Bradford White SX) Service Manual Download Page 22

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Accessing Service Mode on Control Display

For models with Honeywell Integrated Control

4. Setpoint (Display/Change)

SELECT

SET

Status

°F

idle

setpoint

Operational

5. °F/°C (Display/Change)

SELECT

SET

Status

°F/C°

idle

Operational

°F

setpoint

6. Differential (Display only - shows the differential of the thermostat)

SELECT

SET

Status

°F

idle

Differential

Operational

Summary of Contents for SX)

Page 1: ...ualified service providers Models Covered by This Manual For The Bradford White eF Series Ultra High Effeciency Models EFR160T120 EN SX EF60T125 E N X A 2 EF60T150 E N X A 2 EF60T199 E N X A 2 EF100T150 E N X A 2 EF100T199 E N X A 2 EF100T250 E N X A 2 EF100T300 E N X A 2 EF100T399 E N X A 2 Denotes Warranty Years Ultra High Efficiency Water Heaters ...

Page 2: ... Blower Testing and Replacement 52 V Exhaust Pressure Switch Testing and Replacement 54 VI Hot Surface Igniter Testing and Replacement 60 VII Flame Sensor Testing and Replacement 62 VIII Spark Rod Gap Adjustment and Replacement 64 IX Ignition Module Control Board Replacement 66 X Transformer Replacement 68 XI Intake Pressure Testing and Replacement 69 XII Vent Safety Switch Testing and Replacement...

Page 3: ...imings 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 eF Series Ultra High Efficiency Water Heater operational faults Please read this service manual completely and provide as mu...

Page 4: ... 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 Manometer Two types available a liquid U tube type or a digital magna helic type This device is used to measure gas an...

Page 5: ...urner ignition with direct spark ignition A high voltage spark jumps from the spark rod to the burner surface to ignite the gas Eliminates burned out hot surface igniter replacements Water heater display will show diagnostic codes in the event the water heater needs servicing Aids in diagnosing and servicing the water heater Water heater display can show previous error code history to further aid ...

Page 6: ...5 8 28 28 28 28 28 28 28 28 28 5 5 5 5 5 5 5 5 5 13 13 13 13 13 13 13 13 13 40 40 40 40 60 60 60 60 60 42 42 42 42 62 62 62 62 62 52 52 52 52 73 1 8 73 1 8 73 1 8 73 1 8 73 1 8 53 53 53 53 74 74 74 74 73 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 570 570 570 570 900 900 900 900 950 Shpg Wt lbs T P Valve Open NPT Gas Conn Dia NPT Space Heating Conn Dia Front Wtr Conn Dia H Flr to Gas Conn G Flr To Air...

Page 7: ... 50 W C EF100T150 see note 2 1 22 W C EF60T150 EF100T250 2 08 W C EF60T125 0 55 W C EF100T300 see note 3 Note 2 5 6 W C on serials prior to AH5039107 Note 3 0 8 W C on serials prior to AK5288269 Power supply Dedicated 120 VAC 60 Hz 15A GFI Approved Gas Type Natural or Propane Unit must match gas type supplied Venting System Power vent balanced direct vent or unbalanced direct vent See vent tables ...

Page 8: ... 120VAC primary 24VAC secondary 40VA Vent Safety Switch Normally closed opens 350 F manual reset Blower 120VAC 60Hz 6 1 amps 6400 RPM Approved Gas Type Natural or Propane Unit must match gas type supplied Venting System Power vent balanced direct vent or unbalanced direct vent See vent tables on page 7 Approved Vent Materials PVC or CPVC Gas Supply Minimum NPT schedule 40 black iron pipe recommend...

Page 9: ...ect Vent Systems Air intake CAN NOT exceed exhaust by more than 30 feet Power Vented Systems PVC CPVC Total length of exhaust piping must not exceed Maximum Vent Length Shown below Maximum Vent Length feet Model Number 3 EF60T125 EF100T150 120 EF60T150 EF100T199 EF60T199 EF100T300 100 80 60 4 170 150 130 110 EF100T399 50 100 EFR 1 60T120 60 120 2 170 30 30 30 N A N A Balanced Direct Vent Systems P...

