhaust pressure switch will open the gas valve closes and error code 67 will appear on the control display When the condition is corrected the error code will disappear and the water heater will resume normal operation No resetting of the control display is needed for the pressure switch error code 4 ERROR CODE 67 a If the vent safety switch located near the exhaust pressure switch should open the gas valve will close the blower will post purge and error code 67 will appear on the display The lockout condition will reset once the problem is corrected and the switch reset Refer to Vent Safety Switch Testing and Replacement in this Service Manual CONNECTION WIRING DIAGRAM Ba at DIAGRAM BLACK 120 V SCHEMATIC WHITE 120 V 120VAC G _ ereen GROUND POWER POTENTI el ISTAT EBM BLOWER BESTEN iS Lo m p bane ANODE RODS T FAN MODULATION J3 CONTROL BOARD J8 1 PRESSURE PRESSURE VOLLERO SWITCH SWITCH RL THERMOSTAT J8 yr PART OF CONTROL BOARD BURNER GROUND IGNITER BOARD CIRCUIT HONEYWELL CONTROL BOARD R7910B WOOT TLE i SPARK ELECTRODE
3. SENS A BU G HIGH LIMIT ECO PART OF CONTROL BOARD CIRCUIT EBM BLOWER SPEED CONTROL FAN GROUND J2 FAN POWER 24V DC rm a m Z mi COLLECTOR N C HIGHLIMIT PRESS SWITCH SWITCH FLAME HIGH VOLTAGE SPARK SENSOR SPARK ROD OUTPUT 10 BRADFORD WHITE WATER HEATERS Troubleshooting System Observation for Models with Direct Spark Ignition Water Heater Fault Water heater does not operate Display Error Code Water heater display does not N WARNING Er E RAAE PAY 120 volt potential exposure Use caution making voltage checks to avoid personal injury Check main power supply to water heater fuse circuit breaker plug receptacle line cord or wiring to water heater ZN CAUTION Use caution not to damage connectors when making voltage measurements or jumping terminals Check to make sure switch on front of control panel is in the ON position Refer to control board illustration Voltage at transformer across black and white wires should be 110 120 VAC Check line cord with volt meter Replace line cord if defective Verify primary voltage at the Transformer Refer to control board illustration Voltage at connector location J8 across blue and yellow wires should be 24VAC Verify secondary voltage at the control board If not check transformer Replace transformer if defective Black amp White wires Yellow amp Blue wires
4. If gasket is NOT affected by any of the above gasket replacement is not required Install combustion assembly using new gasket or fully inspected gasket from step 1 Secure combustion assembly at the burner mounting insert using screws from step 6 on previous page Tighten screws evenly Reconnect high voltage cable to spark rod flame sensor blower and gas valve Reconnect PVC venting gas supply and silicone tubing to gas valve Turn on gas supply to heater and check for gas leaks repair any gas leaks found Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instruction located in the installation and operating instruction manual Replace surround cover on top of water heater Gas valve venturi may vary by gas type LP shown BRADFORD WHITE EK Service Procedure II Combustion System Testing and Replacement Combustion System Replacement Procedure Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Fully inspect burner mounting insert gasket for the following a Tears d Dirt or debris b Missing material e Other imperfections that would inhibit proper seal c Cracks If gasket is NOT affected by any of the above gasket replacement is not required Install combustion assembly using new gasket or fully inspected gasket from step 1 Secure combustion assembly at the burner mounting insert
5. 120 volt potential exposure Isolate the appliance and reconfirm power is disconnected Un latch and remove top surround cover from top of l l using a multi meter heater Fold back insulation just in front of burner to expose temperature sensor see photo below Disconnect temperature sensor from control see photos below Unclip sensor from well and pull sensor to remove do not remove well Install new sensor completely into well and reinstall sensor clip Connect temperature sensor to control Fold insulation back into place Be sure there are no wires in contact with burner Restore 120 volt power supply and water supply to water heater check and repair any leaks found Confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instruction located in the installation and operating instruction manual Replace surround cover on top of heater Disconnect sensor harness from control board Sensor shown fully inserted into well Sensor clip shown properly installed Insulation folded back to expose temperature sensor 20 ____U y amp r1 1 k bl rr l_ t0 ktltL HlMHFL lt LS HL BB L LLLNR Lun_LRD b WhRN RNL R BRADFORD WHITE WATER HEATERS Service Procedure II Combustion System Testing and Replacement Observe burner operation through the sight glass located on the combustion inser
6. Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Step 12 N WARNING Position main power switch to OFF Disconnect unplug water heater from 120 volt power Source 120 volt potential exposure Isolate the appliance and reconfirm power is Un latch amp remove surround cover from top of heater disconnected using a multi meter Fold back insulation in front of combustion assembly to expose flame sensor see photo below Disconnect wire lead from flame sensor Remove the 2 sensor mounting screws magnetic tip long reach Phillips screw driver and remove flame sensor amp gasket from transition base flange Remove any residual gasket material from transition base flange Install new flame sensor with new gasket provided using screws from step 6 Arrange flame sensor with hook towards burner Reconnect flame sensor wire Fold insulation back into place Be sure no wires are in contact with burner flange Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instructions located in the installation and operating instruction manual Replace surround cover on top of water heater Flame Sensor Gas valve venturi may vary by gas type LP shown BRADFORD WHITE e ___ Qt_Y _ _ur tt _ S lr ___e llS NNC NR U UH
7. The combustion gases then travel through a three pass flue system keeping the gases moving at a high velocity The combination of high turbulence and velocity results in an optimum transfer of heat from the flue gases into the water Burner operation is controlled using an electronic ignition module The module monitors the status of the electronic thermostat vent temperature limit switch vent system pressure switches and a flame sensor to control output voltage to blower motor spark rod and gas valve The module contains programming which determines the sequence of operation and timings for purge periods trial for ignition flame sensing and lockout The module will also provide diagnostic information to help in determining the cause of system lockouts The contents in this manual are detailed informational tools to assist in the proper diagnosis of the Ultra High Efficiency Water Heater operational faults Please read this service manual completely which provides detailed information regarding the Ultra High Efficiency Water Heater operation and installation specific concerns BRADFORD WHITE E 3 How to Use This Manual It is intended for this manual to be used by qualified service personnel for the primary purpose of troubleshooting analysis and repair of the Bradford White EF100T399 serial number LD34005014 and after Understanding the sequence of operation section of this manual will contribute greatly to troubleshooting this pr
8. L NNK L LU N UL LL LK rr Spark Rod Gap Inspection and Adjustment Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Burner Tube Service Procedure VIII Spark Rod Gap Adjustment and Replacement Remove combustion system as described in N WARNING Combustion System Removal Procedure Spark gap must be set from 3 16 to 1 4 Failure to Measure spark gap between the spark rod and set and verify proper spark gap may result in a delayed ignition resulting in damage to the water heater burner tube Acceptable spark gap is from 3 16 to 1 4 see photo below If spark gap is not between 3 16 to 1 4 the spark rod may be carefully bent by supporting the end near the ceramic insulator with pliers and bending the end near the burner tube with needle nose CAUTION pliers see photo below Use caution while performing these steps to Re measure and verify spark gap is between 3 16 prevent stressing or cracking the ceramic insulator to 1 4 after bending Verify the integrity of all gaskets and replace where required Reinstall the combustion system per Combustion System Replacement Procedure and check several ignitions to ensure the burner lights smoothly Hold spark rod near ceramic Spark Rod insulation Bend spark rod near burner tube Reg Pen VE te ee 36 I BRADFORD WHITE WATER HEATERS Spark Rod Replacement Procedure Step 1 Step 2 St
