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Manual 238-53597-00B REV 5/20

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Models Covered

by This Manual:

EF120T4003N(A)3

EF120T5003N(A)3

Commercial Ultra High Efficiency Models

with Direct Spark Ignition

Effective: April, 2020

ECO 8160

Summary of Contents for EF120T4003N3

Page 1: ...ICE MANUAL Troubleshooting Guide and Instructions for Service To be performed ONLY by qualified service providers Models Covered by This Manual EF120T4003N A 3 EF120T5003N A 3 Commercial Ultra High Ef...

Page 2: ...Service Procedure IV Gas Valve Replacement 29 Service Procedure V Blower Testing and Replacement 30 Service Procedure VI Blocked Vent Pressure Switch Testing and Replacement 32 Service Procedure VII...

Page 3: ...agnostic information both on the control board and digital display to help in determining the cause of system lockouts The contents in this manual are detailed informational tools to assist in the pro...

Page 4: ...Phillips head screw driver 2 tip 1 4 in nut driver pliers common needle nose socket set including a 1 1 16 deep well socket wire cutters wire strippers wire crimpers torpedo level small shop vac step...

Page 5: ...e Open Shipping Wt LBS 120T400 399 999 119 71 73 1 1 1 1 1120 120T500 499 999 119 71 74 7 8 1 1 1 1 1135 DIMENSIONS MILLIMETERS Model No Input Rate KW Storage Capacity Liter A Height B Floor to Alt Ho...

Page 6: ...24 volts Temperature range 100 to 183 F Used to set tank temperature F or C show operating status display error codes error code history and limit maximum setpoint temperature Control Board Operates o...

Page 7: ...l of all elbows and straight pipe intake and exhaust must not exceed maximum lengths from tables above Example A 4 in balanced direct vent system has 10 ft of straight exhaust pipe and 10 ft of straig...

Page 8: ...ccur the digital display with flash error code 137 pressure switch is open or vent safety switch is open while the unit is waiting to restart 5 minutes the normal sequence of operation 6 Once the flam...

Page 9: ...al display The control board can only be reset in the Service Mode which is detailed in the Troubleshooting section of this Service Manual pg 11 3 ERROR CODE 67 a If the exhaust terminal becomes block...

Page 10: ...factory installed A full installation operation and troubleshooting manual is provided with the gateway kit CAUTION Before beginning any Troubleshooting operations listed below please note that the g...

Page 11: ...al display operates see next page Check main power supply to water heater Check fuse circuit breaker plug receptacle line cord and wiring to water heater Check to make sure switch on front of control...

Page 12: ...ying temperature sensors Does blower post purge for 30 seconds System O K Check to see if digital display shows any other error codes 67 pressure switch 67 vent safety switch or 80 high limit If so re...

Page 13: ...oamps when the burner is operating Step 3 Press the lower right Next button and the digital display will flash and show the number of any alert codes If alerts are present and the unit is not operatin...

Page 14: ...wer right Next button and the digital 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 Service Mode Pr...

Page 15: ...ears on the display Step 2 Press DONE button for new setting to take effect immediately If the DONE button is not pressed the new temperature setting will take effect in approximately 10 seconds To De...

Page 16: ...isplay from q qF to q qC or C to F Enter Set Up Mode by pressing both UP DOWN buttons together for 3 seconds NOTICE Pressing the NEXT button instead of DONE will enter the display to show unused scree...

Page 17: ...quency voltage and VA meet the specifications See Service Procedure X Transformer Replacement pg 40 53 Reverse polarity x Check the control board and digital display connections x Check the control bo...

Page 18: ...wires and that there is no moisture on the flame sensor x If problem persists and all other checks have been verified replace the control board 110 Ignition failure occurred x Burner failed to light...

Page 19: ...ensor 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 digit...

Page 20: ...ay be reset x Reconnect and switch on power to the water heater x Press button under Reset and hold for 3 seconds x Set thermostat to the desired setting x Water heater will start x Monitor temperatur...

Page 21: ...26 5208 5094 4982 4873 4767 110 4663 4562 4464 4368 4274 4183 4094 4006 3922 3839 120 3758 3679 3602 3527 3453 3382 3312 3244 3177 3112 130 3048 2986 2925 2866 2808 2752 2697 2643 2590 2538 140 2488 2...

Page 22: ...stall new sensor completely into well and reinstall sensor clip 8 Connect temperature sensor to control 9 Fold insulation back into place Be sure there are NO wires in contact with burner 10 Restore 1...

Page 23: ...s it stable between 7 14 W C static heater not running See images on page Is gas supply pressure regulator adjustable to maintain proper and stable setting Inadequately sized regulator Adjust gas supp...