Page 10: ...ted by the PURGE LED on the module 5 Igniter warm up 18 seconds indicated by the IGNITER LED on the module 6 Trial for ignition 4 seconds three trials a Flame establishing period 2 5 seconds gas valve and igniter on indicated by the IGNITER and VALVE LED on the module b Burner on flame proving period 1 5 seconds looking for minimum of 1 micro amps indicated by the FLAME VALVE LED on the module 7 S...

Page 11: ...of continuous call for heat from the thermostat Three ignition trials will be attempted each hour until the thermostat is satisfied For models prior to CF serial numbers Ignition Module Specifications Ignition heating functions in response to thermostat Hot surface ignition using a microprocessor to control timing flame sensing using flame rectification ignition retries Monitoring of system pressu...

Page 12: ...hour to attempt to close the switch and restart ignition sequence Flame sensor circuit If flame is lost gas valve is shut down system will post purge and system attempts re ignition For models starting with CF serial numbers and later For models starting with CF serial numbers and later Prior to energizing blower ignition module checks to make sure the vent temperature switch is in the normally cl...

Page 13: ...CF serial numbers and later Ignition Module Specifications Ignition heating functions in response to thermostat Hot surface ignition using a microprocessor to control timing flame sensing using flame rectification ignition retries Monitoring of system pressure switches and limit switches Control of gas valve inducer motor and hot surface igniter element based on thermostat demand and status of saf...

Page 14: ...e switch failed to close or open will be shown on the display Steady State Operation Burner continues to operate until Thermostat circuit opens gas valve closes blower continues to operate for 30 second post purge period If the normally closed blocked vent pressure switch opens the gas valve closes the blower continues to operate indefinitely and error code 29 will be displayed after a couple minu...

Page 15: ...normal operation No resetting of the control display is needed for the pressure switch error code 4 ERROR CODE 26 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 26 will appear on the display The lockout condition will reset once the problem is corrected and the switch reset Refer to Vent Safety Switc...

Page 16: ...ee Ignition Module Replacement Replace transformer see Transformer Replacement N N Y Y Is ignition module power and flame light flashing Reset heater by interrupting power Reestablish power and Adjust thermostat to call for heat tank must be cold Allow heater to run through heating cycle Did heater complete heating cycle and did blower post purge See next page System is OK Supply voltage polarity ...

Page 17: ...ng and Replacement Probable Cause Combustion system see Combustion System Testing and Replacement Probable Cause Intake pressure switch Only for models prior to CF serial number see Intake Pressure Switch Testing and Replacement Probable Cause Blower see Blower Testing and Replacement Probable Cause Exhaust pressure switch see Exhaust Pressure Switch Testing and Replacement LED STATUS Purge light ...

Page 18: ... personal injury Is 24VAC present between RED and BLACK wire pin connections on the back of Control Display 1 2 3 8 6 5 4 3 1 1 2 1 4 1 3 3 2 1 1 5 3 P2 P4 P5 P7 P3 CONTROL BOARD P10 P9 J1 Refer to Control Board illustration Voltage at primary pins P2 1 P2 3 will be 110 120 If not check Line In pins P3 1 P3 4 Check line cord with volt meter Replace line cord if defective Refer to Control Board ill...

Page 19: ...re sensors Error code 63 on display see Combustion System Testing and Replacement Does blower post purge for 30 seconds System okay N Y N N N Y Y Y Y From previous page N CAUTION Use caution not to damage connectors when making voltage measurements or jumping terminals WARNING 120 volt potential exposure Use caution making voltage checks to avoid personal injury 1 2 3 8 6 5 4 3 1 1 2 1 4 1 3 3 2 1...