9. Remove the two screws holding each the spark rod and flame sensor in place long reach magnetic Phillips screw driver Carefully remove spark rod and flame sensor from combustion assembly Step 8 Remove the 4 nuts 7 16 wrench holding the BURNER burner transition in place Lift the blower gas TRANSITION valve transition assembly from burner mounting insert remove gasket and set aside BURNER FLANGE SONNEN EII BURNER TRANSITION MOUNTING NUTS GASKET Step 9 Remove burner tube from burner mounting insert See next page for burner tube inspection procedure BURNER FLANGE GASKET BURNER MOUNTING INSERT Gas valve venturi may vary by gas type LP shown BRADFORD WHITE _ __ rr1 _ A H_ HHH ljR F NR DE K ___U_UMME_ qU F q LU _ _ _ 7V _ _0 0_8 0 0 o _ _mgt Service Procedure III Burner Tube Inspection and Replacement N WARNING Heater components may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Burner Tube Inspection Step 1 Step 2 Inspect burner tube as follows Acotech metal fiber mesh burner a Outer fiber mesh should be uniform with no tears or deterioration b Gently squeeze burner tube Burner tube should feel firm without any soft areas around the sides or at the bottom c Visually inspect inside burner tube burner tube should be
10. and Replacement 36 Service Procedure IX Ignition Module Control Board Replacement 38 Service Procedure X Transformer Replacement 39 Service Procedure XI Vent Safety Switch Testing and Replacement 40 Service Procedure XII Anode Baffle Inspection and Replacement 42 Water Heater Installation Check list ccceccsecceeeeeceeeeeeteeeseeseeeeeeeeeeseeeseeeeeeees 47 Water Heater Service Report 48 SEUI RR O A 49 IOS SLY OF SINS anni 52 NOOS ee E i 52 2 E BRADFORD WHITE Introduction The Bradford White Ultra High Efficiency Water Heater is designed to deliver a remarkable thermal efficiency rating in a quiet running unit with venting options that allow for installation flexibility Several technologically advanced design features are incorporated in the design that will require additional knowledge on the part of the qualified service provider The information in this manual will instruct service and maintenance professionals on the function proper diagnosis and repair of The Bradford White Ultra High Efficiency Water Heater The Bradford White Ultra High Efficiency Water Heater uses a low NOx premix power burner located at the top of the water heater to direct a turbulent flame down into a submerged combustion chamber This turbulence causes a thorough mixing of gas and air for optimum combustion
11. held inside the well with the clip If the problem persists and the sensor and wiring check O K then replace the control module Condition Check the sensor wire harness from the sensor to the control module Make sure there are no loose connections to the control plug DHW TEMP Check the resistance reading from each of the outside wires to the center common wire If the ohm readings are not fairly close replace the sensor Replace the control module if the problem persists and the sensor and wire connections are not defective Sensor Fault Check to see if flame is present inside the combustion chamber before or after the ignition cycle If so check to make sure the gas valve is wired correctly Check for voltage at the gas valve connection Replace the gas valve if defective If no flame is visible outside of the ignition sequence run cycle then make sure the flame sensor is wired to the correct terminal Make sure the ignition cable is not crossing the flame sensor wire or ignition ground wires If problem persists and all other checks have been verified replace the control module Flame detected out of sequence Burner failed to light or stay lit after 3 retries Hold condition will reattempt ignition after 15 minute waiting period Check gas valve wiring and gas valve operation during the ignition cycle If burner lights but quickly goes out check the flame sensor wire or the flame sensor Ignition Failure If
12. intact with no areas of deterioration Ports should be free of any debris If burner tube is affected by any of the above replacement is required Refer to burner tube replacement procedure below Burner Tube Replacement Procedure Note Provide the model and serial number for the correct replacement burner Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Fully inspect burner flange gaskets igniter and flame sensor gaskets for the following a Tears d Dirt or debris b Missing material e Other imperfections that would inhibit proper seal c Cracks If gaskets are NOT affected by any of the above gasket replacement is not required Install burner tube with gaskets into burner mounting insert Be sure gasket surfaces are free of debris Reconnect the blower gas valve transition assembly to burner mounting insert Secure using nuts from step 8 on previous page Carefully reinstall flame sensor with gasket and spark rod with gasket and secure with screws from step 7 on previous page Reconnect wire harnesses to sensor and igniter Reconnect wire harnesses to blower motor and to gas valve Reconnect PVC venting gas supply and silicone tubing to gas valve Turn on gas to heater and check for gas leaks repair any gas leaks found Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instruction
13. located in the installation and operating instruction manual Replace surround cover on top of water heater 26 E BRADFORD WHITE WATER HEATERS Service Procedure IV Gas Valve Replacement Gas Valve Replacement Procedure Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Position main power switch to OFF AN WARN N G Disconnect unplug water heater from 120 volt power source 120 volt potential exposure Isolate the appliance and reconfirm power is disconnected using a multi meter Turn off gas supply to water heater Un latch amp remove surround cover from top of heater From the gas valve disconnect the gas connection PVC venting wire harness and silicone tubing Remove the 2 to 3 gas valve mounting screws Torx bit located as shown below on the venturi mounting flange and remove gas valve from water heater Remove any residual gasket material from blower and venturi mounting flange Install new gas valve with new gasket provided Secure gas valve in place using screws from step 6 Reconnect PVC venting gas supply silicone tubing amp wire harness to gas valve Turn on gas supply to heater and check for gas leaks repair any gas leaks found Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instruction locate
14. low 0 40 or less replace pressure switch Exhaust tube pressure tap location S i Exhaust tube at bottom of heater BRADFORD WHITE eC WATER HEATERS Service Procedure VI Blocked Vent Pressure Switch Testing and Replacement Exhaust Pressure Switch Replacement Procedure Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 5 16 head pressure switch mounting screw Wire leads Position main power switch to OFF position Loosen adhesive backed rubber escutcheon from service panel access cover and slide escutcheon back along exhaust pipe to allow for removal of cover Remove screws from service panel access cover nut driver and remove cover from heater see photos below Disconnect silicone tubing and wire leads from pressure switch see photos below Remove pressure switch mounting screws 5 16 wrench and remove pressure switch Assemble new pressure switch to heater using screws from step 5 Reconnect wire leads Note wire leads are interchangeable with either terminal Reconnect silicone tubing to pressure switch as follows a Exhaust pipe tubing connects to single tap located on switch Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instructions located in the installation and operating instruction manual Rein
15. meter leads of heater side safety circuit harness Call for See photo below Y technical support Is there continuity through RED wire leads of heater side safety circuit harness See photo below Is there continuity across intake pressure switch Depress reset button on Does vent safety switch Is heater there continuity across function high limit switch See photo below Replace exhaust pressure switch See Exhaust Pressure Switch Replacement Procedure Verify proper switch Replace vent Safety circuit O K operation See safety switch See Blower Veni Salely See Veni Replace exhaust pressure switch Testing amp Switch Testing safely Switch See Exhaust Pressure Switch Replacement and Replacement Check control display On LL 5 Y Pressure switch a is O K N Replacement Procedure Replacement Procedure i D For serials s starting with LK and after All prior will have red jumper harness o EX i 4 ss WES K i I f E Hal i Harness gt Flashing after 5 Call for lt TN minutes Error technical l N code 67 again support Control Side Heater Side _ Reset Button Harness Correct blower problem See Blower Testing and Replacement Check blower for p