Page 24: ...urner tube see Burner Tube Inspection pg 27 Does the burner stay lit Does the burner operate normally until thermostat is satisfied Call Technical Support System O K Y Y Y Y Y N N N N Y Y Y Y N Refer...

Page 25: ...harness 6 Disconnect flame sensor and blower wire harnesses Disconnect high voltage cable from spark rod connection 7 Remove the 5 bolts 1 2 socket holding the burner mounting insert in place 8 Caref...

Page 26: ...Secure combustion assembly at the burner mounting insert using screws from Step 6 on previous page Tighten bolts evenly 3 Reconnect high voltage cable to spark rod flame sensor blower and gas valve 4...

Page 27: ...e spark rod and flame sensor in place long reach magnetic Phillips head screwdriver Carefully remove spark rod and flame sensor from combustion assembly 8 Remove the 4 nuts 7 16 wrench holding the bur...

Page 28: ...are NOT affected by any of the above gasket replacement is not required 2 Install burner tube with gaskets into burner mounting insert Be sure gasket surfaces are free of debris 3 Reconnect the blowe...

Page 29: ...erial from blower and venturi mounting flange 8 Install new gas valve with new gasket provided Secure gas valve in place using screws from Step 6 9 Reconnect gas supply intake venting wire harness and...

Page 30: ...Blower Replacement Procedure pg 31 Are collector high limit switch and pressure switches in normally closed Correct safety circuit problem per safety circuit trace see Blocked Vent Pressure Switch Tes...

Page 31: ...om venturi mounting flange and transition flange 10 Install new blower with new gasket provided Secure blower in place using screws from Step 8 11 Reconnect gas valve assembly to blower with new gaske...

Page 32: ...Procedure pg 41 Check digital display Is it on within 5 minutes Pressure switch is O K Is the display flashing after 5 minutes Is error code 67 present again Call Technical Support Check blower for pr...

Page 33: ...o correct blockage below Replace blocked exhaust vent switch see Blocked Exhaust Vent Switch Testing and Replacement pg 32 With ohmmeter check pressure switch for continuity Contacts should be closed...

Page 34: ...tch mounting screws 5 16 nut driver and remove pressure switch common screwdriver 6 Assemble new pressure switch to heater using screws from Step 5 7 Reconnect red wire leads Note Wire leads are inter...

Page 35: ...or wire lead see Flame Sensor Replacement Procedure pg 36 Remove flame sensor from water heater Check continuity from tip of flame sensor to end of wire lead Is there continuity Is flame sensor free o...

Page 36: ...any residual gasket material from transition base flange 8 Install new flame sensor with new gasket provided using screws from Step 6 Arrange flame sensor with hook towards burner 9 Reconnect the fla...

Page 37: ...ages below 4 Clean spark rod with steel wool or emery cloth 5 Re measure and verify spark gap are between 3 16 to 1 4 after bending 6 Verify the integrity of all gaskets and replace where required 7 R...

Page 38: ...Combustion System Removal Procedure and verify spark gap following Spark Rod Gap Inspection and Adjustment Reassemble combustion system following Combustion System Replacement Procedure 10 Fold insula...

Page 39: ...n the top back side of the control board first 7 Tilt the control board and slide control board hook tabs from slots in the metal panel see images below 8 Replace the control board and all wire connec...

Page 40: ...ace and remove transformer from control board see image below 6 Install new transformer and secure in place with screws from Step 6 7 Reconnect primary and secondary wires to the transformer leads are...

Page 41: ...y across high limit switch see image below Does the water heater function Call Technical Support Replace vent safety switch see Vent Safety Switch Replacement Procedure pg 41 Reset heater observe heat...

Page 42: ...ow 4 Disconnect grey wire leads from vent safety switch see image below 5 Remove the 2 switch mounting screws Phillips screwdriver and remove switch from heater 6 Install a new switch using screws fro...

Page 43: ...wered anode system is disconnected 1 Check the power supply or wire connections to the powered anode control 120 VDC 2 Indicator light diagnostic codes a If the LED is flashing red then there is a mal...

Page 44: ...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 bottom safety sw...

Page 45: ...____________________ Is trap provided Y or N _________________________ Exhaust Collector Pressure Inches W C ___________________________ Combustion CO2 ____________________ CO ____________________ Ins...

Page 46: ...___________________________________________ ____________________________________________________________ ____________________________________________________________ __________________________________...

Page 47: ...________________________________ _____________________________________________________________________ _____________________________________________________________________ ___________________________...

Page 48: ......

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