Page 20: ... Up buttons together and hold for 3 seconds until Max Setpoint is shown in the display Step 2 Pressing Select button will change display to next mode SELECT SET Status F idle Operational Water Temp The following is the sequence of modes available in Service Mode by pressing the Select button Error Code Number Display Reset This is only shown if there is an operating error in the User Mode SELECT L...

Page 21: ...nsor Temperature Displayed Water Temperature Average SELECT SET Status F idle Water Temp Operational 21 SELECT SET Status F idle Operational Max Setpoint value in Water Heater Display Max Setpoint 3 Flame Current of Burner Flame Sensor Displays only in the Heating Cycle SELECT SET Status Heating Operational Flame Current µA 21 ...

Page 22: ...ed Control 4 Setpoint Display Change SELECT SET Status F idle setpoint Operational 5 F C Display Change SELECT SET Status F C idle Operational F setpoint 6 Differential Display only shows the differential of the thermostat SELECT SET Status F idle Differential Operational 22 22 ...

Page 23: ...ture setpoint Step 1 In service mode press the Select button until Max Setpoint is displayed WARNING Setting the water temperature to the maximum set point can result in scalding hot water delivered to the faucets It is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the installation Make sure the water heater control display is not in a...

Page 24: ...alue This will limit the maximum setpoint the user can select Note The maximum setpoint is approximately 180 F Step 4 Press Set button to confirm new Max Setpoint value and stop setting mode Max Setpoint stops flashing SELECT SET Status F idle Operational Max Setpoint SELECT SET Status F idle Operational Max Setpoint Max Setpoint continues to flash while making adjustments 24 SELECT SET Status F i...

Page 25: ... maximum setting The Water Heater Display can be set back to the User Mode immediately by pressing both the Temperature Up and Select buttons together for 3 seconds SELECT SET Status idle Operational Max Setpoint Exiting Service Mode Display of Water Temperature Step 1 In Service Mode Press the Select button until Water Temp is displayed in the upper right section of the water heater display This ...

Page 26: ...ugh hot water to start the burners Step 2 Enter the Service Mode described previously Step 3 Press the Select button until a number value is displayed with Flame Current to the right of the number The value displayed is in microamps µA SELECT SET Status Operational Flame Current Heating µA To Display and Change Temperature Setpoint Step 1 In Service Mode press the Select button until Setpoint is s...

Page 27: ...play WARNING Setting the water temperature to the maximum set point can result in scalding hot water delivered to the faucets It is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the installation Make sure the water heater control display is not in a public area that can result in the temperature settings being improperly adjusted NOTIC...

Page 28: ...LECT SET Status F idle setpoint Operational To Display and Change Temperature Format F C To Change Temperature Format in Display from F to C or C to F Step 1 While in Service Mode press Select button until F C is shown in the upper right portion of the water heater display SELECT SET Status idle Operational F F C Step 2 Press Set button to change temperature format F C symbol will flash in the wat...

Page 29: ... button to change temperature format to C SELECT SET Status idle Operational C F C Step 3b Press Temperature Down button to change temperature format to F SELECT SET Status idle Operational F F C Step 4 Press Set button to confirm F or C format F C will stop flashing SELECT SET Status F idle Operational F F C 29 29 ...

Page 30: ...e Water Heater Display and the following section in this Service Manual explains the error codes with corrective actions to repair the water heater SELECT SET idle Service Needed Example of Error Code in the Display Error Code History In Service Mode pressing the Select button after the Software Version item 8 in the previously described sequence of service modes will show an error code history if...

Page 31: ...ep 2 Press the Temperature Down button to select the error code index starting with the most recent error code 10 SELECT SET Status idle Operational Step 3 Press the Select button to view the error code for code 10 If there is a number displayed note what the number is The label next to the water heater display will identify the code number If no number is displayed with only a in the water heater...

Page 32: ... next error code index and press Select to view the error code number if any for that index number Continue on to index 1 the oldest error code index The water heater display will store up to 10 error codes with the oldest code starting in code index 1 with the most recent code in code index 10 Step 7 10 seconds after the last button press the Water Heater Display will revert back to the current e...