16. run constantly Replace Control Module Check resistance of high voltage cable Resistance should be 0 1 ohms If resistance is high replace spark cable If spark cable is good replace control board Remove high voltage wire connected at the spark rod and hold approximately 1 4 from metal ground with insulated pliers during the ignition cycle 3 second spark trial period Is there spark to ground Can sparking be N seen heard at the spark rod to the burner Y Error code 110 on display Check continuity of spark rod and spark Does main burner light N See mam Summer lights dii rod gap to burner see section Spark flame signal in section l Rod Gap Adjustment Combustion System Testing Y and Replacement Check to see if control display shows any other error codes 67 pressure switch 67 vent safety switch or 80 high limit If so refer to the appropriate section for testing and replacement Does burner continue until thermostat set point is reached See setting display in Service Mode and displaying J8 J9 temperature sensors e I See Combustion System Testing and Replacement Does blower post purge for 30 seconds Y System okay _ nm WATER HEATERS Troubleshooting Step 1 Press and hold the lower right button under Next in the lower right display for at least 3 seconds PRESS NEXT
17. 60 Hz 1 5 3 5 amps 8000 RPM Combustion Levels CO2 8 11 CO less than 0 04 400 PPM air free BRADFORD WHITE E T 8 Specifications Vent Tables Balanced Direct Vent Systems Total length of intake piping and exhaust piping added together must not exceed Maximum Combined Length Shown below Maximum Combined Length feet Model Number EF100T399 Unbalanced Direct Vent Systems Air intake CAN NOT exceed exhaust by more than 30 feet Power Vented Systems SEE APPROVED MATERIALS Total length of exhaust piping must not exceed Maximum Vent Length Shown below Maximum Combined Length feet Model Number EF 100T399 WARNING The EF100T399 model is not approved for 2 inch diameter vent pipe Venting with 2 inch pipe may result in damage to the water heater or cause an unsafe condition DO NOT use 2 inch vent or air intake pipe Notes 1 Multiply the total number of 90 elbows intake and exhaust by 5 feet Do not include the termination fittings or 3 condensate elbow 2 Multiply the total number of 45 elbows intake and exhaust by 2 1 2 feet 3 Add this to the total length of straight pipe intake and exhaust 4 The sum total of all elbows and straight pipe intake and exhaust must not exceed maximum lengths from tables above Example A 3 Balanced Direct vent system has 10 feet of straight exhaust pipe and 10 feet of straight intake pipe It has 1 90 elbows in the exha
18. BUTTON FOR 5 SECONDS TO ENTER AX WARNING The following procedure is for service and installation personnel only Resetting lockout conditions without correcting the malfunction can result in a hazardous condition Step 2 The display will show the flame sense current in microamps when the burner is operating Step 3 Press the lower right Next button and the display will show flash and show the number of any Alert codes If alerts are present and the unit is not operating contact technical support for help ALERT CODE SHOWN IN WATER HEATER DISPLAY BRADFORD WHITE nS Troubleshooting Step 4 Press lower right Next button and the display will flash and show the number of any Lockout codes LOCKOUT CODE SHOWN IN WATER HEATER DISPLAY Step 5 Press lower right Next button and the display will show the temperature sensor reading SENSOR TEMPERATURE READING Step 6 Press lower right Next button and the display will show the Manual firing rate adjustment This function is not currently used Any adjustment made has no effect Step 7 End of screens in Diagnostic Mode Press Done button on lower left to exit Diagnostic Mode back to DHW setpoint in the User Mode NOTICE The screens will stay in the Diagnostic Mode for 12 5 minutes after the last button press for viewing unless Done button is pressed to exit Diagnostic Mode 14 EEEEEEeE BRADFORD WHIT
19. C volts DC Amps micro amps and ohms Thermometer Used to measure water temperature An accurate thermometer is recommended Water Pressure Gauge Used to measure water supply pressure Also used to determine tank pressure by adapting to the drain valve of the heater Jumper Leads A length of wire 12 min with alligator clip at both ends Various Hand Tools Pipe wrench channel locks open end wrench set 12 crescent wrench Allen wrench set torx bit set screw drivers common amp phillips long reach 12 magnetic tip phillips head screw driver 2 tip 14 nut driver pliers common amp needle nose socket set including a 1 1 16 deep well socket wire cutters wire strippers wire crimpers torpedo level small shop vac step ladder and flashlight 4 E BRADFORD WHITE WATER HEATERS Features Features of Honeywell Integrated Control System e Attractive digital water heater display on control panel for setting and displaying the temperature setpoint Pressing temperature UP and DOWN buttons changes the temperature setpoint Temperature format may be displayed in F or C e Single control board with plug in wiring controls temperature ignition and blower operation e Reduced number of parts for servicing and wiring e Plugin wiring reduces chance of miswiring e Burner ignition with direct spark ignition A high voltage spark jumps from the spark rod to the burner surface to ignite the gas Eliminate
20. E WATER HEATERS Troubleshooting DIAGNOSTIC ERROR CODES AND TROUBLESHOOTING PROCEDURES FOR EF100T399 MODELS WITH HONEYWELL LOW FIRE START CONTROL SYSTEM Definition of Code Cause of Problem and Actions Taken to Correct Check power supply to the water heater Make sure water heater is plugged in and the breaker is on Check if there is 120 volts power supply to the LINE connections on the control board If 120 volts is present check for 24 volts output to SECONDARY terminals on the Control Board Check for loose wires defective transformer Check wire harness connections from display to the control board Verify wiring to the control board with wiring diagram Check power supply to make sure voltage and frequency is correct 3 48 58 60 Internal Faults Check for 24 volts from the transformer to the control board Reset module by interrupting power or pressing the reset button on the module No code blank display Measure the incoming line voltage Voltage should be 115 125 volts If the voltage is not within this range or there is drastic fluctuation then Voltage too low or high have the incoming power supply checked If the line voltage is satisfactory check the output from the transformer to make sure it is 22 26 volts Replace transformer or wiring if defective Check the module and display connections AC Inputs phase Check the module power supply and make sure that frequency voltage and VA cap
21. Ss BRADFORD WHITE WATER HEATERS Ultra High Efficiency Models with Direct Spark Ignition Gas Water Heaters SERVICE MANUAL Troubleshooting Guide and Instructions for Service To be performed ONLY by qualified service providers Models Covered by This Manual EF100T399 E N X A 2 Serial Number LD34005014 and AFTER Denotes Warranty Years Effective August 2014 ECO 7897 Manual 238 51163 00A REV 8 14 Save this manual for future reference Ultra High Efficiency Models with Direct Spark Ignition Table of Contents INFOGUCIO ore 3 MOW tO USS TAIS IVAN cc iii SANTA AIA tte 4 T00 S REQUIFEC TOFSCVICe iaia 4 Bre 0 e ene ee een eee inn 5 n gt 91 1611 625 14 6 gt err A E EE E 6 SCQUEnNce orOPeralloAib ar ee 9 TOUDIESNOOUNG cricca i 11 Service Procedure Thermostat Circuit Testing and Replacement 17 Service Procedure Il Combustion System Testing and Replacement 21 Service Procedure Ill Burner Tube Inspection and Replacement 25 Service Procedure IV Gas Valve Replacement i 27 Service Procedure V Blower Testing and Replacement 28 Service Procedure VI Blocked Vent Pressure Switch Testing and Replacement 30 Service Procedure VII Flame Sensor Testing and Replacement 34 Service Procedure VIII Spark Rod Gap Adjustment
22. Turns Polarity Spark Gap Exhaust Collector Pressure Positive Inches W C CO Installation Site Contact Name amp Phone Number 48 BRADFORD WHITE WATER HEATERS Parts List Water Heater Full Assembly ombustion Surround Assembly urner Assembly Specify model nd Pass Top Collector Cover crew 10 16 x 3 4 ent Termination Elbow hermostat Sensor Probe affle 4 Flue Specify Model affle 2 Flue ire Harness Service Panel amp P Relief Valve xhaust Collector ondensate Elbow ilieone hose uter Door Service Panel SF Escutcheon xhaust Pressure Switch uts ollector Limit Switch crew 6 32 x 3 8 leanout Access Cover leanout Gasket crew 5 16 18 x 3 4 HH Grade 5 leanout Cover old Water Inlet Hydrojet Assembly o Handle Brass Drain Valve oncentric Vent System Optional hermostatic Mixing Valve Optional hermal Well SME Cleanout Access Cover 35 ASME Cleanout Gasket ASME Screw 5 16 18 x 3 4 HH Grade 5 Customer must specify complete model 7 Intake Pressure Switch for serial s number and serial number when ordering starting with LK and after service parts I O Olm alz oo gz o oo a xoa Noo 7 00 O Z m 3 iN MIO 5 6 oO O DN gt s s OZ oOo EXHAUST SERVICE AREA DETAIL ASSEMBLED 6 8 o 20 N 35 BRADFORD WHITE ai Parts List Combustion Surround Assembly 1 AA Keeper Latch amp Catch Sc
23. acity of the transformer meet specifications Check to make sure the wiring connections on the control module from terminals J4 10 and J8 2 are connected together Check the blower modulation wire harness connection from the blower to the control module at J2 connection Make sure the pin terminals make solid contact Measure the resistance of each wire in the wire harness from the 62 Fan speed not proved terminal ends Replace wire harness if defective Check if there is 17 30 volts DC between the Yellow and Green wires reversed on the blower 5 wire harness Check if there is 17 30 VDC between the yellow and green wires on the blower 5 wire harness Check wiring to the normally closed blocked vent pressure switch and vent limit switch Service panel near vent outlet connection Use a voltmeter to find out if the pressure switch or high limit switch has opened ILK Off Interlock Off If so determine the cause blocked vent terminal clogged condensate drain high temperature in compartment If limit switches are closed check wiring for shorts Measure continuity If limit switches and wiring check O K replace control module BRADFORD WHITE A Troubleshooting Check the wiring from the sensor to the control module Measure the resistance of each outside wire to the center wire High Limit Overheat If either outside wire has a much different resistance reading replace the sensor Make sure the sensor is securely
24. assembly to blower with new gasket provided Secure gas valve in place using screws from step 7 Reconnect intake vent and gas line to gas valve assembly and check for gas leaks Repair any leaks found Reconnect the 2 wire harnesses to blower assembly restore 120 volt power supply amp gas supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instructions located in the installation and operating instruction manual Replace surround cover on top of water heater ie Gas valve venturi may vary by gas type LP shown BRADFORD WHITE _ _ kN LLLL i Q U HNNNNRLLN LLOU lt UU LLF LLLULL O Service Procedure VI Blocked Vent Pressure Switch Testing and Replacement Sequence of operation The blocked vent pressure switch monitors the pressure in the exhaust tube The switch contacts are normally closed and will not open unless there is a blockage in the exhaust venting or terminal Snow ice debris If the blocked vent pressure switch contacts open after the thermostat initiates the blower the blower will remain on for to 5 minutes waiting for the contacts to close If the contacts remain open the blower will stop and error code 29 will display Error Code 67 Does blower energize N Is there continuity through GREY wire N WARNING 120 volt potential exposure Isolate the appliance and reconfirm power is disconnected using a multi
25. d in the installation and operating instruction manual Replace surround cover on top of water heater Nat gas valve venturi LP gas valve venturi BRADFORD WHITE _ _SLNS OL ULRN NNLIS U LN u U gU w b E M SLIFL LU Service Procedure V Blower Testing and Replacement Does blower energize Ensure control display shows Heating Raise temperature setpoint if necessary Is there 120VAC across the white and black wires at the incoming power harness connection see photo at right Call for technical support Refer to ignition module control board illustration Is there 24VAC between blue and yellow wires at location J8 Is there 120VAC across white and N black wires at the Repair replace wire blower See harness photo at right Replace biower See Blower Replacement Procedure Refer to ignition Y module control board N illustration Is there Replace ignition 24VAC between blue module control board and yellow wires at location J8 Are collector high limit switch and pressure switches in normally closed position Determine power source DOOR 120 VAC an power correct connection Check amp draw through BLACK wire lead of blower motor Is there 6 to 3 0 amps Is blower wheel secured to blower motor shaft Black wire leading to blower looped through am
26. e Soule Nar recommend 7 0 W C min running Power vent balanced direct vent or unbalanced direct Venting System vent See vent tables on page 8 Approved Venting Materials PVC CPCV and approved polypropylene venting u OT eA e 10 18 from top 24 from front 4 sides and rear Servicing Maximum Water Supply 150 PSI Pressure 11 900 Ohms 70 F ECO opens 207 F Max Thermostat Sensor Redundant sensor for ECO Sensor inside well for easy replacement of sensor Digital display 24 volts Temperature range 70 180 degree F Used to set tank temperature deg F or deg C show operating status display error codes error code history limit maximum setpoint temperature Operates on 24 volt from transformer Controls tank temperature ignition functions combustion blower See Control Board Li ignition timings in sequence of operation for Integrated Control 120 VAC primary 24 VAC secondary 40 VA Spark Rod Igniter 0 22 nominal gap to the burner surface Flame Sensor Output el 1 micro amp Typical range 5 to 30 micro Negative regulation 24 VAC 72 PSI max 4 5 W C Gas Valve ioe oe minimum running inlet Vent Safety Switch Normally closed opens 350 F manual reset Blocked Exhaust Vent 24 VAC normally closed opens when pressure Pressure increases to 2 70 W C Control Display Blocked Intake Vent 24 VAC normally closed opens when vacuum Pressure increases to 2 38 W C 120 VAC
27. e control N connectors ari appliance and reconfirm power is disconnected harness during the flame establishing period Note Control display must show Heating for operating status control harness using a multi meter N Replace control Y energize N Replace gas valve harness and or gas valve See Gas Y Pressure Pressure Valve Replacement Procedure LP gas Nat gas valve venturi Check for obstruction at inlet of gas valve Is inlet free of obstruction Inspect burner tube see Burner Tube Inspection Does burner light smoothly without evidence of coughing or huffing n Does burner operate Call for Does burner stay lit normally until technical thermostat is satisfied support Check flame sensor Are there at least 1 to 5 micro amps min during 1 5 second flame proving period Value may be displayed on the control display by accessing Service Mode System O K Replace flame sensor see Flame Sensor Replacement Procedure Service Procedure II Combustion System Testing and Replacement Combustion System Replacement Procedure Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Fully inspect burner mounting insert gasket for the following a Tears d Dirt or debris b Missing material e Other imperfections that would inhibit proper seal c Cracks
28. ector cover per Collector Cover Installation Procedure Reinstall collector insulation and control panel reconnect control panel wire harnesses Restore 120 volts to water heater and verify proper heater operation following the instructions on the lighting instruction label or the lighting instruction located in the installation and operating instruction manual Replace surround cover on top of water heater 440 I BRADFORD WHITE WATER HEATERS Service Procedure XII Anode Baffle Inspection and Replacement Powered Anode Replacement WARNING Heater components may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury The powered anode control module is located on the right vertical side of the control panel inside the surround panel The control has a LED indicator light to show the status of operation When the tank is filled with water and the power supply is on to the water heater the light should have a steady green glow to indicate that protection current is flowing and operating normally If the indicator light is not glowing the power supply to the water heater or powered anode system is disconnected Step 1 Check the power supply or wire connections to the powered anode control Step 2 Indicator light diagnostic codes a If the control is flashing red then there is a malfunction with the powered anode system Make sure there are no bare spo