Page 33: ...CURRENT FLAME SENSED OUT OF NORMAL SEQUENCE BEFORE OPENING GAS VALVE OR AFTER CLOSING GAS VALVE FLAME DETECTED BEFORE IGNITION FLAME DETECTED AFTER A HEATING CYCLE COMPLETES PRESSURE SWITCH FAILED TO CLOSE OR OPEN STUCK OPEN LOWER SENSOR READINGS FAULTY FLAME ROD SHORTED TO GROUND AC LINE FREQUENCY ERROR SIGNAL TOO NOISY OR FREQUENCY INCORRECT LINE VOLTAGE TOO LOW OR HIGH DC OUTPUT VOLTAGE UNSTABL...

Page 34: ... portion of the display The control will also go through 3 attempts to relight the burners every hour in the soft lockout condition All other error codes will put the water heater into a Hard Lockout condition in which the water heater will not operate and cannot be reset in the User Mode To reset a hard lockout first enter the Service Mode described earlier by pressing both the Temperature Up and...

Page 35: ...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 Check Sensor Resistance See Sensor Resistance Testing following section Y N Condition Water Heater Not Operating Display shows error code 65 High Water Temperature over 200 F If wire harness is...

Page 36: ...Enter service mode on the water heater display see illustration Press button under Lockout 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 well below 200 F WARNING Do not operate water heater without verifying that the overheating condition has been correc...

Page 37: ...ngs correct see photo at right Y Y Replace thermostat sensor see Thermostat Sensor Replacement Procedure Replace temperature dial potentiometer see Thermostat Potentiometer Replacement Procedure N N N Replace thermostat circuit board see Thermostat Board Replacement Procedure Y Check sensor harness continuity Is there continuity Check temperature dial harness continuity Is there continuity Replace...

Page 38: ...1625 1595 1566 1537 1509 1481 1454 1427 170 1402 1376 1351 1327 1303 1280 1257 1235 1213 1191 180 1170 1150 1129 1110 1090 1071 1053 1035 1017 999 190 982 965 949 933 917 901 886 871 857 842 200 828 814 801 788 775 762 749 737 725 713 In Degrees F APPENDIX A Sensor Resistance at Various Temperatures Example If temperature of sensor is 84 F then the resistance through the sensor would be 8449 see s...

Page 39: ...Thermostat Sensor Replacement Procedure Check AC source to determine why there is no power Replace ignition module see Ignition Module Replacement N Check continuity through ECO red wires of thermostat sensor Check at temperature less than 160 F Is there continuity see photo at right N Replace ignition module see Ignition Module Replacement Y Replace thermostat circuit board see Thermostat Board R...

Page 40: ...confirm proper operation following the lighting 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 heater Thermostat Board Replacement Procedure Hot Surface Ignition Step 1 Position main power switch to OFF Step 2 Disconnect unplug water heater from 120 volt power source St...

Page 41: ...side of surround see photos above Step 9 Reconnect wires to potentiometer Note Wire leads are interchangeable with either wire Step 10 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 Step 11 Replace surround cover ...

Page 42: ...ation back into place Be sure there are no wires in contact with burner Step 10 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 Step 11 Replace surround cover on top of...

Page 43: ...w is there 120VAC across terminals P6 1 and P6 2 Note Igniter LED must be lit during this check Y N Replace hot surface igniter see Hot Surface Igniter Replacement Procedure Replace ignition module see Ignition Module Replacement Procedure N Y Do you see the igniter glowing through burner site glass during the warm up period Proceed to next page With manometer check inlet gas pressure Is it stable...

Page 44: ...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 Y Does burner operate normaly until thermostat is satisfied N System OK Y Turn ...

Page 45: ...r see Spark Rod Gap Inspection 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 N Y Can Sparking be seen heard at the spark rod to the burner Proceed to next page With manometer check inlet gas pressure Is it stable between 7 14 W C static heater not running see illustrations at right Is gas ...

Page 46: ...rt 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 Y Does burner operate normaly until thermostat is satisfied N System OK Y Turn VENTURI set screw clockwise until its bottomed out Turn screw co...