29. ed in the installation and operating instruction manual Reinstall service panel access cover and rubber escutcheon Rubber Escutcheon a li j Vent Safety Switch BRADFORD WHITE A Service Procedure XII Anode Baffle Inspection and Replacement Disassembly Procedure for Access to Anodes amp Flue Baffles N WARNING Heater components may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Control Panel mounting screw Position main power switch to OFF Disconnect Unplug water heater from 120 Volt N WARNING power Source 120 volt potential exposure Isolate the appliance and reconfirm power is disconnected using a multi meter Un latch amp remove surround cover from top of heater Disconnect wire harnesses to allow for removal of control panel Note Where ever possible rather than disconnecting at the control panel follow wire harness away from control panel and disconnect at control component location Remove the three control panel mounting screws nut driver and remove control panel from the water heater see photos below Completely remove insulation two pieces from top of heater to expose collector cover Remove all collector cover screws 5 16 socket and remove collector cover see photos below B
30. einstall into heater Restore water supply and check for and repair any leaks found Step 7 Reinstall collector cover per Collector Cover Installation Procedure Step 8 Reinstall collector insulation and control panel reconnect control panel wire harnesses Step 9 Restore 120 volts to water heater and verify proper heater operation following the instructions on the lighting instruction label or the lighting instruction located in the installation and operating instruction manual Step 10 Replace surround cover on top of water heater BRADFORD WHITE EK Service Procedure XII Anode Baffle Inspection and Replacement Flue baffle inspection and replacement WARNING Heater components may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Disassemble heater per Disassembly Procedure for Access to Anodes amp Flue Baffles Remove flue baffles from heater pliers 8 two inch baffles amp 2 four inch baffles Visually inspect flue baffles Flue baffles should show signs of oxidation this is normal If the oxidation has deteriorated any portion of the flue baffle replacement is recommended If any restrictors are missing replacement is recommended Upon completion of inspection or subsequent replacement reinstall flue baffles into heater Reinstall coll
31. ep 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Step 12 Service Procedure VIII Spark Rod Gap Adjustment and Replacement Position main power switch to OFF AN WARN N G Disconnect unplug water heater from 120 volt 120 volt potential exposure Isolate the appliance and reconfirm power is disconnected using a multi meter power source Un latch amp remove surround cover from top of heater Fold back insulation in front of combustion assembly N WARNING to expose spark rod see photo below Disconnect wire lead from spark rod If the spark rod is replaced for any reason the combustion system MUST be removed and the Remove the 2 mounting screws magnetic tip long spark gap to the burner measured and adjusted reach Phillips screw driver and remove spark rod amp properly gasket from transition base flange Remove any residual gasket material from transition base flange Install new spark rod with new gasket provided using screws from step 6 Arrange spark rod with hook towards burner off center mounting hole towards the front of the water heater Remove combustion system following Combustion System Removal Procedure and verify spark gap following Spark Rod Gap Inspection and Adjustment Reassemble combustion system following Combustion System Replacement Procedure Fold insulation back into place Be sure no wires are in contact with burner fla
32. ermostat circuit opens gas valve closes blower continues to operate for 30 second post purge period b If either 1 Pass Collector vent safety contacts normally closed or either of the blocked vent pressure switch contacts normally closed open while the burner is on then gas valve closes and the unit will retry a normal sequence of operation If issue remains on restart the unit will go into recycle as described in the example above on 4c 6 Thermostat satisfied 7 Gas valve closes burner extinguished 8 Blower post purge for 30 seconds BRADFORD WHITE qe 9 Sequence of Operations Lockout Conditions The system will go into lock out mode for the following reasons 1 ERRORCODE 110 a Control board will go into Soft Lockout if the main burner cannot be lit or fails to prove flame after 3 ignition trials The water heater display indicates a lockout condition by showing an error code number 110 with Service Needed in the control display window Refer to error codes in the diagnostic section of this Service Manual In a Soft Lockout condition the control will wait for 15 minutes and then make 3 more attempts to light the main burners Soft lockout reset is accomplished by depressing the lower right button under Reset for 3 seconds 2 ERROR CODE 80 a Ifthe top of the tank should exceed 207 F then the high limit control will shut off the burner and the water heater will go into a Hard Lockout
33. ge measurements or jumping terminals not to damage or deform connectors or connector pins Draw water from the T amp P valve Compare temperature with temperature ohms chart below Example If the temperature is 84 F then the resistance through the sensor would be 8449 see shaded area Note Sensor resistance increases as the temperature falls In Degrees F QC O DE O O I I I I 24772 22771 20445 17440 19716 60 16314 14025 14548 14160 19823 1347 12185 9528 80 2208 sore e es o 8250 e057 7660 7686 7507 so gas 7165 7000 ease 6668 esot 6988 6238 6008 5961 eo fio no ne mo oo 101 1083 1038 107 00 _ In Degrees C e 0 1 2 38 a s e T 8 _O 32648 31026 29495 28049 26682 25389 24166 23010 21915 20879 60 2488 2400 2316 2235 2157 2083 2011 1942 1876 1813 80 1256 1216 1177 1140 1105 1070 1037 1005 974 94 90 96 888 861 835 810 786 763 741 719 698 BRADFORD WHITE e _ MN NNNE LU U FLL LUMLU hl cd ukBKLE N O Service Procedure I Thermostat Circuit Testing and Replacement Thermostat Sensor Thermistor Replacement Procedure Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 N WARNING Position main power switch to OFF Disconnect unplug water heater from 120 volt power SOUICE
34. ing Current British Thermal Units Carbon Monoxide Carbon Dioxide Direct Current Direct Spark Ignition Energy Cut Off Ground Fault Interrupt Gallons per Minute Hertz Light Emitting Diode Oxides of Nitrogen National Pipe Thread Pounds per Square Inch Revolutions per Minute Volt Amps Volts Alternating Current Inches of Water Column Degrees Centigrade Degrees Fahrenheit Micro Amp WATER HEATERS NOTES NOTES NOTES 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
35. l period Is should be 0 1 Ohm If resistance is high replace spark cable If spark cable is there spark to ground good replace control board Y 120 volt potential exposure Use caution making voltage Replace spark rod see checks to avoid personal injury Spark Rod Gap Inspection and Replacement Meter probe Check continuity of spark rod Is reading 0 1 Ohm Volt meter set of OHM setting N 2 Spark Does main burner light Check spark gap to rod burner see Spark Rod Y n Gap Inspection Meter probe CHECK SPARK ROD RESISTANCE Proceed to next page BRADFORD WHITE ee es Service Procedure Il Combustion System Testing and Replacement Observe burner operation through the sight glass located on the combustion insert mounting flange Normal burner operation should ignite smoothly without evidence of coughing or huffing upon ignition The burner flame should be a blue flame near the burner surface in a uniform flame pattern Occasional yellow or white streaks are normal Note On this high input model that uses metal fiber mesh burner a red glow from the burner surface is normal Continued from previous page Check to see brown and blue N WARNING wires are Refer t trol board illustrati i propery eter to control board Illustration IS connected to there 24VAC between brown and Molex 120 volt potential exposure Isolate the blue wires coming out of th
36. lt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instruction located in the installation and operating instruction manual Replace surround cover on top of water heater BRADFORD WHITE DO O Service Procedure XI Vent Safety Switch Testing and Replacement Sequence of operation Error code 67 will display indicating an open circuit for the vent safety switch Determine if temperature has reached 350 F before resetting switch and restoring operation If evidence of extreme temperature is present call technical support Ignition Control Module Side N WARNING Heater Side 120 volt potential exposure Isolate the appliance and reconfirm power is disconnected using a multi meter Locate harness conection Is there continuity through See photo at right GREY lead wires of heater side harness see photo at right Replace vent safety switch See Vent N Safety Switch Replacement Procedure N Call technical support Does heater function Reset h ater observe heating cycle Does switch open Depress reset button on high limit switch Is there continuity across high limit switch See photo below For serials s starting with LK and after All prior will have red jumper harness System O K N N Is temp over 350 F Y Does switch open
37. nge Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instructions located in the installation and operating instruction manual Replace surround cover on top of water heater ZN WARNING Spark gap must be set from 3 16 to 1 4 Failure to set and verify proper spark gap may result in a delayed ignition resulting in damage to the water heater BRADFORD WHITE O E Gas valve venturi may vary by gas type LP shown Service Procedure X Ignition Module Control Board Replacement Control Board Replacement Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Replace surround cover on top of water heater not be on all controls Control Board I fo F n l j A x PIPPO FE FTTZZZZZA 4 lt _ lt PI A s Wo a i te ES 4 r Pi gt Y y 4 Position main power switch to OFF AN WARN N G Disconnect unplug water heater from 120 volt power source 120 volt potential exposure Isolate the appliance and reconfirm power is disconnected using a multi meter Un latch and remove top surround cover from top of water heater Locate control board Carefully disconnect all wire connections from control board Note It may be necessary to identify wires for proper re connection Depress the plastic tabs on the bottom side of
38. nting must stay within the required lengths and diameter see table below Proper support of the venting pipe is a MUST every 5ft vertical and 3ft horizontal Termination must be located to prevent re circulation of flue gases Medium to long sweep 90 elbows or straight exhaust terminal coupling recommended Gas Requirements Gas piping sized adequately L P or 1 Nat Install a properly sized regulator if unknown assure an adequate volume of gas is available 7 W C is required when the unit is running Gas pressure must stay below 14 W C static pressure Pressure drops between static pressure and operating flow should be less than 3 W C Condensate Requirements Condensate line needs to slope to a drain at a minimum of 4 per foot Make sure the condensate line does not have the potential to freeze If using more than one heater and using a common condensate line make sure the condensate line is properly sized Service Mechanical Room Provide adequate space for servicing heater Leave room to get to the top and bottom pressure switches as well as enough overhead room to remove the anode rods for servicing 18 min Vent Tables Balanced Direct Vent Systems PVC CPVC Total length of intake piping and exhaust piping added together must not exceed Maximum Combined Length Shown below Maximum Combined Length feet Model Number EF 100T399 Unbalanced Direct Vent Systems Air intake CAN NOT exceed exhaus
39. oduct An Installation Check List is shown towards the end of this manual Compare the installation against this installation check list to confirm all requirements are met A Service Report is shown towards the end of this manual Completing this form will assist in the troubleshooting efforts Should you need to call for technical support please provide the information Shown on this form to the support technician to ensure accurate troubleshooting Troubleshooting begins with System Observation to determine failure mode as indicated by error codes on the system display Troubleshooting continues with Failure Modes and Probable Cause directing the service provider to a series of test procedures to determine root cause of failure Component replacement procedures directly follow the test procedures for a given component In some difficult to diagnose conditions it may be necessary to isolate the heater from the vent system to determine root cause Contact technical support immediately if diagnosis is not determined using the methods described in this service manual Tools Required for Service Manometer Two types available a liquid U tube type or a digital magnehelic type This device is used to measure gas and or air pressures 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 A
40. ottom right photo shows heater with collector cover removed allowing access to anode rod and flue baffles a For anode service see Anode Inspection and Replacement Remove control panel b For flue baffle service see Flue Baffle Inspection and Replacement c For powered anode service see Powered Anode Replacement 1 i oe oe Pa DF fr 5 an i F i chi Ee i Collector cover Flue Baffles 42 VI BRADFORD WHITE WATER HEATERS Service Procedure XII Anode Baffle Inspection and Replacement Anode inspection and replacement N WARNING Heater components may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Step 1 Turn off water supply and drain water heater Step 2 Disassemble water heater per Disassembly Procedure for Access to Anodes amp Flue Baffles Step 3 Depressurize the tank using the drain valve Step 4 Locate and remove anode rod from heater 1 1 16 hex socket Step 5 Visually inspect anode rod Anode rod should show signs of depletion this is normal If the depletion is of the original diameter approximately diameter replacement is recommended If any of the steel core of the anode is exposed replacement is recommended Step 6 Upon completion of inspection or subsequent replacement apply thread sealing tape or other thread compound to threads of anode and r
41. p probe Replace blower See Blower Replacement Procedure Are collector high limit switch and Y pressure switches in normally closed Replace ignition module control Correct safety circuit problem per safety circuit trace See Blocked Vent Pressure Switch Testing WATER HEATERS Service Procedure V Blower Testing and Replacement Blower Replacement Procedure Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Step 12 Step 13 Step 14 Position main power switch to OFF N WARNING Disconnect unplug water heater from 120 volt power source 120 volt potential exposure Isolate the appliance and reconfirm power is disconnected using a Un latch amp remove surround cover from top of multi meter heater Turn off gas supply to water heater Disconnect the 2 wire harnesses from blower Disconnect intake vent and gas supply from gas valve assembly Remove the 2 to 3 gas valve mounting screws Torx bit located on the venturi mounting flange Refer to page 27 for more details Remove The 4 blower flange mounting screws 5 32 Allen wrench and remove blower from transition flange Remove any residual gasket material from venturi mounting flange and transition flange Install new blower with new gasket provided Secure blower in place using screws from step 8 Reconnect gas valve
42. prior DO NOT OPERATE to 350 F HEATER System over heating immediately contact technical support Replace vent safety switch See Vent Safety Switch Replacement Procedure N WARNING Make sure exhaust collector compartment is not overheating 350 F before resetting vent safety switch If there is evidence the collector compartment is overheating CALL TECHNICAL SUPPORT 40 I BRADFORD WHITE Service Procedure XI Vent Safety Switch Testing and Replacement Vent Safety Switch Replacement Procedure Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Position main power switch to OFF Loosen adhesive backed rubber escutcheon from service panel access cover and slide escutcheon back along exhaust pipe to allow for removal of cover see photos at below Remove screws from service panel access cover nut driver and remove cover from heater see photos below Disconnect wire leads from vent safety switch see photo below Remove the 2 switch mounting screws Phillips screw driver and nuts 5 16 wrench and remove switch from heater Install new switch using screws from step 5 Reconnect wire leads Note Wire leads are interchangeable with either switch terminal Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instruction locat