Page 47: ...e cable from spark rod connection Step 7 Remove the 5 bolts socket holding the burner mounting insert in place Step 8 Carefully remove combustion assembly with gasket from water heater Step 9 See next page for combustion system installation procedure Combustion System Removal Procedure WARNING 120 volt potential exposure Isolate the appliance and reconfirm power is disconnected using a multi meter...

Page 48: ...nect wire harnesses to hot surface igniter or high voltage cable to spark rod flame sensor blower and gas valve Step 4 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 Step 5 Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting i...

Page 49: ...stion assembly For Direct Spark Ignition models remove the two screws on the spark rod bracket and remove the spark rod Step 8 Remove the 4 nuts 7 16 wrench holding the burner transition in place Lift the blower gas valve transition assembly from burner mounting insert remove gasket and set aside Step 9 Remove burner tube from burner mounting insert See next page for burner tube inspection procedu...

Page 50: ... 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 Step 2 Install burner tube with gaskets into burner mounting insert Be sure gasket surfaces are free of debris Step 3 Reconnect t...

Page 51: ... the gas valve disconnect the gas connection PVC venting wire harness and silicone tubing Step 9 Reconnect PVC venting gas supply silicone tubing wire harness to gas valve Turn on gas supply to heater and check for gas leaks repair any gas leaks found Step 10 Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction l...

Page 52: ...C between P3 7 and ground Y N Thermostat not calling for heat see Thermostat Circuit Testing Correct safety circuit problem per safety circuit trace section Blocked Vent Pressure Switch Testing Y Y Is there 120VAC across the white and black wires at the terminal block see photo at right N N Refer to ignition module control board illustration Hot Surface Ignition Models Is there 120VAC between P5 1...

Page 53: ...ine to gas valve assembly and check for gas leaks repair any leaks found Step 13 Reconnect wire harness to blower assembly restore 120 volt power supply 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 Step 14 Replace surround cover ...

Page 54: ...re switch see Exhaust Pressure Switch Replacement Procedure Replace vent safety switch see Vent Safety Switch Replacement Procedure Call technical support Y N Depress reset button on vent safety switch Is there continuity across high limit switch see photo below Refer to Check Collector Pressure see next page Check blower for proper operation see page 27 Is blower OK N Check PURGE LED status on ig...

Page 55: ... With monometer take a reading at the exhaust tube pressure tap location Is value negative see illustration below Check exhaust collector pressure at the exhaust collector pressure tap location see illustration below Is there positive pressure equal to or greater than pressure switch settings below EXHAUST PRESSURE SWITCH SETTINGS EF 60 100 T199 2 58 W C EF100T150 1 50 W C see note 1 EF60T150 EF10...

Page 56: ...Reconnect silicone tubing to pressure switch as follows a Exhaust pipe tubing connects to negative side of switch identified by the symbol located on switch b Exhaust collector tubing connects to positive side of switch identified by the symbol located on the switch Step 10 Reinstall service panel access cover and rubber escutcheon Exhaust Pressure Switch Testing and Replacement For serial numbers...

Page 57: ...volt potential exposure Use caution making voltage checks to avoid personal injury Flashing after 5 minutes Error code 29 again Call for technical support Correct blower problem see Blower Testing and Replacement N Y Note HOT SURFACE IGNITION MODELS ONLY The blocked vent pressure switch must be used with the revised ignition control identified with a yellow label Heater side harness Control side h...

Page 58: ...ne cause and correct Y Is vent system total length compliant with vent tables in the instruction manual Reconfigure vent system to be compliant with vent tables see Specifications Y N With monometer take a reading at the exhaust tube pressure tap location Is value negative or slightly postitive see illustration below Y N With ohmmeter check pressure switch for continuity Contacts should be closed ...