43. rew 8 32 x 1 2 RHCR Control Panel Assembl acket Head 28 1 4 Gre Customer must specify complete model number and serial number when ordering service parts i or fo C ai T sem Hen gt Pra ZIA 134 22A 14A T T MAIAT A a ie wAY a gt ni 2 Combustion Assembl 3A Burner Ass y Specify model 16A Screw 8 32 x 1 4 RHCR 7A Screw 10 32 x 3 4 SHCS 20A Nut Hex Washer BRADFORD WHITE WATER HEATERS 50 AC BTU H CO CO2 DC DSI ECO GFI GPM Hz LED NOx NPT PSI RPM VA VAC W C C F UA Notes BRADFORD WHITE tt k_e rFr lt r lt r lt _ DV Vv Ww w w O0 q q hdq xw _ 0v0 0 0 0_r rro_ D D y y y v yQq 0QmZ0 y _ _ _ _ _ lt rr r rP P rrrmi Glossary of Terms Alternating Current British Thermal Units Carbon Monoxide Carbon Dioxide Direct Current Direct Spark Ignition Energy Cut Off Ground Fault Interrupt Gallons per Minute Hertz Light Emitting Diode Oxides of Nitrogen National Pipe Thread Pounds per Square Inch Revolutions per Minute Volt Amps Volts Alternating Current Inches of Water Column Degrees Centigrade Degrees Fahrenheit Micro Amp WATER HEATERS AC BTU H CO CO2 DC DSI ECO GFI GPM Hz LED NOx NPT PSI RPM VA VAC W C C ae UA Notes D2 E E MM ZZZ I BRADFORD WHITE Glossary of Terms Alternat
44. roper operation See Blower Testing and Replacement Is the blower O K N WARNING Make sure exhaust collector compartment is not overheating 350 F before resetting vent safety switch If there is evidence the collector compartment is overheating CALL TECHNICAL SUPPORT Refer to Check Collector Pressure see next page 30 I BRADFORD WHITE Service Procedure VI Blocked Vent Pressure Switch Testing and Replacement Check Exhaust Intake Tube Pressure With manometer take a reading at the exhaust tube pressure tap location Is value negative or slightly positive see ilustration below With ohmmeter check pressure switch for continuity Contacts should be closed Y Pressure switch is O K Is exhaust intake venting system Clear obstruction blocked or Determine cause obstructed Also and correct check condensate elbow and drain Reconfigure vent system to be compliant with vent tables see Specifications Is vent system total length compliant with vent tables in the instruction manual Replace blocked vent switches See Blocked intake exhaust vent Switch Testing and Replacement Is pressure in exhaust tube near 2 7 w c or more If so correct blockage above If exhaust pressure is low 0 40 or less replace pressure switch Is pressure in intake tube near 2 3 w c or more If so correct blockage above If intake pressure is
45. s burned out hot surface igniter replacements e Water heater display will show diagnostic codes in the event the water heater needs servicing Aids in diagnosing and servicing the water heater e Water heater display can show previous error code history to further aid in servicing the water heater BRADFORD WHITE E 5 Specifications CONTROL DISPLAY AIR IN ILET TEMPERATURE ADJUSTMENT ON OFF SWITCH GAS CONNECTION SEE TABLE T amp P REUEF VALVE I _ Ly jet _ ______ ee 1 NPT SIDE 18 3 8 46 7 cm saan 1 1 2 NPT HOT WATER OUTLET A H 6 15 3 cm C E 1 1 2 NPT COLD mene oe 1 NPT SIDE F LET 3 4 DRAIN D TOP_VIEW LA 2 1 2 MIN C CONDENSATE DRAIN CONNECTION 3 7 6 cm EXHAUST CONDENSATE ELBOW Dimensions INCHES Storage eee i i pping Model No Capacity do Weight U S Vent i l l i Gallons Outlet l l Storage i Shipping Model No a ira Weight i Da nn ia KG Outlet EF100T399 1157 379 1972 718 127 330 1524 1600 1857 1861 38 25 2 25 41 6 r_ e o fPii Sc _______ _ _ BRADFORD WHITE WATER Specifications Power Supply Dedicated 120 VAC 60 Hz 15A GFI Cas Suvni Minimum 1 Nat L P na Schedule 40 black iron pipe recommended Approved Gas Type Natural or Propane Unit must match gas type supplied 14 0 W C maximum static 4 5 W C minimum running ary H
46. sor if damaged Check sensor resistance see Sensor Resistance Testing following section BRADFORD WHITE e RM c lt k LFlL LL PU A lt LO U_UMKSJNkH WATER HEATERS Service Procedure I Thermostat Circuit Testing and Replacement WARNING Condition Water heater not operating Display shows error code 80 high water temperature over 200 F continued from previous page Do not operate water heater without verifying that the overheating condition has been corrected Once cause of overheating condition has been diagnosed and corrected the control may be reset Reconnect and switch on power to the water heater Press button under Reset and hold for 3 seconds Set thermostat to the desired setting Water heater will start Monitor temperatures for one complete heating cycle making sure the maximum tank temperature remains below 200 F This water heater is equipped with a manual reset type gas shutoff device designed to shut off the gas to the burners if excessive water temperature occurs To reset the control press the lower right button under RESET in the display for 3 seconds Error code 80 indicates high limit lockout condition Step 1 Press for 3 seconds to reset control WATER HEATERS Service Procedure I Thermostat Circuit Testing and Replacement APPENDIX A Sensor Resistance at Various Temperatures Be careful when making volta
47. stall service panel access cover and rubber escutcheon Silicone tubing Rubber escutcheon SERVICE PANEL b ACCESS 32 I BRADFORD WHITE WATER HEATERS Service Procedure VI Blocked Vent Pressure Switch Testing and Replacement Intake Pressure Switch Replacement Procedure Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Position main power switch to OFF position Unlatch amp remove surround cover from top of heater Disconnect silicone tubing and wire leads from pressure switch see photo below Remove pressure switch mounting screws 5 16 wrench and remove pressure switch Assemble new pressure switch to heater using screws from step 4 Reconnect wire leads Note wire leads are interchangeable with either terminal Reconnect silicone tubing to pressure switch as follows a Intake pipe tubing connects to single tap located on switch Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instructions located in the installation and operating instruction manual Replace and re latch the surround to top of the heater 5 16 head pressure switch mounting screws Wire leads Silicone tubing For serials s starting with LK and after All prior will have red jumper harness BRADFORD WHITE ES Service Proced
48. t by more than 30 feet Power Vented Systems PVC CPVC Total length of exhaust piping must not exceed Maximum Vent Length Shown below Maximum Combined Length feet Model Number EF100T399 WARNING The EF100T399 model is not approved for 2 inch diameter vent pipe Venting with 2 inch pipe may result in damage to the water heater or cause an unsafe condition DO NOT use 2 inch Vent or Air Intake Pipe Note Each 90 elbow is equivalent to 5 feet of straight pipe Note Each 45 elbow is equivalent to 2 5 feet of straight pipe BRADFORD WHITE e l fl t1 l l L 1 I RA lHk M k h lt e lt e_ RQNLL L L cUORJ L Water Heater Service Report Date Service Provider Phone Number Venting PVC CPVC Vent size 3 4 Intake 90 Elbows qty Exhaust 90 Elbows qty Gas Line Size amp Material Gas Pressure Static Distance from Meter to Water Running Inlet RICALCA Manifold Electrical Line Voltage Low Voltage Igniter Resistance Flame Sense uA LED Flashing Y or N Which One s Error Codes on Control Display Condensate Line Size amp Material Length Is trap provided Y or N Combustion CO Installation Site Name amp Address Intake 45 Elbows qty Exhaust 45 Elbows qty Model Number Serial Number Length of Straight Pipe Intake Length of Straight Pipe Exhaust Setting from Bottom in
49. t mounting flange Normal burner operation should ignite smoothly without evidence of coughing or huffing upon ignition The burner flame should be a blue flame near the burner surface in a uniform flame pattern Occasional yellow or white streaks are normal Note On this high input model that uses metal fiber mesh burner a red glow from the burner surface is normal N Reconfigure gas supply piping Verify minimum gas supply piping requirements of Minimum 1 NPT Nat 3 2 NPT L P Schedule 40 black iron pipe recommended Y Inadequately sized regulator Adjust gas With manometer check inlet gas pressure Is it stable between 7 amp 14 W C static heater not running See illustrations at right N supply regulator Is gas supply pressure regulator adjustable to maintain proper and stable setting Does inlet gas pressure drop more than 2 W C during Se Inlet burner ignition SNA Removing screw from Tap inlet gas pressure tap will immediately allow gas to flow from pressure tap Volt meter set of OHM setting LP gas Nat gas valve venturi Can sparking be seen heard at the spark rod to burner Remove high voltage wire connected at the spark rod and hold approximately from Check resistance of high N voltage cable Resistance metal ground with insulated pliers during the ignition cycle 3 second spark tria
50. the control board first Tilt the control panel and slide control hook tabs from slots in the control panel see photo below Replace control board and all wire connections Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instruction located in the installation and operating instruction manual These two connections may TILT Unclip here SB BRADFORD WHITE WATER HEATERS Service Procedure X Transformer Replacement Transformer Replacement Procedure Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Position main power switch to OFF N WARNING Disconnect Unplug water heater from 120 Volt POME RSE 120 volt potential exposure Isolate the Un latch amp remove surround cover from top of water f 2PPliance and reconfirm power is disconnected heater using a multi meter Disconnect primary leads black amp white and secondary leads blue amp yellow from the transformer connections are different sizes to prevent interchanging Remove the 2 nuts 7 16 nut driver holding the transformer in place and remove transformer from control panel see photo below Install new transformer and secure in place with screws from step 6 Reconnect primary and secondary wires to transformer leads are different sizes to prevent interchanging Restore 120 vo
51. the flame sensor rod is badly corroded with deposits clean with Occurred sandpaper or replace Check the inlet gas supply to make sure the pressure is sufficient and does not drop after the gas valve opens Make sure the combustion blower is operating during the ignition and run cycle Check the venting system to make sure the inlet and exhaust terminals and venting system is not blocked If blower speed is not verified from the PWM Pulse Width Modulation signal within 5 minutes the previously described error code 62 Light off Rate Proving changes from a hold condition to this lockout code condition Failed Check the harness and pin terminals for a good connection to the control module Replace the blower or control module if the wire harness is good ILK Open Check if blocked vent pressure switches or vent limit switch are open Interlock Open If all switches check O K replace control module BRADFORD WHITE WATER HEATERS 16 Service Procedure I Thermostat Circuit Testing and Replacement IMPORTANT NOTE This procedure assumes a cool tank Condition Water heater not operating Display shows error code 93 sensor reading faulty Unplug or disconnect electrical power to the water heater Check continuity of wire harness to sensor Resistance of harness should be close to 0 ohms Replace wire harness if high resistance is measured over 5 ohms Check wires for intermittent connec
52. tions shorts frayed insulation Replace if necessary If wire harness is O K check sensor resistance detailed in Appendix A sensor resistance at various temperatures at the end of the thermostat testing and replacement section Replace sensor if needed Turn power ON to water heater Run water heater through heating cycle and verify proper operation Sensor temperature can be viewed when burner shuts off see section on viewing the display in Service Mode Condition Water heater not operating Display shows error code 80 high water temperature over 200 F WARNING Do not reset the display from the hard lockout state without correcting the cause of the overheating condition Turn power OFF Draw water to cool tank below 120 F Check sensor Sensor is held in place with a clip fastened to the well see photo Check sensor wire for potential damage or breaks in the wire insulation Is the sensor fully inserted into the well N 4 N WARNING 120 volt potential exposure Use caution making voltage checks to avoid personal injury N CAUTION Use caution not to damage connectors when making voltage measurements or jumping terminals Checking continuity of sensor disconnected from control board Sensor shown fully inserted into well Sensor clip shown properly installed Continued on next page If sensor clip is damaged replace clip Replace sen
53. ts in the wire insulation to the powered anode rods Step 3 Check all electrical connections The powered anode rods are insulated from the water heater tank in the bushing a With an ohmmeter check continuity between the powered anode terminal and the bushing There should not be continuity If there is continuity replace the powered anode assembly POWERED ANODE CONTROL MODULE LED INDICATOR LIGHT POWERED ANODE POWERED ANODE POWERED ANODE THERMOSTAT BULB BRADFORD WHITE aE Service Procedure XII Anode Baffle Inspection and Replacement Collector Cover Installation Procedure Step 1 Remove old silicone from top surface of collector flange and collector cover Step 2 Apply bead of Ultra Copper Silicone around entire collector flange surface Allow caulk to cure for 10 minutes Step 3 Carefully reinstall collector cover tighten screws evenly Step 4 Allow a minimum of 6 hours before putting heater back in service Apply 1 2 bead of ultracopper silicone around entire collector flange surface 46 I BRADFORD WHITE WATER HEATERS Water Heater Installation Check list Product Handling Carefully uncrate the heater Move in place with a hand truck do not use the venting pipes for handles Electrical Requirements Make sure there is 120 volts line voltage Line voltage must be properly polarized Adequate ground supplied to the heater Venting Requirements All ve
54. ure VII Flame Sensor Testing and Replacement Flame Sensor Testing Procedure N WARNING 120 volt potential exposure Use caution making voltage checks to avoid personal injury Flame sensor may be too hot to handle take necessary precautions Refer to ignition Y CREARE module control board illustration 24 volts should maintain beyond the 1 5 second flame proving period Is there 24 VAC across brown and blue wires coming out of the control harness Refer to illustration below is there a minimum of 1 pA during 1 5 second flame proving period With flame sensor disconnected from ignition module check continuity to ground Is there continuity to ground Replace flame sensor with gasket and or wire lead See Flame Sensor Replacement Procedure Remove flame sensor from water heater Check continuity from tip of flame sensor to end of wire lead Gira Is there continuity QUOTO CHI a N Is flame sensor free of Y Is ceramic of flame oxidation sensor cracked Y i J8 J9 N Il foo TERHET Clean or replace flame Replace flame sensor B sensor See Flame Sensor See Flame Sensor Replacement Procedure Replacement Procedure b J J5 DINI Pe n 34 RI BRADFORD WHITE WATER HEATERS Service Procedure VII Flame Sensor Testing and Replacement Flame Sensor Replacement Procedure Step 1 Step 2
55. using screws from step 6 on previous page Tighten screws evenly Reconnect high voltage cable to spark rod flame sensor blower and gas valve Reconnect PVC venting gas supply and silicone tubing to gas valve Turn on gas supply to heater and check for gas leaks repair any gas leaks found Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighting instruction located in the installation and operating instruction manual Replace surround cover on top of water heater Gas valve venturi may vary by gas type LP shown 240 I BRADFORD WHITE WATER HEATERS Service Procedure Ill Burner Tube Inspection and Replacement N WARNING Heater components may be HOT when performing the following steps in this procedure Take necessary precaution to prevent personal injury Burner Tube Removal Procedure Step 1 Position main power switch to OFF VAN WARNING Step 2 Disconnect unplug water heater from 120 volt power source 120 volt potential exposure Isolate the Step 3 Turn off gas supply to water heater appliance and reconfirm power is disconnected using a multi meter Step 4 Un latch amp remove surround cover from top of heater Step 5 From the gas valve disconnect the gas connection PVC venting wire harness and silicone tubing Step 6 Disconnect wire harness from blower assembly Step 7
56. ust and 1 90 elbows in the intake It has 1 45 elbow in the exhaust and 1 45 elbow in the intake Therefore 2 90 elbows x 5 feet 10 feet 2 45 elbows x 2 feet 5 feet 20 feet of straight pipe 10 feet 5 feet 35 feet System is within Maximum Combined Length from table above EEE BRADFORD WHITE Sequence of Operations 1 Thermostat calls for heat 2 Combustion blower starts 3 Blower pre purge period of 30 seconds 4 Trial for ignition 5 seconds 3 trials a Flame establishing period 3 seconds gas valve opens sparks from spark rod to burner surface to ignite the gas b Burneron flame proving period 2 seconds Requires a minimum of 1 0 microamp through flame sense rod to prove flame c If either 1 Pass Collector vent safety contacts normally closed or either of the blocked vent pressure switch contacts normally closed are open then the ignition sequence will not start and an error code 67 Pressure switch failed to close open or vent safety switch failed to close open will flash once on the display then the unit will go into pre purge Hold while the unit is waiting for the issue to be corrected If the issues continues to occur the system display with flash error code 137 Pressure switch is open or vent safety switch is open while the unit is waiting to restart the normal sequence of operation 5 Steady State Operation Burner continues to operate until a Th
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