Page 59: ...e switch to heater using screws from step 5 Step 7 Reconnect wire leads Note wire leads are interchangeable with either terminal Step 8 Reconnect silicone tubing to pressure switch as follows a Exhaust pipe tubing connects to single tap located on switch Step 10 Reinstall service panel access cover and rubber escutcheon Blocked vent Switch Testing and Replacement For serial number CF or later Step...

Page 60: ...rface igniter see Hot Surface Igniter Replacement Procedure Replace ignition module see Ignition Module Replacement Procedure N Check harness connection from igniter to ignition module Y Hot surface Igniter Testing Procedure Volt meter set to OHM setting Meter probe Hot surface igniter CHECK IGNITER RESISTANCE IGNITION MODULE WARNING 120 volt potential exposure Use caution making voltage checks to...

Page 61: ...flange Step 8 Install new igniter with new gasket provided using screws from step 5 Arrange igniter flange with off center hole towards front of heater Step 11 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 Step ...

Page 62: ...3 5 Direct Spark Ignition Models Is there 24VAC between P5 5 and P5 8 Y N Call for technical support 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 Is there continuity N Y WARNING 120 volt potential exposure Use caution making voltage checks to avoid persona...

Page 63: ...using screws from step 6 Arrange flame sensor with hook towards burner Step 1 Position main power switch to OFF Step 2 Disconnect unplug water heater from 120 volt power source Step 3 Un latch remove surround cover from top of heater Step 11 Restore 120 volt power supply to water heater and confirm proper operation following the lighting instructions on the lighting instruction label or the lighti...

Page 64: ...with needle nose pliers see photo below Step 4 Re measure and verify spark gap is between 3 16 1 4 after bending Step 5 Reinstall the combustion system per Combustion System Replacement Procedure and check several ignitions to ensure the burner lights smoothly Spark Rod Burner Tube Spark Rod Hold spark rod near ceramic insulator Bend spark rod near burner tube CAUTION Use caution while performing ...

Page 65: ...spection and Adjustment Step 1 Position main power switch to OFF Step 2 Disconnect unplug water heater from 120 volt power source Step 3 Un latch remove surround cover from top of heater Step 11 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...

Page 66: ...e to insure proper reinstallation Step 6 Remove the 3 screws Phillips screw driver holding the ignition module in place and remove ignition module from control panel Step 9 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 ...

Page 67: ...t may be necessary to identify wires for proper re connection Step 6 Depress the plastic tabs on the blower side of the control board first Step 7 Tilt the control panel and slide control hook tabs from slots in the control panel see photo at right Step 8 Replace control board and all wire connections Step 9 Restore 120 volt power supply to water heater and confirm proper operation following the l...

Page 68: ...transformer leads are different sizes to prevent interchanging Step 9 For Hot Surface Ignition models Reconnect blue yellow wire leading from the P2 connection on ignition module to thermostat board Note the blue wire must connect to the 24 volt HOT terminal see photo at right Step 1 Position main power switch to OFF Step 2 Disconnect Unplug water heater from 120 Volt power source Step 3 Un latch ...

Page 69: ...d Replacement or Blower Testing and Replacement Y N Y N N Y Is intake vent system obstructed Y N Call for technical support Clear obstruction See Exhaust Pressure Switch Testing and Replacement or Blower Testing and Replacement Used on EF water heaters prior to CF serial number Is there continuity through the normally closed intake pressure switch see photo above Y Isolate disconnect heater from i...

Page 70: ... silicone tubing from step 6 to pressure switch Step 10 Reconnect red wires from step 5 to pressure switch Note wires are interchangeable with either switch terminal Step 11 Restore 120 volt power supply to heater verify proper heater operation following the instructions on the lighting instruction label or the lighting instructions located in the installation operation manual Step 12 Replace surr...

Page 71: ... position of normally closed If the vent safety switch contacts are open not in normal position the ignition module waits indefinitely for contact to close The vent safety switch must be manually reset to close the switch contacts For Direct Spark Ignition models error code 26 will display indicating an open circuit for the vent safety switch Determine if temperature has reached 350 F before reset...

Page 72: ...ee photo at right Step 5 Remove the 2 switch mounting screws Phillips screw driver and nuts 5 16 wrench and remove switch from heater Step 6 Install new switch using screws from step 5 Step 7 Reconnect wire leads Note wire leads are interchangeable with either switch terminal Step 9 Reinstall service panel access cover and rubber escutcheon Step 8 Restore 120 volt power supply to water heater and ...

Page 73: ...ector cover see photos at right Step 6 Completely remove insulation two pieces from top of heater to expose collector cover Step 8 Photo 44 shows heater with collector cover removed allowing access to anode rods and flue baffles a for anode service see Anode Inspection and Replacement b for flue baffle service see Flue Baffle Inspection and Replacement c for powered anode service see Powered Anode...

Page 74: ...ly thread sealing tape or other thread compound to threads of anode and reinstall into heater Restore water supply and check for and repair any leaks found Step 6 Reinstall collector cover per Collector Cover Installation Procedure Step 7 Reinstall collector insulation and control panel reconnect control panel wire harnesses Step 8 Restore 120 volts to water heater and verify proper heater operati...

Page 75: ...on of inspection or subsequent replacement reinstall flue baffles into heater Step 5 Reinstall collector cover per Collector Cover Installation Procedure Step 6 Reinstall collector insulation and control panel reconnect control panel wire harnesses Step 7 Restore 120 volts to water heater and verify proper heater operation following the instructions on the lighting instruction label or the lightin...

Page 76: ...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 spots in the wire insulation to the powered anode rods Step 3 Check all electrical connections The powered anode rods are insulated from the water he...

Page 77: ...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 bead of Ultra Copper Silicone around entire collector flange surface 77 77 ...

Page 78: ...e 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 Note each 3 4 90 Elbow is equivalent to 5 feet of straight pipe Note each 3 4 45 Elbow is equivalent to 2 5 feet of straight pipe 78 Unbalanced Direct Vent Sys...

Page 79: ...Pressure Size Material Length Condensate Line Igniter Resistance Flame Sense Micro Amps Venturi Exhaust Collector Pressure Setting from Bottom in Turns Positive Inches W C LED Flashing Y or N Which One s Combustion CO2 CO Installation Site Contact Name Phone Number Service Provider Phone Number Is trap provided Y or N Installation Site Name Address Length of straight pipe exhaust Spark Gap _______...

Page 80: ... Wire Harness Service Panel 11 Plastisert Nipple 1 NPT 12 Plug 13 Nipple 14 T P Relief Valve 15 Exhaust Pipe PVC w Hose Barb 16 Condensate Trap Elbow 17 Silicone Hose 18 Outer Door Service Panel 19 Vent Pipe Support Bracket 20 NSF Escutcheon 21 Exhaust Pressure Switch 22 Nut 23 Vent Safety Switch 24 Screw 6 32x 3 8 25 Cleanout Access Cover 26 Cleanout Gasket 27 Screw 5 16 18 x HH Grade 5 28 Cleano...

Page 81: ...ssy 3A Burner Assy 4A Blower EBM 5A Silicone Hose 6A Hose Tee Fitting 7A Screw 10 32 x3 4 8A Gasket Screw 9A Gas Valve 10A Nipple NPT X3 11A Reducer x NPT 12A Nipple NPT x 6 13A 2 dia Flex Reducer 14A Inlet PVC 15A Gasket Blower Transition 16A Screw 8 32 x RHCR 17A Gasket Flame Sensor 18A Flame Sensor 19A Transition Tube 20A Nut Hex Washer 21A Gasket Hot Surface Igniter 22A Hot Surface Igniter 23A...

Page 82: ...crew 8 32 x 1 2 3C Intake Pressure Switch 4C Control Mounting Panel 5C Thermostat PC Board 6C Transformer 120VAC x 24VAC x 40VA 7C Terminal 8C Terminal Strip 9C Power Cord 10C Control Wire Harness 11C Thermostat Wire Harness 12C Igniter Extension Wire 13C Blower Wire Harness 14C Power Switch Wire Harness 15C Flame Sensor Wire Harness 16C Rectifier Harness 82 ...

Page 83: ... 12 Plug 13 Nipple 14 T P Relief Valve 15 Exhaust Pipe PVC w Hose Barb except EF100T399 16 Condensate Trap Elbow specify model 17 Silicone Hose 18 Outer Door Service Panel specify model 19 Vent Pipe Support Bracket except EF100T399 20 NSF Escutcheon 21 Exhaust Pressure Switch 22 Nuts 23 Collector Temperature Limit Switch 24 Screw 6 32x 3 8 25 Cleanout Access Cover 26 Cleanout Gasket 27 Screw 5 16 ...

Page 84: ...y model 4A Blower EBM specify model 5A Silicone Hose 6A Burner Mounting Insert Gasket 7A Screw 10 32 x3 4 8A Gasket Screw 9A Gas Valve specify model 10A Nipple specify model 11A Reducer specify model 12A Nipple specify model 13A 2 dia Flex Reducer or PVC reducer for 399 14A Inlet PVC 15A Gasket Blower Transition specify model 16A Screw 8 32 x RHCR 17A Gasket Flame Sensor 18A Flame Sensor 19A Trans...

Page 85: ...t PC Board Transformer 120VAC x 24VAC x 40VA Terminal Terminal Strip Power Cord Control Wire Harness Thermostat Wire Harness Powered Anode Control Harness 399 only Powered Anode Harness 399 only Powered Anode Control 399 only Rectifier Harness specify model Blower Wire Harness specify model Power Switch Wire Harness Flame Sensor Wire Harness 1C 2C 3C 4C 5C 6C 7C 8C 9C 10C 11C 12C 13C 14C 15C 16C 1...

Page 86: ...ple 1 NPT 12 Plug 13 Nipple 14 T P Relief Valve 16 Condensate Trap Elbow specify model 17 Silicone Hose 18 Outer Door Service Panel specify model 20 NSF Escutcheon 21 Exhaust Pressure Switch 22 Nuts 23 Collector Temperature Limit Switch 24 Screw 6 32x 3 8 25 Cleanout Access Cover 26 Cleanout Gasket 27 Screw 5 16 18 x HH Grade 5 28 Cleanout Cover 29 Cold Water Inlet Hydrojet Assembly 30 No Handle B...

Page 87: ...fy model 14A Inlet PVC 15A Gasket Blower Transition specify model 16A Screw 8 32 x RHCR 17A Gasket Flame Sensor 18A Flame Sensor 19A Transition Tube 20A Nut Hex Washer 21A Spark Rod 22A Spark Rod Gasket 23A Burner Mounting Gasket 24A Burner Tube 25A Burner Mounting Gasket 26A Burner Mounting Insert 1B Latch Assy 2B Screw 8 32 x RHCR 3B Ignition Control Assy 4B Jacket Head 5B Main power switch 6B H...

Page 88: ...C Control Board 3C 4C Transformer 120VAC x 24VAC x 40VA 5C Terminal 6C Terminal Strip 7C Power Cord 8C Controller Wire Harness 9C Transformer Primary Wire Harness 10C Transformer Secondary Wire Harness 11C Blower Wire Harness 12C Power Switch Wire Harness Sensor Wire Harness 7C 9C 8C 11C 5C 4C 1C 3C 2C 6C 12C 10C 13C 13C High Voltage Spark Cable 88 ...

Page 89: ...y Cut Off GFI Ground fault interrupt GPM Gallons per Minute HSI Hot Surface Igniter Hz Hertz LED Light Emitting Diode NOx Oxides of Nitrogen NPT National Pipe Thread PSI Pounds per Square Inch RPM Revolutions per Minute VA Volt Amps VAC Volts Alternating Current W C Inches of Water Column C Degrees Centigrade F Degrees Fahrenheit µA Micro Amp 89 89 ...

Page 90: ...NOTES 90 90 ...

Page 91: ...NOTES 91 91 ...

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